Caltrans Route 80 Rehabilitation

This stretch of Route 80, spanning from the State Route 4 separation in Hercules to the Carquinez Bridge in Crockett was exhibiting signs of distress due to decades of high traffic use, resulting in poor ride quality and the potential for pavement failure. To address these issues, Caltrans determined that full replacement was needed.

This is a vital and highly traveled stretch of I-80, so prolonged work with long closures and reduced lanes wasn’t an option. To reduce the number of overnight weekly closures needed to complete the work and shorten the project duration, most of the work was completed in just four weekend closures, reducing the construction schedule by nine full months. Over the course of the four weekend closures, a remarkable total of 25,000 cubic yards of concrete was placed. Notably, during the final 104-hour closure over Labor Day weekend, a substantial 9,575 cubic yards of concrete was placed, setting a record in volume of CRCP placed over a single weekend.

The work accomplished during the final closure condensed what would have taken 106 nightshifts over five to six months into a mere four days of round-the-clock work. Completing this volume of work typically requires approximately two months, and such achievements are rarely seen in the state of California. Furthermore, it's worth noting that the 104-hour closure was not only a triumph in terms of volume but also in punctuality, finishing 12 hours ahead of the planned schedule.

PROJECT DETAILS:

   Location: Contra Costa County, CA
   Duration: 3/2023 – Present
   Value: $60 million

  Type: Design-Bid-Build
  Client: Vanguard
  Owner: Caltrans

Innovative Solutions to Adhere to a Fast-Paced Schedule

G3 is providing mix design, field qualification and onsite quality control inspection, sampling and testing for the Lean Concrete Base-Rapid Setting (LBD-RS). As a part of our scope, G3 utilized concrete maturity sensors to determine concrete maturity, aiding the project in adhering to its fast-paced schedule.

G3 is one of few firms that have utilized this method for concrete maturity, this approach involves embedding maturity meter sensors approximately two inches beneath the concrete surface to measure the heat of hydration, which correlates directly to concrete strength. Data is then collected rapidly through mobile phones, providing a remarkably efficient alternative to traditional strength testing as it eliminates the need to transport samples between the project site and the lab.

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