Route 210 Roadway Rehabilitation
Owner/Lead Design Firm/Structural Engineer: California Dept. of Transportation
General Contractor: Flatiron West Inc.
Design Support: City of Pasadena; County of Los Angeles
Subcontractors: A.C. Dike Co.; American Civil Constructors West Coast; Cooper Engineering Inc.; Crown Fence Co.; Ferreira Coastal Construction Co.; Gerco Contractors Inc.; Griffith Co.; Harber Cos.; Hardy & Harper Inc., Integrity Rebar Placers
This project rehabilitated 77 lane miles of distressed pavement and upgraded roadway elements, lighting, electrical systems and signage. The four-year job replaced approximately 400,000 sq yd of pavement slabs and bridge approach slabs at 16 locations along 9.7 miles of freeway. The contractor used 11 types of pavement—some experimental—including precast jointed plain concrete, two-lift composite pavement, continuously reinforced concrete pavement and jointed plain concrete pavement.
The project team installed precast panels for approximately 11 lane miles of the restoration to minimize traffic disruptions through a congested urban area. Crews added the 4,900 precast panels at night, and lanes reopened to traffic before the morning commute.
The team partnered with the Federal Highway Administration to install one mile of two-lift composite pavement system using recycled pavement on an eastbound segment of the 210 Freeway. It was the first time in the U.S. this pavement system has been used. Through collaboration the team identified several changes that led to substantial savings—for example, using rapid-set concrete for curved connectors rather than the precast panels specified. That improved constructibility while generating $3.9 million in savings that was used for additional roadway improvements.