Why CRCC is Better
Castle Rock Construction Company always strives to provide a quality product in all of our operations. On all our projects we have a quality control meeting with all scopes for the project to determine what will be expected. In these meetings we establish a quality control plan with action plans to attain expected quality levels.
CRCC has set the smoothness of our concrete pavement as a number one priority and we have taken several measures over the last five years to attain this priority.
- Castle Rock Construction designed an optimized concrete mix for every project. The mix design is a flexural strength mix with four aggregates. The goal of this mix was to produce a consistent mix which could maintain a Coarseness Factor (CF) of 60 and a Workability Factor (WF) of 35 in a modified Shilstone Graph. This was accomplished with the use of a four bin feeder and pug mill being added to the concrete batch plant. The four bin feeder was used to provide the proper proportions of the four aggregates to the pug mill which mixed the aggregate into a single aggregate which is then fed to the batch plant. The purpose of this proportioning and mixing was to aid in the production of a more consistent concrete batch and a better platform for the concrete paver with the ultimate goal of producing a smoother ride on the concrete paving.
- Wire stringline is used which is checked daily to make sure there was less than .2 inch deflection when a 3 pound weight is hung on the stringline.
- The team uses a spreader to help control surge at the paver to consistently maintain head pressure, grout box pressure and the roll size at the oscillating correction beam of the dowel bar inserter attachment.
- Behind the paver a “V Float” was used to eliminate chatter.
- A real time profiler is utilized behind the paver to monitor slab smoothness and to monitor the effects of changes to the paving process on smoothness.
The end result is a very consistent concrete being produced and very good rides on our projects. The paving team produces a concrete pavement with IRI numbers in the mid 50’s. Our goal is to get our IRI numbers in the 40’s. The levels we are at now lead the industry in smoothness and CRCC is not yet satisfied.
This attention to quality has led to local awards for the following projects in the last 5 years: US 34 Greeley, US 385 Idalia, US 287 Wildhorse, US 287 Boyero, State Highway 47 Pueblo, I-70 at Burlington, Havana and 40th Denver, Pena Blvd Denver International Airport, William White Blvd Pueblo, Quebec Street Commerce City, Central Park Interchange with I-70 Denver, State Highway 160 Alamosa, US 85 Greeley and Broadway 16th to 20th Denver.
National concrete paving awards in the same period were as follows:
- US 34 Business Greeley
- US 287 Wild Horse
- Havana and 40th Denver
- Pena Inbound Outbound Denver International Airport
- William White BLVD Pueblo
- State Highway 121 Wadsworth White Topping Northglenn
- Central Park Interchange with I-70 Denver
- State Highway 160 Alamosa.
Owners who hire Castle Rock Construction can expect the attention to quality which makes our company better than the rest.