February 12, 1997

Mr. Paul E. Toussaint

Division Administration

Federal Highway Administration

P. O. Box 536

Frankfort, Kentucky 40622

Dear Mr. Toussaint:

SUBJECT: Barren County

I-65, Interstate Rehabilitation

FD52 005 0065 048-052 008 C; ACIM 00652 046

Post Construction Review

A post-construction review was held on the subject project on December 10, 1996, in the District 3 office. The following personnel were in attendance:

Robert Semones C. O. Highway Design

Paul Doss Federal Highway Administration

Tim Enton……………. District 3, Construction

Kent Gilley District 3, Construction

Kenneth Cox District 3, Pre-Construction

Charles Briggs Central Office, Operations

Daryl Price District 3, Crew 319, Construction

Phil Carter District 3, Construction

The attendees reviewed the project plans, and construction change orders. An on site investigation followed the meeting. This post construction meeting dealt with issues pertaining to pavement rehabilitation.

The following change orders were discussed:

There have been two (2) change orders to date on the project.

The inside lane closure devices were place to allow a two foot overlap on the outside lane to accommodate the pavement step outs and eliminate the vertical drop off adjacent to the lane center line. This encouraged traffic to use part of the shoulders causing them break apart. Due to the volume of traffic and the urgent need for repairs, the contractor mobilized a paving crew from another job to temporality repair the shoulders with leveling and wedge material until a more permanent solution could be applied the next morning. In order to stabilize the outside shoulders throughout the duration of the lane closure, it was decided to overlay the outside shoulder and lane with approximately 3 inches of bituminous base. The increase in the above reference items of work shall provided full compensation for all labor, equipment and materials necessary to perform the emergency repairs and overlay the outside shoulders with bituminous base.

After the inside lane was completed, traffic had to be switched. The bituminous base material described above had to be removed from the concrete pavement prior to the breaking and seating operation. The milled material had to be placed on the shoulder and used as embankment-in-place.

The proposal required the project to tie into a previously completed break and seat project. The bid quantities for milling and texturing were set up for two inch and a half (1.5") edge keys only. In order for the break and seat, approximately 500 feet of the overlay taper from the previous project had to be removed causing a significant increase in the milling and texturing quantity.

The proposal required the project to tie into a previously completed break, seat and overlay project at mile point 51.90. The specified mile point of 51.90 fell approximately 643 feet short of tying into the previously completed project causing an increase in bid items.

The bituminous surface for the shoulders on this project did not require rut lessening modifier. In order to place the four (4) foot inside shoulder surfacing material with conventional paving equipment, it was decided to add the rut lessening modifier to the inside shoulder mix. Also, the rut lessening modifier was added to the temporary Class "I" Base previously mentioned in this change order to give the pavement more strength due to the existing condition of the shoulders. The cost of the PMAC additive in the temporary Class "I" Base was agreed to be shared equally between the Department and the Contractor.

It was decided to use DGA embankment material in lieu of soil through the rock cut areas to reduce erosion in the ditch line.

This portion of the change order was necessary because of the installation of the pavement edge drains. The installation of the edge drains was performed in the lane that had been broken and overlaid in lieu of installing both sides two weeks prior to breaking, eliminating the need for the four (4) inch bituminous base plug in the edge drain trench. The increase shall provide full compensation for all labor, equipment and materials necessary to construct the edge drain trench to existing pavement elevations using crushed stone No. 57.

The edge drain outlets on this project were set up to have perforated pipe headwalls. During construction it was discovered that several of the existing drainage structures could be used for the edge drain outlets in lieu of headwalls.

The quantities established in the proposal failed to include Type IV pavement markers. In order to comply with the current Standard Drawings the increase in the above reference item was necessary to add pavement markers Type IV to this project.

The purpose of this change order was to permit the use of "Hydro Stik" Tackifier in lieu of SS-1H on an experimental basis only. The "Hydro-Stik" Tackifier shall be applied at the manufacture’s recommended rates and at no additional cost to the Department.

Increase.. $0.00

Discussion:

It was suggested that the shoulder components be the same as mainline since the shoulders have to be used as detour lanes at sometime in the future. As stated earlier, once the traffic was shifted the shoulder failed. This type of failure must be considered on future jobs in this area before maintenance of traffic is set up on the project. This type of shoulder failure had happened on past jobs.

There was a special note on delineator posts but no bid item set up. There was concern about considering delineators before job lets.

Need to have curve data for transitions. Need notes on plans for this information.

The notes pertaining to cleaning ditches was not clear.

The No. 2 stone around the perforated pipe headwalls has been washing out. It was suggested that sod be used around the perforated pipe headwalls.

It was suggested that a cheaper type headwall be used at the edge drain outlets.

Total Length = 3.50 miles

Contractor:

Scotty’s Contracting and Stone Co., Inc.

P.O. Box 4500, Bowling Green, Ky., 42102-4500

The original project bid was.. $1,960,000

Change orders.. $237,505.28

Total .. $2,197,505.28

The attendance of all the participants in this post-construction review is greatly appreciated.

Sincerely,

J. M. Yowell, P.E.

State Highway Engineer

BY: John B. Sacksteder, P.E.

Director, Division of Highway Design

JMY:JBS:rts:pcr7-96.doc

cc: Post-construction Review Participants

Charles Raymer

FHWA File S. Williams

Design File C. Phillips

W. Crace L. Ferguson

J. Stone K. Gilley

P. Gravely

S. Cornett

S. Goodpaster

G. Sharpe