February 24, 1997

Mr. Paul E. Toussaint

Division Administration

Federal Highway Administration

P. O. Box 536

Frankfort, Kentucky 40622

Dear Mr. Toussaint:

SUBJECT: Warren County

U.S. 68 - Auburn-Bowling Green Road

FD 52 114 0068 000-005 113 C;NH 00801 054

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 Eaton……………. District 3, Construction

Mike Bruce Johnson, Depp and Quisenberry

Maurice Jordan Johnson, Depp and Quisenberry

Kenneth Cox District 3, Pre-Construction

Jim Hudson District 3, Design

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 widening and realignment of old U.S. 68

The following change orders were discussed:

There have been sixteen (16) change orders to date on the project.

Due to environmental issues with the extension of an existing box culvert and channel change it was decided to dowel into the existing box culvert instead of removing concrete masonry and splicing to the existing reinforcement. The structure plans were modified to incorporate an angle into the extension. This eliminated the need for a large channel change. This method also eliminated fourteen shade trees that were proposed in the landscaping plan.

An extension of one (1) working day was allowed.

Decrease for initial extension. $2,870.00

Increase for ultimate extension.. $11,051.24

Final increase.. $8,181.24

The Special Note requiring coverage by "General KPDES Permit for Storm Water Point Sources" applies to this project. Additional devices to trap sediment are required to reach the specified goal of trapping 80% of the sediment generated by construction activities as due to the need to modify the shape, size, location, etc. of the silt basins to accommodate site conditions. In compliance with the KPDES permit, straw bale silt fence and silt checks are required.

Increase.. $35,950.00

The contractor requested that the department apply the requirements of the most current gradation charts and deduction tables for crushed stone base on the project. This came about due to some confusion regarding the requirements of the crushed stone base as produced by Kentucky Stone. The contractor requested that the updated gradation requirements as outlined by the memorandum dated April 28, 1993 by Mr. Wesley Glass (Division of Materials) be in effect on the project. This was done at no cost to the department.

Increase.. $0.00

An existing field entrance Lt. of Sta. 339+00 was omitted from the roadway plans. The change order included work necessary to construct an entrance approach in the same location as the existing one.

The roadway plans were developed before the department began using excelsior blanket and sod in most ditches. It was determined that excelsior blanket could be used in lieu of sod in some ditches at a savings to the department. This change order also included a bid item for a drop box inlet Type 3 located at Sta. 503+50.21. The drop box was set up on plans but was not bid.

An extension of one (1) working day was approved.

Increase .. $11,804.20

The original bid for removal of underground storage tanks included the contaminated soil around it. It was determined at time of construction that the surrounding soil was not contaminated. This soil was then used as embankment in place thus providing a savings to the department. The price per cubic yard for special excavation was the result of a supplemental agreement with the contractor.

Excavate and dispose contam. Soil - 150.00 yd³ @ $50.00/yd³ = -$7500.00

Special excavation - 42.00 yd³ @ $20.00 /yd³ = +840.00

Net decrease. $6,600.00

This change order provided an adjustment in the unit bid price for bituminous materials because of the J.M.F. (job mix formula) asphalt content differing from the target asphalt content. The difference in unit price reflects the adjustment for Bituminous Mix for Base Class I, Binder Class I, and Surface Class AK.

Decrease for original items. -$3,003,329.35

Increase for target asphalt content. +$3,019,374.83

Net Increase.. $16,045.48

A revised traffic control plan was performed "in house" (Traffic Control Revision No.1 ). Additional quantities included a Temporary Concrete Median Barrier and Crash Cushion Type VI-T. These items were used in Phase IV and located at approximately Sta. 510+00. This change order also included work items relating to a commercial entrance at Sta. 499+47 Rt. And an added entrance at Sta. 492+76 Rt. The entrance at Sta. 499+47 serves an excavation contractor and it was deemed necessary to include a 50’ radius to allow proper turning movements with heavy equipment trailers. The added entrance at Sta. 492+76 Rt. Is the result of a request from the property owner. This change order also included items to relocate gas lines. One gas line shown upon the plans had no provision for relocation. These service lines were encased as were the others on the plans. An extension of one (1) working day was granted.

Increase.. $25,291.45

After Temporary Connector No. 1.0 was completed and work began on Phase II Construction, a ponding problem between the temporary connector and the new construction was discovered at approximate Sta. 316+00. In order to drain the ponded water and prevent it from overtopping the temporary connector, a culvert pipe was installed Lt. of Sta. 316+00. To prevent cutting of the new pavement to remove the culvert pipe, safe loading is required after the pipe is no longer needed. The entrances Lt. of Sta. 355+86 and St. 356+92 were originally designed to leave the existing entrance pipes in place. However, elevation checks indicated that the pipes are approximately six (6) inches high and must be replaced to allow for proper roadway ditch drainage. These items are also included in this change order. Due to unusually wet conditions during the construction phase, the number of entrances requiring maintenance and the use of lime stabilization on the project had caused the plan quantity for traffic bound base to be insufficient. An extension of one (1) working day was allowed.

Increase.. $24,714.50

This change order provided the adjustment in the unit bid price for bituminous concrete materials when the J.M.F. asphalt content differed from the target asphalt content. This adjustment was necessary because of a change in aggregate source.

Bit. Conc. Surf. Cl. AK-HT (5.7)- 6000 tons @ $28.410 = -$170,460.00

Bit. Conc. Surf. Cl. AK-HT (5.3%) - 6000 tons @ $27.97 = +$ 167,820.00

This change order reflected the costs of the partnering concept as outlined in Special Provision No. 99(91) in the project proposal. The Special Provision states that any cost associated with the partnership will be shared equally by both parties. The following decrease is the contractor’s equal share of expenses through June 13, 1994.

Several additional sinkholes have been encountered on this project during construction. The sinkholes had to be filled and capped in accordance with the requirements for the treatment of open sinkholes. Two existing entrances that were not shown on the plans were discovered Lt. of Sta. 339+00 and Lt. of Sta. 482+50. This change order included the work necessary to install entrance pipes at the mentioned locations. The entrance approach Rt. of Sta. 522+19 did not align with the property owner's existing entrance and fence gate. At the property owners request the entrance was moved to Rt. Sta. 521+52. The required additional forty (40) square yards of cement concrete entrance pavement and decrease of thirty six (36) linear foot of standard curb because the new location fell within the limits of curb and gutter. Also, the entrance approach Lt. of Sta. 482+50 previously mentioned was not discovered until the curb and gutter was poured. This required the removal of thirty two (32) linear feet of standard curb and gutter and the addition of 35.6 square yards of cement concrete entrance pavement. An additional entrance pipe was added Rt. of Murphy Road Approach Sta. 53+54. This addition was the result of a design error that routed flow from an eighteen (18) inch and fifteen (15) culvert into a single fifteen entrance pipe. This error was not discovered until the ten (10) foot of fill was constructed at the location.

Increase.. $9,027.56

An entrance was added at Sta. 426+50 Rt. by permit on this project. The property owner furnished the required twenty eight (28) linear feet of fifteen (15) inch entrance pipe and the contractor installed the pipe for the property owner at no expense. The added amount of material necessary to install the entrance is 16.45 cubic yards.. The property owner had issued a check for the embankment material. This change order also reflected the cost of flattening the slope from Sta. 492+00 to Sta. 494+00 at the request of the property owner. The property owner is disabled but continues to mow the slope in front of his and the adjacent property for an elderly neighbor. The property owner feels very uncomfortable mowing the proposed 3:1 slope with his riding mower. The contractor submitted a bid for the additional material necessary to flatten the slope and the work was performed on a cost plus basis. Also an entrance was added to this project by Change Order #11 at Sta. 482+50 Lt. On this change order, the amount of embankment material necessary to construct the entrance was omitted from the quantities. The contractor requested to install the fill material on the same cost-plus basis as above. An extension of one (1) working day was allowed.

Increase.. $1,330.62

This change order reflected the savings from the partnering concept.

Decrease.. $1,752.60

Additional four (4) inch perforated pipe and non-perforated pipe was used in a section of subgrade from Sta. 524+00 to Sta. 531+00 Rt. where wet conditions were encountered. It was decided to install four additional sections of perforated pipe and four additional perforated pipe headwalls in order to provide the necessary drainage that the rock subgrade to clay interface required. The proposed Median Crossover #1 had to be moved from its original location east 1400 feet because of a problem with alignment. Sam Hinson reviewed the existing conditions and decided to move the median crossover to provide a smoother transition from existing westbound and eastbound lanes. The existing road construction signs and the new detour signs were already erected at the proposed median crossover site and had to be moved again when the crossover was relocated. The west bound section of this project through Rockfield is a curb and gutter section. According to the traffic control plan, traffic was to utilize the binder course until the final phase of construction. This resulted in a small area next to the curb and gutter that would trap water and cause a spread which could, in turn, be a traffic hazard in freezing conditions. The decision was made to install a bituminous wedge next to the curb to minimize the above risks. Before the final surface course was installed, the wedge had to be removed by milling and texturing. Also, various tie-ins per the traffic phases had to be milled to allow proper lift thickness installation. An extension of one (1) day was allowed.

Increase.. $11,452.68

The roadway plans called for a ditch to drain an overflow crossdrain for a retention pond at Sta. 510+20. The ditch was to be installed right of centerline and flow along the parking lot of the Rockfield Restaurant adjacent to an approach road. However the outlet elevation of the crossdrain was too high to properly drain. Therefore a portion of the parking lot on the right of way of the approach road had o be lowered in order to allow proper drainage. This work, to include excavation, wasting and bituminous surface was done on a cost plus basis. During construction of the Rockfield-Browning Road approach, the contractor encountered two gas service lines that were not shown on the plans. The lines had to be relocated because of the lowered ditch grade.

Increase.. $1,530.38

This change order reflected the savings to the department by the partnering process.

Decrease.. $1,543.58

Project comments are as follows:

1. Cheaper to use 1 inch base instead of lime stabilization in this area of red clay. It takes the lime longer to stabilize in the red clay soil area.
2. Other comments are described in the above change orders.

Total Length = 5.30 miles

Contractor:

Scotty’s Contracting and Stone Co., Inc.

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

The original project bid was.. $8,426,819.81

Change orders.. $125,832.60

Total .. $8,552,652.41

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