February 15, 2000
Mr. William Monhollon, P.E.
Chief District Engineer
District 5
977 Phillips Lane
P. O. Box 37090
Louisville, KY 40233
Subject: Jefferson County
Bardstown Road (US 31E)
Item No. 5-120.01
Post-Construction Review
Dear Mr. Monhollon:
A post-construction review was held on the subject project on Wednesday, January 19, 2000 in the District 5 Conference Room. The following personnel were in attendance:
R. R. Meyer D-5, T.E.B.M. Construction
Barry Sanders D-5, Construction
Andre Johannes C.O. Highway Design
Robert Semones C.O. Highway Design
Siamak Shafaghi C.O. Highway Design
Ed Kirk D-5, Construction
Tala Quinio D-5, Highway Design
Kevin Villier D-5, Highway Design
The attendees reviewed the project plans and construction Change Orders. There were eleven (11) Change Order on the project. An on site investigation followed the meeting. This prost construction review meeting dealt with the grade, drain and incidental surfacing of the Louisville-Bardstown Road from the Snyder Freeway extending to Floyd’s Fork.
The following Change Order were discussed:
CHANGE ORDER NO. 1
The contract proposal contained the Special Note for Building Inspection, Asbestos Containing Materials (ACM) Removal, and Demolition. Upon inspection of the structures listed in the proposal, asbestos was discovered in the buildings on Parcels 13 and 19. The required items "Site Preparation", "ACM Removal", "ACM Disposal" and "Closure Report" were listed in the Special Note but were not bid items. It was necessary to add these items to the contract.
At 37 feet left of Station 638+30 a six inch diameter water well was discovered in the roadway section. A bid item for plugging this water well was established on this contract.
In order to provide erosion control, it was necessary to construct silt fence in various areas on the project.
An increase of 1 Working Day was allowed for this Change Order
Increase $37,426.00
CHANGE ORDER NO. 2
Guardrail End Treatment Type 4A were substituted for Guardrail End Treatment Type 4 in accordance with current design criteria.
The Contractor submitted a Value Engineering Proposal to replace culvert pipe with aluminized steel pipe. The aluminized steel pipe utilized met design requirements for cover heights and the 24" and 30" sizes had no corrugations on the interior of the pipe.
The structural steel for the neoprene expansion dams was changed from steel angles with straps to steel plates with studs. This new design was easier to install but increased the amount of structural steel required for both the northbound and southbound bridges. The Division of Bridges recommended this change.
An increase of 1 Working Day was allowed for this Change Order.
Decrease $6,628.12
CHANGE ORDER NO. 3
Approximately 3000 LF of the 16" water main was installed with field lok gaskets. Upon testing the water main it was discovered that an unacceptable amount of leaking was occurring. It was unclear whether the leaks were caused by the materials used or if the contractor’s workmanship was causing the leaks to occur. An investigation was performed to determine the exact cause of the leaks and it was determined that defective materials were used. The manufacturer that supplied the Louisville Water Company with the 16" pipe agreed to reimburse the costs that were necessary for the investigation and also the costs for the removal and replacement of the 16" water main where field lok gaskets were used. No agreement could be reached for the cost of the removal and replacement of the water main so this work was performed on a cost-plus basis.
An increase of 3 Working Days was allowed for this Change Order.
Increase $181,000.49
CHANGE ORDER NO. 4
In order to provide access for gas mains, it was necessary to construct 6" steel casing pipe across the roadway at Station 522+86, Station 540+57 and Station 571+15.
New service lines had to be installed for parcels #18, #28, and #44. This work was necessary because the new construction displaced gas service for the parcels above.
In order to maintain future access for TKR Cable, a 4" steel conduit was installed at Station 486+20. The installation was according to the specifications of the cable company. The existing cable was abandoned in place.
The contractor submitted a Value Engineering Proposal to eliminate the lowering of the existing 16" water main and encase the water main in concrete. The contract plans indicated that the existing 16" water main was to be lowered where it crosses the inlet ends of the culverts located at Station 479+63.58 and Station 495+00. The Department and the Louisville Water Company concurred that this was a cost saving alternative and that the less than normal clearance would be acceptable provided a minimum of 24" of cover was obtained. However, in lieu of concrete encasement, a buffer of crushed stone and 6" concrete cap was constructed above the water main.
On parcels #10, #11, #18, #33, #45, #52, #59, and #63 the existing water service was diverted to the water meter vaults located along the new mater mains which were constructed on this project. This work was omitted from the utility plans.
As indicated in Change Order No. 3, it was agreed to remove and replace the 16" water main that was installed with faulty lok gaskets. While the issue was being resolved, a temporary tie-in was constructed at Station 637+60 to allow road construction to continue without delay. Since this work was an indirect result of the faulty field lok gaskets, the Louisville Water Company agreed to reimburse the Department the cost of this work.
An increase of 3 Working Days was allowed for this Change Order.
Increase $110,115.97
CHANGE ORDER NO. 5
The traffic notes on sheet 52 of the plans outlined the construction of two (2) detours to allow the construction of both Fairmount Road and the intersection of New US 31E with Fairmount Road. The contractor submitted a Value Engineering proposal to eliminate Detour #1 while providing a modification of Detour #2.
The plans indicated a new water main was to cross a fenced parcel at Rt. Station 467+50. In order to maintain the enclosure and the safeguard this area during construction, a temporary fence was erected along the construction easement limits.
At Station 503+00 the plans indicated the existing 12" water main was to be relocated to Station 502+70. In order to tie into the existing water main without a prolonged disruption of service to customers, it was agreed to install a gate valve on the existing water main before constructing the tie-in with the new water main.
An increase of 1 Working Day was allowed for this Change Order.
Decrease $3,951.64
CHANGE ORDER NO. 6
The plans indicated that the berm to be constructed on the new US 31E from Lt. Station 478+00 to Station 516+00, have a varied cross slope along its backside ranging from 1.5:1 to 2:1. In order to provide effective protection of this slope, it was agreed to install an excelsior blanket along the entire length of the berm.
The construction phasing on this project required changes to the existing traffic patterns and roadway markings. The contract did not include a bid item to remove the existing striping so it was agreed to set up a bid item for "Removing Striping."
In reference to Change Order No. 3, an agreement could not be reached on a supplemental unit price for the removal of the 16" water main that had been constructed with defective gaskets. The actual value of the work performed as determined from cost-plus records was agreed to be $22,893.64 versus the previously estimated value of $60,000.00. The Louisville Water Company agreed to reimburse the Department the cost of this item.
In reference to Change Order No. 4, and agreement could not be made on a supplemental unit price to install a ¾" water service for parcel #59. However, due to the length of the service, a 1 ½" diameter line was needed to replace the ¾" diameter line already in place.
Actual fittings, which were not included as bid items, were necessary to construct the water mains according to the plans.
An increase of 6 Working Days was allowed for this Change Order.
Decrease $13,711.56
CHANGE ORDER NO. 7
In reference to Change Order No. 4, an agreement was made to install a 6" steel casing for a gas line at Station 522+86. With the previously agreed supplemental unit price, it was understood to place the casing in the rock trench that was excavated for the telephone company casing at the same location. However, the telephone company requested that no other utility be installed in the same trench so it was necessary to shift the location of the gas casing to Station 523+09. A new supplemental unit price for Steel Casing 6" was established.
The 6’ x 6’ x 53’ box culvert located Left of Station 631+75 and the 6’ x 4’ x 64’ box culvert located Left of Station 658+50 both crossed beneath existing US 31E where the new US 31E incorporated the existing roadway within its embankment section. These culverts had to be removed. However, no unit bid price for this work was established in the contract. Therefore a supplemental item had to be established for "Remove Box Culvert".
The new US 31E crossed the entrance roadways connecting the Glenmary subdivision with the existing US31E. The new construction eliminated the lighting, which previously delineated the entrance roadways. Since the new section of US 31E will not be open to traffic under this contract, and due to existing site conditions and the new entrance roadways, it was agreed to provide lighting at each of the affected entrances. The supplemental unit price for "Lighting" was full compensation for the installation, maintenance, and electric consumption of three (3) streetlights over a two (2) year period.
The 1 ½" joints on the bridges on US31E over Floyds Fork widened due to approach slab settlement and rotation of the joints. Upon recommendation of the Central Office Division of Construction, the existing neoprene joint seal was removed and the joint was sealed with silicone. The neoprene that was removed from the joints became the property of the Department.
An increase of 1 Working Day was allowed for this Change Order.
Increase $24,670.72
CHANGE ORDER NO. 8
The grade was raised on the relocated Fairmount Road to clear a 16" water main that was discovered at Old Bardstown Road. Since the pipe for two entrances had already been constructed at plan grade, it was necessary to remove and relay this pipe.
It was necessary to remove the pavement markers in order to resurface existing pavement. However, no bid item was included in the contract for "Remove Type V Marker" so a supplemental bid item was established for this work.
Additional work and fittings which were not included as bid items was necessary to construct the water mains according to the plans and had to be established on the contract.
The Louisville Water Company changed the layout of the 12" water main at Left Station 597+00. Since blasting for the original layout had already been performed, it was agreed to compensate the contractor for this extra work. The Louisville Water Company agreed to reimburse the Department the cost of this item of work.
An increase of 1 Working Day was allowed for this Change Order.
Increase $8,680.50
CHANGE ORDER NO. 9
Actual field measurements determined the quantities for "Structure Excavation Solid Rock", and Channel Lining Class II and III were underestimated. Additional quantities of these items were necessary to complete the project as designed.
The surfacing contract scheduled to follow this grade and drain contract began before the final surfacing for this project was completed. At that time, for the sake of maintaining continuity and rideability of the mainline pavement, it was agreed to not surface the remaining intersections and roadways under this contract.
According to the negotiations for the purchasing of right-of-way from the owner of Parcel 23, an agreement was made to remove the concrete walled sand filter at Left Station 526+25. Since the plans did not indicate this work and because an agreement could not be made as to the cost of this work, it was agreed to perform the work on a cost-plus basis.
At Right Station 549+00 to 552+00 an excess land purchase by the Department borders the right-of-way. With the removal of a house at this location, the land in this area was not graded for proper drainage. Since the plans did not indicate grading along the right of way to provide drainage for this area and because an agreement could not be made as to the cost of this work, it was agreed to perform the work on a cost-plus basis.
An increase of 1 Working Day was allowed for this Change Order.
Decrease $43,714.00
CHANGE ORDER NO. 10
At approximate station lt. 493+00 on US31E, a pond is situated off the right-of-way in the Glenmary subdivision. Due to deposits of silt from the project area, it was necessary to drain and dredge the pond. Since it was deemed that some of the silt had been deposited from the proposed roadway grade before the project started, costs for this work was shared equally by the Department and the Contractor. The actual cost of this work was determined based on the cost-plus method.
Contract Working Days were unaffected by this Change Order.
Increase $7,640.00
CHANGE ORDER NO. 11
In reference to Change Order No. 10 it was agreed to drain and dredge a pond at approximate station lt. 493+00 with the cost shared equally by the Department and the Contractor. The actual value of the work performed, as determined from cost-plus records, it agreed to be $22,269.02. Therefore, the 50% share in costs is equal to $11,134.51 versus the previously estimated cost in Change Order No. 10 of $7,640.00.
Contract Working Days were unaffected by this Change Order.
Increase $3,494.51
Project Statistics are as follows:
Project Length=3.751 Miles
Contractor: Rose Construction Company, Inc.
P. O. Box 309
3016 New Haven Road
Bardstown, KY 40004
Total Original Contract Amount $ 9,742,278.10
Total Approved Change Orders $ 293,888.36
Total Revised Contract Amount $10,036,166.46
The attendance of all 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
cc: C. Raymer David Kratt A. Johannes B. Sanders R. R. Meyer
C. Knowles Ed Kirk S. Cornett S. Goodpaster R. Divine
K. Villier J. Stone J. Mettille D. Newman Rose Construction