February 26, 1997

Mr. Paul E. Toussaint

Division Administration

Federal Highway Administration

P. O. Box 536

Frankfort, Kentucky 40622

Dear Mr. Toussaint:

SUBJECT: Jefferson County

Fern Valley Road

FD 52 056 7163 172 C;STPM 08753 009

Post Construction Review

A post-construction review was held on the subject project on November 21, 1996, in the District 5 office. The following personnel were in attendance:

Robert Semones C. O. Highway Design

Robert Farley Federal Highway Administration

Paul Doss……………. Federal Highway Administration

Andre Johannes C.O. Design

Daryl Greer. C.O. Design

Amar Singla Presnell Associates Inc.

Rob Harris District 5

Barry G. Sanders. District 5

Sherrill Smith.. District 5

Doug Smith.. Division of Materials

Bradley Hamblin. C.O. Construction

Raymond Meyer.. District 5

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 new construction of Fern Valley Road from two (2) lane to six (6) lane curb and gutter.

The following change orders were discussed:

There have been nine(9) change orders to date on the project.

Phase 1 construction stated that nine (9) cross drains that traverse existing Fern Valley Road between Sta. 56+70 to Sta. 89+20 had to be constructed. This was going to be accomplished by the use of temporary gravel run arounds. Two problems were discovered when attempting the cross drain construction:

1. Existing utility poles right of centerline had not been relocated making construction of the turn arounds impossible.
2. The new curb box inlets fell within the limits of existing Fern Valley Road.

Therefore, it was agreed to install temporary drainage near the locations of the permanent pipe by the drill and bore method using twenty (20) inch casing. This method did not impact traffic. This change resulted in a savings of $60,990.48 by eliminating the DGA required for the detours.

Three (3) working days was allowed

Final increase.. $63,999.00

After preparing the subgrade according to the specifications and plans from right Sta. 57+00 to right Sta. 60+00, the tensar was placed according to the manufactures recommendations. The DGA was then back dumped. Almost immediately, the DGA began pumping and rutting (approximately 4 inches). During compaction the material pumped and rolled. Cone penetrometer results showed that a penetration of two (2) feet below subgrade was obtained with little resistance. This indicated that the material under the subgrade was very unstable. To alleviate this problem it was proposed to modify the roadbed using portland cement. For establishing quantities the depth of modification was sixteen (16) inches, percent cement was 7%, and soil unit weight was 110 pcf. . in order to decrease the delays required for curing, it was agreed to utilize a special geotextile fabric. The fabric was required to have a grab tensile strength of 600psi.

Increase.. $487,302.50

The sanitary sewer at Sta. 12+17 right was to be lowered in Phase 2. In order for this work to be completed it was necessary lower a thirty (30) inch water main. The lowering of the water main was controlled by the relocation of LG&E electrical poles to the south right of way line. The proposed dates of relocation were not met therefore causing delays. In order to expedite the work necessary to clear the electrical facilities and allow for the lowering of the water main, it was agreed to have the contractor relocate the electrical service for Parcel 18 once the new LG&E poles were in place. It was also agreed that the contractor be responsible for obtaining all inspections, meeting all applicable codes, paying for any fees, and matching any grades for further improvements planned by the owners of Parcel 18.

Increase.. $10,536.53

Prior to work beginning on the project, water would drain off the parking lot for Parcel 38 and into the existing ditch. When the header curb was constructed from Sta. 53+00 to Sta. 56+20 right this water ponded in the parking lot. To correct the problem it was agreed to construct a sloped and flared headwall with a ten (10) pipe at the low spots along the header curb and tie this drainage into the proposed fifteen (15) inch reinforced concrete pipe. The plans for a ten (10) inch ductile iron sewer crossing at Sta. 12+17 did not indicate that special backfill materials were required. The Metropolitan Sewer District inspector, however, directed that Type 1 (sand, flushed and jetted) was to be used. The inspector stated that #57 stone would suffice in lieu of sand. Since the backfill was different and more costly than what the plans specified, it was agreed that the supplemental unit price for "#57 Stone Backfill" shall be full compensation for all labor, equipment, materials, and incidentals necessary to provide the material. It was further agreed that the compensation be for material only.

Increase .. $4,276.00

After the subgrade was cut and suitably prepared from Sta. 52+02 Old Fern Valley Road, the subgrade was stabilized using Geotextile Fabric-Special as outlined in Change Order #2. The DGA was then back dumped. Almost immediately severe pumping and rutting began to occur. The pumping was severe enough to expose the geotextile fabric in several areas. In order to correct the problem and expedite the reopening of Old Fern Valley Road to traffic, it was agreed to undercut approximately 1.5 feet and refill with "No. 3 Stone".

Increase. $34,764.00

The owner of Parcel P1 had refused to sell the department the necessary property for the permanent drainage easement as shown on plans. In order to avoid a protracted legal challenge, which would have delayed the project, it was agreed to revise the proposed drainage, which required a very small permanent drainage easement.

Net Increase.. $12,721.74

In reviewing the plans it was discovered that four (4) Curb to Barrier Wall Transitions were to be constructed, however no quantity was established. This change order established the price to construct the four "Curb to Barrier Wall Transition".

Increase.. $8,000.00

In reviewing the plans and pay quantities, it was discovered that payment for the removal of the existing Fern Valley Road Bridge over Fern Valley Ditch had been omitted. This change order established the price for "Remove Existing Structure".

Increase.. $24,154.05

In order to reconstruct Jeanine Drive, it was necessary to close Jeanine Drive to traffic. This was due to grades of the new sanitary sewer being located in the center of Jeanine Drive. Also, the grade difference between new Jeanine Drive and existing Jeanine Drive made maintaining traffic hazardous. It was therefore agreed to fabricate temporary signs along a detour route for the closed portion of Jeanine Drive. The roadway plans called for the construction of reinforced concrete box culvert extensions on a double barrel elliptical storm sewer at Sta. 108+72 Fern Valley Road. The construction was detailed on Sheet 82, however the quantities for the work was omitted. This change order established the unit price for the culvert extensions.

Increase.. $30,175.45

Project comments are as follows:

1. The boring process under the existing roadway should be considered on more jobs. Need to look at other alternates before using gravel turn arounds.
2. Need to look at the use of tensar as compared to cement soil stabilization. The soil cement stabilization seemed to be the more superior alternate in this case due to the underlying soil conditions
3. Relocating utilities on time was a major issue on this job. Although utility companies were notified in a timely fashion, the utility relocation still delayed some phases of the project. Project should have not been let until utilities had been relocated.
4. There was an issue about right of way not being cleared so that the utilities could be relocated.
5. There was an oversight on the drainage of an adjoiners parking lot in change order #4. This should have been discovered in the design phase.
6. Need to look at backfill parameters for the local MSD company. Need to have their specifications before plans are complete so that no changes are made during construction. It was stated during the meeting that the proposed backfill parameters had been sent to the local MSD but MSD did not respond until the construction phase.
7. Need to acquire all right of way easements before construction phase.
8. Need to look at adjoiners concerns about property value when proposing drainage easements upon the property. This needs to be considered in the initial design phase.
9. There was an oversight of setting up barrier transition to curb.
10. Need to make sure all items in the plans are accounted for in the cost of the job. Some items were on plans but did not have bid items set up which may delay construction.
11. Not having right of way cleared and utilities relocated before construction caused a claim by the contractor for the sum of $477,812.00

Total Length = 2 miles

Contractor:

Highway Structures, Inc.

4623 Illinois Avenue

Louisville, Ky. 40213

The original project bid was.. $5,905,331.41

Change orders.. $675,929.27

Total .. $6,581,260.68

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:pcr11-96.doc

cc: Post-construction Review Participants

Charles Raymer

FHWA File R. Sutherland

Design File M.A. Talbot

W. Crace

J. Stone

P. Gravely

S. Cornett

S. Goodpaster

G. Sharpe