November 9, 1999

Mr. Roger Coffey, P.E.

Chief District Engineer

District Eight

US 27

P. O. Box 780

Somerset, KY 42501

Subject: Pulaski County

Whitley City-Somerset Road

Item No. 8-00269.21

Pulaski County

Somerset Bypass

Item Nos. 8-0121.01,.02

Post-Construction Reviews

Dear Mr. Coffey:

Post-construction reviews were held on the subject projects on Wednesday, October 20, 1999 in the District 8 Conference Room. The following personnel were in attendance:

Paul Francis District 8, Preconstruction

Joe Cochran Quest Engineers

Jim Guinn Quest Engineers

Richard Ledford Hinkle Contracting Corporation

Ray Adams Vaughn & Melton

Michael Jones Vaughn & Melton

Siamak Shafaghi C. O. Highway Design

Joette Fields C.O. Highway Design

Robert Semones C.O. Highway Design

D. L. Kerr District 8, Construction

Ron Laugherty District 8, Construction

The attendees reviewed the project plans and construction Change Orders. There were 13 (thirteen) Change Orders for the Whitley City- Somerset Road project and a total of 10 (ten) Change Orders for the Somerset Bypass project.

On site investigations followed the meeting. These post-construction review meetings dealt with Grade, Drain and Bituminous Surface on the Whitley City-Somerset Road and Grade, Drain, and Bituminous Surface on the Somerset Bypass from Industrial Park to KY 80. The Somerset Bypass was divided into two contracts. The Grade, Drain and incidental Surface were on the first contract and mainline Bituminous Surfacing was on the second contract.

The following Change Orders were discussed:

CHANGE ORDER NOS. 1 & 2 (WHITLEY CITY-SOMERSET ROAD)

These Change Orders were necessary to change the method of installation of the utilities across mainline US 27. The original plans called for open trenches which were to be backfilled with flowable fill material. The conduits were bored through the roadway embankments in lieu of an open cut trench. It was felt that traffic flow through this area was enhanced and the contractor’s traffic control costs were reduced.

An increase of 7 Working Days was allowed for this Change Order.

Increase $236,302.50

CHANGE ORDER NO. 3 (WHITLEY CITY-SOMERSET ROAD)

This Change Order was necessary to construct a suitable storm drainage system as recommended by District and Central Office Highway Design. Larger culvert pipe was used to facilitate these changes. Two curb box inlets were changed from a Type A to a Type B due to a conflict with the existing right-of-way and a waterline. These boxes were located Rt. Station 358+05 and 358+72. A special junction box was added where an 18-inch cross drain and a sewer line crossed Rt. Station 319+98. Also, the contract quantity for removing existing drop boxes was increased due to the actual field counted amount for this item of work.

An increase of 3 Working Days was allowed for this Change Order.

Increase $104,792.65

CHANGE ORDER NO. 4 (WHITLEY CITY-SOMERSET ROAD)

This Change Order was necessary to relocate gas, water, and sewer utilities throughout the project. Marker tape along with a tracer wire on all plastic gas lines was a

requirement by the City of Somerset’s gas service. However, this item was not a part of the original contract. Additionally, the Natural Resources & Environmental Protection

Cabinet requires that waterlines within a 200’ radius of oil or gas lines underground storage tanks, petroleum storage tanks or pumping stations have pipe joint materials that are resistant to permeation of the petroleum products. Items needed for compliance to this requirement were not included in the original utility plans; therefore, these items were added by Change Order.

An increase of 3 Working Days was allowed for this Change Order.

Increase $133,339.85

CHANGE ORDER NO. 5 (WHITLEY CITY-SOMERSET ROAD)

This change order was necessary to construct an embankment Rt. Station 365+00 to Station 366+00 and also to fill in a cavern Rt. Station 365+20 to Station 365+70 in order to stabilize the existing roadway and retaining wall. The embankment material was large crushed stone and the embankment was constructed on a 1.5:1 slope with a 10’ bench at the top, adjacent to the existing retaining wall. Type IV geotextile fabric was placed on the soil before being covered with stone fill. An existing 24" culvert pipe Rt. Station 365+40 was extended through the rock embankment.

An increase of 12 Working Days was allowed for this Change Order.

Increase $81,662.80

CHANGE ORDER NO. 6 (WHITLEY CITY-SOMERSET ROAD)

This Change Order was necessary provide crushed stone and geotextile fabric in order to stabilize the subgrade of the new outside lanes at various locations throughout the project where unsuitable material was encountered.

An increase of 2 Working Days was allowed for this Change Order.

Increase $68,365.00

CHANGE ORDER NO. 7 (WHITLEY CITY-SOMERSET ROAD)

This Change Order was necessary due to a Construction Revision that involved a redesign of the median, which removed median crossovers and added left turn lanes at the major approaches and traffic generators. Signalization was installed at the intersection of US 27 and Adams Street, the intersection of US 27 and Sallee Street, and at the intersection of US 27 and Columbia Street. The existing pavement was milled down to the failure layer at blowup locations throughout the project in the southbound

lanes. Curb and gutter was removed at various approach roads due to a grade change. The final grade on some approaches was changed to avoid removing large sections of the

existing pavement and rebuilding the roadway. By leaving as much pavement in place as possible, traffic control problems were reduced at these intersections. Also, a Type C Manhole was constructed Lt. Station 357+85. This manhole was required along the line of a 24 inch storm sewer pipe due to a conflict with an 8" x 8" fiber optics bank which runs perpendicular to the storm sewer pipe and also due to a conflict with an 8 inch waterline. The manhole allowed the fiber optics bank to pass through walls of the chamber and enabled normal drainage flow to continue through the 24 inch pipe.

An increase of 25 Working Days was allowed for this Change Order.

Increase $365,997.25

CHANGE ORDER NO. 8 (WHITLEY-CITY-SOMERSET ROAD)

This Change Order was needed to install excelsior blanket in lieu of method II Seeding and Protection from Station 297+50 to Station 365+50. Placing the Type II Seeding caused problems with the public because of tack overspray. Central Office Division of Construction recommended this change during an erosion control review.

Also, Bituminous Wedge Curb was installed adjacent to various entrances and parking lots throughout the project.

An increase of 1 Working Day was allowed for this Change Order.

Increase $21,500.00

CHANGE ORDER NO. 9 (WHITLEY CITY-SOMERSET ROAD)

This Change Order was necessary to construct a suitable storm drainage system from existing 24 inch pipe Rt. Station 354+10 to an existing outlet ditch Rt. of Columbia Street approach at Station 52+85. The new system required a Manhole Type A Rt. approach Station 50+96, a curb box inlet Type F Rt. approach Station 51+61 and a Drop Box Inlet Type 1 Rt. Approach Station 52+85. This revised drainage system replaced the original system shown on the contract plans which only provided surface ditches for drainage in this area. Also, the aggregate base construction was revised in order to provide increased base stabilization for the inside (median) shoulders and the new left turn/storage lanes Lt. and Rt. from Station 298+00 to Station 353+50. The base construction included geotextile fabric on the subgrade with a layer of #2 crushed aggregate and a layer of crushed stone base in lieu of the 12 inch layer of DGA as specified in the original contract plans. The layer of #2 crushed aggregate extended from the edge of the existing pavement to the median ditchline and worked as an untreated drainage blanket providing positive drainage into the ditch and eliminated the need for 4" perforated edge drain.

An increase of 3 Working Days was allowed for this Change Order.

Decrease $1,369.80

CHANGE ORDER NO. 10 (WHITLEY CITY-SOMERSET ROAD)

This Change Order was necessary to establish quantities for removing and hauling guardrail. The quantities for this required work were omitted from the contract plans. Integral curbs were constructed adjacent to existing concrete entrances throughout the project. PVC Drain Pipe-8 Inch was needed to connect an existing drain to a new storm sewer system on the project and a string of 18 inch reinforced concrete pipe had to be relocated and laid at a different grade due to encountering an 8 inch gravity flow sanitary sewer line.

Contract time was unaffected by this Change Order.

Increase $3,793.00

CHANGE ORDER NO. 11 (WHITLEY CITY-SOMERSET ROAD)

This Change Order was necessary to construct a 4 inch concrete overlay on the existing pavement in the southbound lanes and adjacent approaches for the intersection of US 27 and Old KY 80 West and the intersection of US 27 and Cumberland Parkway. Also a 5 inch asphalt concrete overlay on the existing pavement in the northbound lanes and adjacent approaches for the intersection of US 27 and Old KY 80 and the intersection of US 27 and KY 80 Bypass was constructed. A quantity of Bituminous Concrete Base Class I was deducted from the project due to an actual underrun of this material. Items for the removal of underground storage tanks were deleted from the contract because no underground storage facilities were encountered on this project.

An increase of 33 Working Days was allowed for this Change Order.

Increase $437,568.75

CHANGE ORDER NO. 12 (WHITLEY CITY-SOMERSET ROAD)

Thermoplastic Pavement Marking 4 inch was substituted for painted 4 inch pavement striping. This change was made due to thermoplastic striping having an estimated lifetime of six years compared to the painted striping that would have to be repainted annually.

Contract Working Days was unaffected by this Change Order.

Increase $14,720.00

CHANGE ORDER NO. 13 (WHITLEY CITY-SOMERSET ROAD)

This Change Order was necessary to reimburse the contractor for documented cost for mobilization and bond related to the deletion of the median edge drain system.

The edge drains were deleted due to a construction revision. The subcontractor had already delivered the materials and mobilized equipment for the construction of the edge drain system when the revision was made. Also, in order to expedite the project, the Department agreed to furnish the steel strain posts for an added signal at the Columbia Street intersection. Additionally, the contractor was compensated for traffic control provided for the Ky Transportation Center’s testing operation at the intersection of KY 80 and US 27 and the intersection of Cumberland Parkway and US 27. Asphalt Drainage Blanket Type II was decreased due to an underrun of this material on the project.

Contract Working Days were unaffected by this Change Order.

Decrease $2,406.09

CHANGE ORDER NO. 1 (SOMERSET BYPASS GRADE & DRAIN SECTION)

This Change Order was necessary to add items to remove a 500-gallon underground storage tank that was encountered on Parcel #77.

An increase of 1 Working Day was allowed for this Change Order

Increase $11,600.00

CHANGE ORDER NO. 2 (SOMERSET BYPASS GRADE & DRAIN SECTION)

This Change Order was necessary to provide additional quantities of pipe in order to lengthen the drainage structures on the project from Station 336+00 to Station 435+00 and lengthen the vertical curve at VPI Station 387+00. The contract was originally set up as 2-lane construction with 4-lane ultimate construction involving 600,000 yards of waste material. The lengthening of the vertical curve will decrease the amount of embankment needed to construct the ultimate construction. Also, lengthening the drainage structures will allow the use of some waste material in the ultimate embankment and prevent the ultimate construction from becoming a borrow job.

The contractor requested to place Class IV Channel in lieu of Class II and Class II Channel Lining. Limestone rock from the project was used which resulted in a savings to the Department. Silt fence was needed at various locations throughout the project to prevent pollution of sinkholes and streams. Also, temporary fence was installed when the property owners of Parcel No. 2 refused to fence their remaining property. This

temporary fence was constructed in order to keep the landowners cattle out of the construction area.

Concrete was placed in solution channels encountered in the roadway cut on the KY 769 Approach to Stations 41+00 to 45+00. Also, removable striping tape was placed on the mainline at the intersection of the KY 80 By-Pass and this project. This was done because the final pavement had been placed at this intersection, but traffic striping was to be changed once the project was opened to traffic.

An increase of 46 Working Days was allowed for this Change Order.

Increase $29,718.98

CHANGE ORDER NO. 3 (SOMERSET BY-PASS GRADE AND DRAIN SECTION)

This Change Order was necessary to remove waste tires and asbestos material covered in a residential dump area found on the project. These items had to be disposed of in accordance with the current Natural Resources and Environmental Protection Cabinet’s requirements. Also, two precast drop box inlets were purchased from the contractor and delivered to the Pulaski County Maintenance Lot. These boxes were ordered and delivered to the project before the Division of Traffic requested a plan change which omitted the boxes. Traffic bound base and 24 Inch vertical panels were needed to provide access to three parcels form Station 395+00 to Station 454+80.

An increase of 1 Working Day was allowed for this Change Order.

Increase $14,139.30

CHANGE ORDER NO. 4 (SOMERSET BY-PASS GRADE AND DRAIN SECTION)

This Change Order was necessary to substitute 30 inch double entrance pipes in lieu of an 18 inch entrance pipe Rt. Station 69+50 on Highway 769. The additional capacity is required to provide adequate drainage along the approach road and entrance. The decision to change the type of entrance pipe at this location was made after the contractor had ordered and delivered the 18 inch pipe to the project. The Department reimbursed the contractor the documented cost of the pipe. Said pipe was delivered to the Pulaski County Maintenance Barn. Also an entrance was eliminated Lt. Station 65+50 on Highway 769; therefore, the pipe that had already been ordered and delivered was not needed and the contractor was reimbursed the documented cost of this item and this pipe was also delivered to the Pulaski County Maintenance Barn.

A sinkhole that was approximately 75 feet wide along the top of the cut and extended down approximately 75 feet to the intermediate bench located Rt. Station 299+50 to Station 300+25 had to be excavated on a 2:1 slope from the ground line to the base of the sinkhole. The Division of Materials Geotechnical Branch recommended this work after an onsite inspection of the area.

The contractor requested to use Class IV Channel Lining in lieu of Class IA, Class II, and Class II Channel Lining throughout this project. This change in the contract plans was documented in Change Order No. 2. This additional change order deletes the item of Class IA channel lining and zeroes out the remaining quantity of Class II and Class III Channel Lining, which was not completely deleted in Change Order No. 2. The contractor submitted a Value Engineering Proposal to use Class IV Channel Lining and this Change Order compensated the contractor for this approved recommendation.

A school bus turnaround was required on Old Highway 769. An existing entrance was widened and 16 feet of pipe was added to existing concrete pipe. This area needed a school bus turn around because Old Highway 769 became and dead-end road at the completion of the project. Additionally a gabion basket wall was constructed on the project Lt. Station 34+00 on KY 769 in order to redirect the drainage flow from the outlet of a 54 inch pipe into a 12 foot flat bottom ditch which is perpendicular to the pipe.

Contract Working Days were unaffected by this Change Order.

Increase $95,944.94

CHANGE ORDER NO. 5 (SOMERSET –BYPASS GRADE AND DRAIN SECTION)

This Change Order was necessary to increase Roadway Excavation quantities due to a slope revision Rt. Station 290+00 to Station 303+00. Rock was not encountered at the elevation shown on the plans. The top bench had to be lowered and this also required the back slope to extend farther back. Several areas from Station 345+00 to Station 456+50 had to be undercut due to encountering unsuitable material at these locations.

The prices for bituminous mixtures were adjusted on this Change Order in accordance with the project proposal’s Special Note for Asphalt Cement Quantity. Fuel and Asphalt Price adjustments were also required in accordance with Special Provision No. 46K (94) in the project proposal.

The intersections of the mainline approach roads at KY 769, KY 192, and KY 80 were paved to the back of the radius using the pavement design of the ultimate mainline pavement which was constructed on a separate project. Paving these approach intersections to the mainline depth on this project avoided having to remove pavement and pave under traffic on the surfacing contract.

Contract Working Days were unaffected by this Change Order.

Increase $78,786.85

CHANGE ORDER NO. 6 (SOMERSET-BYPASS GRADE AND DRAIN SECTION)

An additional quantity of Roadway Fill-Granular Embankment was required for backfill material under the bottom slab of the concrete box culverts at Station 351+04 and Station 433+38. This select granular material replaced compressible material excavated from between the existing rock line and the plan of bottom slab.

Contract Working Days were unaffected by this Change Order.

CHANGE ORDER NO. 1 (SOMERSET BYPASS –BITUMINOUS SURFACE)

This Change Order was necessary to increase signalization quantities in order to install signalization at the Somerset By-Pass-KY 192 Intersection.

An increase of 3 Working Days was allowed for this Change Order.

Increase $57,128.50

CHANGE ORDER NO. 2 (SOMERSET BYPASS-BITUMINOUS SURFACE)

This Change Order was needed to install the correct guardrail end treatments throughout the project in accordance with the current safety and design standards for guardrail systems.

An increase of 1 Working Day was allowed for this Change Order.

Increase $12,900.00

CHANGE ORDER NO. 3 (SOMERSET BYPASS-BITUMINOUS SURFACE)

This Change Order was necessary to place a ½ inch thick bituminous concrete scratch course over the mainline driving lanes the length of the project. Also, bituminous base class K was quantities were decreased due to an underrun of this material used on the project.

Contract Working Days were unaffected by this Change Order.

Decrease $3,074.00

CHANGE ORDER NO. 4 (SOMERSET BYPASS-BITUMINOUS SURFACE)

The unit price for Crushed Stone Base was adjusted due to an excessive underrun of quantity actually used on the project. The agreed unit price for this supplemental item was calculated using the excessive underrun formula as listed in Section 104.02.02 of the Standard Specifications.

Additional guardrail was needed to construct the guardrail system throughout the project in accordance with current design and safety standards.

An entrance was constructed Lt. Station 75+30 on the KY 192 approach. The construction of this entrance was required in the right-of-way settlement of Parcel No. 75 and required entrance pipe.

24 inch entrance pipe was required to place entrance pipe alongside the existing 24 inch pipe at an entrance Lt. Station 57+35 on the KY 769 approach. The additional capacity was needed to provide adequate drainage along the approach road and entrance. This change was recommended during the final inspection of the project.

Grates on two existing drop box inlets and one existing sloped box outlet had to be replaced. These grates were stolen from the project at some time after completion of the previous grade and drain project but before completion of the surfacing contract.

Contract Working Days were unaffected by this Change Order.

Decrease $330,096.77

Project Statistics are as follows:

Project Length=1.423 Miles

Contractor: Hinkle Contracting Corporation

w/o/s Hinkle Corporation

P. O. Box 200

Paris, KY 40362-0200

Total Original Contract Amount $6,187,199.80

Total Change Order Amount $1,461,228.87

Total Revised Contract Amount $7,648,428.67

Pulaski County-Somerset ByPass Grade and Drain Section

Project Length=3.766 Miles

Contractor: Hill & Hill Company

P. O. Box 555

Corbin, KY 40702

Total Original Contract Amount $8,862,636.25

Total Change Order Amount $ 254,690.07

Total Revised Contract Amount $9,117,326.32

Pulaski County-Somerset Bypass (Bituminous Surface)

Project Length=3.753 Miles

Contractor: Hinkle Contracting Corporation

w/o/s Hinkle Corporation

P. O. Box 200

Paris, KY 40362

Total Original Contract Amount $3,620,870.40

Total Change Order Amount $ - 263,142.27

Total Revised Contract Amount $3,357,728.13

The attendance of all participants in these post-construction review meetings 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:jjf

c: C. Raymer Joe Cox C. Little S. Cornett Ron Laugherty

Paul Francis Larry Kerr J. Gadberry J. Stone J. Mettile

D. Newman David Kratt George Best Ralph Divine C. Knowles

Vaughn & Melton Quest Engrs. Hinkle Corp. Hill & Hill Co.