August 18, 2000

Mr. Jim Rummage, PE

Chief District Engineer

District 9

Elizaville Road

P. O. Box 347

Flemingsburg, KY 41041

PCN 960839 CH 961184

Post-construction Review

Dear Mr. Rummage:

A post-construction review on the subject project was held on May 17, 2000 in the District 9 conference room with the following personnel in attendance:

Siamak Shafaghi C. O. Highway Design

Robert Semones C. O. Highway Design

The attendees reviewed the project plans and construction Change Orders. Nine (9)

change orders had been issued for this project. The meeting was followed by an on-site investigation of the project area. This meeting dealt with issues pertaining to Break, Seat, and Overlay (asphalt) of I-64 from Bullfork Road and Creek overpass extending east to 1.118 miles east of KY 32 Bridge. This meeting dealt with issues pertaining to Grade, Drain, and Surface for a distance of 3.65 miles. This project also involved reconstruction of KY 32 for a distance 0.33 mile to add a continuous turning lane which was accomplished on a "proposal" basis. Plans for this project were developed from field and arial surveys. The following is an account of the change orders and the reasons for the occurrence.

This change order was approved to replace two (2) diesel powered Message Sign with two (2) solar powered units as per Design Memo 19-96. The said units became the property of the Department.

No additional working days were allowed by this change order.

Increase $15,000.00

This change order was approved to authorize the following actions;

1. Provide 4-inch non-perforated pipe at various locations to connect the edge drains to drainage boxes. The said item was left out of the plans.
2. Employ additional Flashing Arrows required for maintenance and control of traffic throughout the construction phase. This item had not been set up in sufficient quantities on the original plans.
3. Change "Machine Preparation of Existing Slab" to complete removal of the existing overlay. This change was due to encountering an existing layer of Latex on the Bridge over Bullfork Road, which had to be removed entirely to prepare the slab for the new overlay.
4. Install sufficient drainage structures such as pipes at various locations and modify inlet structures to ensure proper drainage and most importantly, to prevent run-off from entering the roadway. The necessity for additional drainage structures for preventing water from entering the traveled way became apparent during the construction of median cross-overs.
5. Perform additional surveying necessary to set the grades for the temporary slip ramps.
6. Relocate the previously constructed slope box outlets to provide the required side slope for Slip Ramps B and C. The need for this action became apparent after the construction of the said slip ramps.
7. Install 18-inch junction boxes at Sta. 246+00, 2411+00, and 2418+00. This was due to the field conditions physically not permitting use of the 30 degree prefabricated bends as shown on the plans at the said locations. Consequently, the prefabricated bends were delivered to Rowan County Maintenance and paid for at the invoice price.
8. Plug and abandon a pipe in place to provide for less disruption of traffic. This action did not impact drainage as the new construction provided for alternative drainage on Ramp C.
9. Provide additional erosion control measures such as silt checks, silt fence, and silt fence modified (reinforced with straw bales). It was acknowledged that silt fence placed around the drainage boxes in the median did not perform as expected and failed.
10. Remove the concrete guardrail block-outs on the bridges to enhance safety and provide maximum allowable lane width. This action was necessary, since the traffic control plan required westbound I-64 traffic to be placed in the eastbound speed lanes thereby reducing the lane width to an unsafe level.
11. Transport pre-cast headwalls from another project to be used on this project. These headwalls, for which the contractor had been reimbursed by the Department, could not be used on the other project due to a change in field conditions.
12. Repair paint on the steel girders on the eastbound and westbound bridge. The damage to the paint had inevitably occurred due to the required removal of concrete as noted in subsection "j" above.
13. Repair concrete at the pier columns and endbents of westbound Triplett Bridge substructure which were found grossly deteriorated upon inspection. This item had not been set up on the original plans.

Twenty (20) additional working days were allowed by this change order.

Increase $88,816.67

This change order was issued to authorize the following activities;

1. Placement of temporary erosion control measures on the project throughout the winter months of 1997, during which time, all construction activities were halted due to unfavorable weather conditions.
2. Perform underdrain work parallel to I-64 in a sequence other than what was stated in the contract proposal. This change resulted in extra work and materials and required excavation of a special trench to install the 4-inch underdrains.
3. Extend an existing 15-inch culvert in the median at Bullfork Bridge. This change was necessary to construct the minimum 12:1 slope required at the end of the Crash Cushion Type IX-A.
4. Repair numerous recurring rutted area and potholes in the pavement due to subgrade failure. It was deemed by the Department as not being the contractor’s fault. These areas included approximately 2000 ft. of the westbound shoulder where the westbound traffic was shifted during Phase I of the project. The said area (east of the KY 32 off ramp) was found in continuos disrepair due to subgrade failure causing substantial potholes in the driving lanes. The development of these potholes was of such frequency that the contractor would have to interrupt the work operations to perform pavement repairs. The rapid deterioration of pavement was in part attributed to the questionable functionality of the old road drainage system.
5. Reimburse the contractor for the use of his trucks by the UK Transportation Research Center to conduct strain tests by subjecting westbound KY 32 Bridge and westbound Triplett Creek Bridge to repeated truckloads of sand back and forth.
6. Provide a Junction Box type B. This item had been shown on the Lighting Plans but not set up on the bid items summary sheet.
7. Install #1/3 C Ducted Cable in lieu of the planned #2/3 C lighting cable. This change was per the request by the contractor to use a longer route and a larger size cable to avoid the original layout in rock.
8. Reward the contractor for material bonuses in accordance with Special Note 8B in. This provision which was in effect at the time has been deleted and is no longer applicable.

Fifteen (15) additional days were allowed by this change order.

Increase $134,831.26

This change order was approved to implement addition of a continuous turning lane on KY 32. This change involved reconstruction of KY 32 for a distance of 0.33 mile beginning at Sta. 43+00 and ending at Sta. 60+50, and comprised of all items necessary, including utility relocations, to construct the turning lane.

Fifty (50) separate working days were established by this change order based on an agreement between the Department and the contractor.

Increase $983,154.97

This change order pertained to the widening of KY 32 and was approved to use a Quick Valve to make the switch from the old waterline to the new. This was paramount to ensure the water supply to the city and a hospital that were on the same service line, would not be interrupted. This procedure requested by the City of Morehead, required special knowledge and equipment provided by a sub-contractor.

Three (3) additional working days were allowed by this change order with respect to the construction of KY 32.

Increase $9,956.00

This change order was issued for the emergency repair of westbound shoulder pavement. The westbound traffic on I-64 utilized a partial width of the shoulder as a driving lane, which caused excessive pavement failure posing a serious hazard to the traveling public. The emergency repair required total removal and replacement of 1600 ft. of feet pavement which was deemed necessary by the Department. This work was performed at night and required closing the westbound lane of I-64 and detouring the traffic via US60. During the course of construction, a 60-foot section of woven wire right-of-way fence located between the eastbound and westbound Bullfork Bridge, Triplett Bridge, and the Bridge over KY 32, was inadvertently damaged. The right-of-way fence was repaired or replaced as appropriate.

This change order resulted in a net increase of six (6) working days.

Increase $20,109.70

This change order was related to the widening of KY 32 and was issued to reimburse the Morehead Utility Plant Board for relocating their facilities during roadway construction in accordance with the requirements of KRS 177.053.

No additional working day was necessary for this change order.

Increase $1,193.37

This change order applied to the widening of KY 32. It was implemented to construct a modified paved ditch and lower a Drop Box Inlet to facilitate proper drainage at the intersection of KY 32 and Ramp A (westbound I-64 off ramp). This action was deemed the best remedy for a drainage problem where Ramp A intersected I-64. Also included in this change order was filling and capping of two Drop Box Inlets which were encountered during the construction of KY 32.

the widening of KY 32.

Increase $8,602.15

This change order was issued per the direction of the Division of Traffic to construct traffic signals at the intersection of KY 32 and the I-64 eastbound and exit ramps to alleviate safety concerns. This change order deleted several items that were not utilized on this project. Those items consisted of Asphalt Wedge Curb, Fertilizer 20-10-10, Standard Header Curb, a Curb Box Inlet, and Adjusting Guardrail.

Forty one (41) additional days were allowed by this change order to complete the project post the addition of a turning lane on KY 32.

Increase $13,773.95

The attendance of all participants in this post-construction review is greatly appreciated. Please submit any additional comments to this office by July 7, 2000. All comments will be reviewed and disseminated to the appropriate personnel for consideration.

J. M. Yowell, P.E.

State Highway Engineer

JMY:GS:SS

cc: C. Raymer D. Kratt J. Simpson D. Hite R. Divine S. Cornett J. Stone