March 6, 2000
Ms. Linda Wagner-Justice, P.E.
Chief District Engineer
District 12
North Mayo Trail
P. O. Box 2468
Pikeville, KY 41502
Subject: Knott County
KY 89
Item No. 12-00272.00
Knott County
KY 89
Item No. 12-00274.00
Dear Ms. Justice:
Post-construction reviews were held on the subject projects on February 24, 2000 in the District 12 Conference Room. The following personnel were in attendance:
Danl Hall District 12, Construction
Charles Reichenbach District 12
Joette Fields C.O. Highway Design
Chuck Childers District 12, Construction
Siamak Shafaghi C.O. Highway Design
Charles Neeley District 12, Traffic
Kevin Damron District 12, Preconstruction
Johnnie Ross District 12, Environmental
James Wright District 12, Construction
Linda Wagner-Justice Distrct 12, C.D.E.
Jim Jones District 12, Maintenance
Robert Semones C.O. Highway Design
Mike Harley District 12, Design
The attendees reviewed the project plans and construction Change Orders. There were three (3) Change Orders for the intersection improvement at KY 160 project and five (5) Change Orders for the curve revision project. On site investigations followed the meeting. This post-construction review meeting dealt with an intersection improvement at KY 160/KY 899 and included grade, drain and bituminous surface and two curve revisions on KY 899 that also included grade, drain and bituminous surface.
The following Change Orders were discussed:
CHANGE ORDER NO. 1 (PCN 980010-INTERSECTION IMPROVEMENT)
A dewatering basin and temporary silt fence were added to the contract for the Best Management Plan (BMP) for erosion control. Also, channel lining was relocated along the existing channel to stabilize the creek bank after it had been used to control erosion as part of the BMP plan. Finally, perforated pipe was necessary to drain water from under the proposed roadway fill in an area that was constantly wet with running water.
The culvert was reworked to accommodate the natural flow of the stream. The culvert is a 10 x 8’ triple barrel. The main stream flow was originally set up to flow through the middle culvert barrel. However, the diversion wall was placed to allow the flow to go through an end barrel, which accommodated the natural flow of the stream.
An increase of 1 Working Day was allowed for this Change Order.
Increase $4,771.00
CHANGE ORDER NO. 2 (PCN 980010-INTERSECTION IMPROVEMENT)
Crushed Stone Base was substituted for DGA. This Change was made because the crushed stone base was more readily available and there was no change in the unit price for this item.
Two existing pipes under KY 160 at approximate stations 10+240 and 10+274 were safeloaded. This allowed the existing condition of KY 160 to stay intact as there was no open cut trenches on the roadway. Also, bituminous milling and texturing was used to tie into the existing KY 899 at the end of the project at Station 5+200
An increase of 1 Working Day was allowed for this Change Order.
Increase $2,400.43
CHANGE ORDER NO. 3 (PCN 980010-INTERSECTION IMPROVEMENT)
The contract plans required pavement marker type IV. However, pavement markers type V were needed on this route to accommodate snow removal. The same type of pavement markers were already in place on KY 160 on both sides of this project.
An increase of 1 Working Day was allowed for this Change Order.
Increase $3,495.00
CHANGE ORDER NO. 1 (CURVE REVISIONS)
The contract working days were extended by 40 working days with the stipulation that the contractor would work the project on a single shift basis with no night shift allowed. The decision to only work a day shift was made after several residents in this area expressed concerns about the noise nighttime construction caused. There was no additional cost to the Department for the additional traffic control necessary due to this time extension. Also, contrary to the Standard Specifications, working days were to be charged during the months of December through March if the project was not complete.
As part of the Best Management Plan (BMP) for erosion control on this project as set up by the contractor, temporary silt fence, silt traps and permanent silt checks were added to the contract. Also, water was set up on the Raven Curve section of this project for dust control.
An increase of 40 Working Days was allowed for this Change Order.
Increase $5,546.90
CHANGE ORDER NO. 2 (CURVE REVISIONS)
The existing road was cracking and settling due to erosion of the creek bank at the beginning of the project on the "Raven" section of the project. The damaged section extended back beyond the project limits approximately 40 meters. Railroad Rails-Drilled, Cribbing, and Excavation and Backfill were needed for the embankment failure repair in order to make a good transition from the new section of roadway to the repaired section of the existing roadway.
Guardrail was needed to protect the drop off at the repaired area and to transition to a safe location at each end. Guardrail was also needed to protect the public from hitting a gas well that is located within 7 meters from the edge of pavement of the new road on the outside curve right at Station 8+150.
Crushed Stone Base was substituted on this project in lieu of DGA Base at the same unit price. This change was made simply because of the availability of Crushed Stone Base.
During the project, flooding damaged the existing road at the beginning of the "Raven" curve site. The contractor was required to use Traffic Bound Base on the section for Maintenance of Traffic.
An entrance at the "Raven" curve site was relocated in order to improve sight-distance at this location. A culvert pipe was needed under the entrance to provide drainage for a small area to the left of the entrance. The contractor proposed using a Type S polyethylene pipe. This change was allowed providing there was a minimum of two feet of cover over the pipe.
Contract Working Days were unaffected by this Change Order.
Increase $22,198.92
CHANGE ORDER NO. 3
As per a Geotechnical Note in the plans for the "Hemppatch" curve, undercut excavation to remove a coal seam, was required between Stations 40+100 and 40+250.
The contractor was not paid by the Department to remove or haul the coal. The coal became the property of the contractor.
An additional quantity of water was added at the "Raven" curve site. The quantity of water originally set up was not adequate to properly control the dust.
The concrete headwalls at the inlet ends of the pipes at Stations 40+020 and 40+275 were replaced with Drop Box Inlets type 1. This was done in order to provide a better drainage in the ditch line at these locations.
Pavement Striping quantities were increased. The original quantity of pavement striping was underestimated and was not sufficient to place centerlines and edge lines on the full length of the project.
Crushed Stone Base was substituted for DGA Base on this project. This change was made because of the availability of Crushed Stone Base.
Traffic Bound Base was added to the contract. Traffic was placed on the relocated section of the roadway for several days before paving operations could begin and the traffic bound base was used to maintain the roadway under traffic.
The section of new roadway did not match the section of old roadway safely at the end of the project. The old pavement was removed approximately 17 meters past the ending station and replaced with new pavement in order to provide a better transition from the new roadway to the old roadway.
An increase of 2 Working Days was allowed for this Change Order.
Increase $33,734.47
CHANGE ORDER NO. 4 (CURVE REVISIONS)
The end of the cut at Right Station 40+060 to 40+080 was severely fractured. This area was removed to reduce the danger of the rock falling into the roadway. An additional quantity of roadway excavation was set up to accomplish this work.
As indicated in Change Order No. 3, the existing pavement was removed 56 feet past the end of the job to provide a safer transition from the new pavement to the existing pavement. This Change Order established the quantities of bituminous base and bituminous surface necessary to accomplish this work.
Contract Working Days were unaffected by this Change Order.
Increase $10,993.71
CHANGE ORDER NO. 5 (CURVE REVISIONS)
42 meters of guardrail was removed on Parcel No. 3. This guardrail was blocking and entrance that was added to the job in order to access a waste area on this parcel located right of Station 40+228. The Terminal Section No. 1 on the existing End Treatment Type 2A was reused at no additional charge to the Department. All holes that were left by the removal of the guardrail posts were filled and the shoulder was left in good condition.
The apron and grate on the Drop Box Inlet Type 1 located left at Station 40+020 was modified to provide a safer situation for the traveling public.
The items in this Change Order were necessary as directed by the Resident Engineer and Division of Construction in the Corrective Work Completion Notice.
Contract Working Days were unaffected by this Change Order.
Increase $3,563.92
Additional comments from these post-construction reviews are as follows:
The issue with substituting DGA Base for Crushed Stone Base needs to be addressed statewide. The Division of Materials should have a broader range in the gradation for these two materials since the specifications overlap.
A major problem on the intersection project was a local contractor was hired through a rental agreement. This contractor had no roadway construction experience and the subcontractor did not provide adequate leadership and guidance. No blasting operations were performed on this project. The contractor used jackhammers to construct the rock cuts.
There was a suggestion made to have the District 12, Division of Traffic remove the existing regulatory signs when construction begins on projects and store them until construction ends. The Division of Traffic would then reinstall the needed signs after the contractor has completed construction operations. Currently, the contractor is responsible for all signs and often the signs are not in the best of condition when they are reinstalled. The funding for such an operation would have to be negotiated between the Division of Construction and the Division of Traffic.
Project Statistics are as follows:
Knott County-KY 89/KY 160 Intersection Revision
Contractor: Apex Contracting, Inc.
P. O. Box 798
Paris, KY 40362-0798
Total Original Contract Amount $799,550.49
Total Change Order Amount $ 10,666.43
Total Revised Contract Amount $810,216.92
Knott County-KY 89 (Curve Revisions)
Contractor: Rifle Coal Company
P. O. Box 369
West Liberty, KY 41472
Total Original Contract Amount $2,451,526.21
Total Change Order Amount $ 76,037.92
Total Revised Contract Amount $2,527,564.13
The attendance of all participants in this post-construction review is greatly appreciated.
Sincerely,
J. M. Yowell, P.E.
State Highway Engineer
BY: Gary W. Sharpe, P.E.
Director, Division of Highway Design
JMY:GWS:jjf
C: C. Raymer David Kratt A. Johannes J. Wright K. Damron
Danl Hall Keith Damron C. Childers S. Cornett J. Stone
C. Knowles S. Goodpaster D. Newman J. Mettille R. Divine
Rifle Coal Company Apex Contracting, Inc.