November 17, 2000

Mr. C. L. Meyers, P. E.

Chief District Engineer

District 6

421 Buttermilk Pike

PO Box 17130

Covington, KY 41017-0130

Dear Mr. Meyers:

FD52 059 0075 184-188

Item No. 6-038.20

A post-construction review on the subject project was held on September 20, 2000 in the District 6 conference room with the following personnel in attendance:

Siamak Shafaghi C. O. Highway Design

Robert T. Semones C. O. Highway Design

The attendees reviewed the project plans and construction Change Orders. Twenty (20) 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 Grade, Drain, and Surface of a new lane and rehabilitation of I-75 and the Dixie Highway interchange from 3000 ‘(ft) south of Dixie Highway to Kyles Lane totaling a distance of 1.334 miles. The bridge plans in this project were prepared by the American Consulting Engineers. The meeting was followed by an on-site investigation of the project area. The following is an account of the change orders and the reasons for their occurrence.

This change order was approved to implement a Value Engineering proposal. The Maintenance of Traffic Control Plan originally called for the ramps to be left

open which would require construction of retaining walls. However, prior to the letting, the M.O.T. was revised, whereby the ramps were closed and a detour was provided instead. This resulted in the savings of one (1) year construction time as well as the elimination of the retaining walls. The said proposal was approved by the Central Office Construction personnel.

The working days were not affected by this change order.

Increase $146,184.21

This change order was issued to allow use of load transfer assemblies in all of the mainline shoulders, since mainline shoulders were being utilized to carry traffic during the various construction phases. This change order included emergency repair work performed in the left shoulder Southbound I-75, where traffic had been shifted during traffic phasing. Several transverse joints had begun to fail under traffic and required immediate repair. The said work was approved by the Central Office personnel.

Two (2) additional working days were allowed by this change order.

Increase $129,314.94

This change order was the result of the construction revision to the Northbound

I-75 bridge over Rivard Drive due to conflicts with the existing utilities and heavy residential traffic. The original bridge plans had specified Piers 1 and 2 in close proximity

of the existing utilities and the existing spread footings. Consequently, the proposed spread footings were eliminated and Piers 1 and 2 were placed on Drilled Shafts in lieu of spread footings.

These changes did not affect the working days.

Increase $18,501.48

This change order was approved to authorize a change in the pavement design of Dixie Highway. Due to unsuitable subgarde, numerous utilities, and extremely tight working area imposed by traffic phasing, the pavement design for Dixie Highway (US 27) was changed to include a 10-inch PCC Base widening to tie to the existing concrete pavement which was overlaid with 1 ½ " (inch) surface course. Thus, the necessity to undercut in an extremely utility sensitive area and working between spilt traffic phase was eliminated. This change order included installation of a 15"(inch) Junction Box and a Curb Box Inlet (C.B.I.) Type B to maintain proper drainage due to a 2 ‘(ft) error in the plans, which caused the storm sewer and three (3) drainage boxes to be installed in the wrong location. This change order also reflected use of a ground wire for the race way in the barrier wall, in lieu of a metal conduit as per the direction of the Central Office Division of Traffic.

One (1) additional working day was allowed for this change order.

Increase $60,882.60

This change order was approved to authorize the following activities;

1. Add guardrail and End Treatments Type 1 and 2A to protect the traffic from the 2:1 slope between Left of Ramp A and mainline; Sta. 504+50 to 510+00. From Sta. 472+00 to 475+00, an End treatment Type 2A and an End Treatment Type 3 were added to provide access to the Detention Pond which was part of this project. These end treatments required 350 LF of guardrail installation and removal.
2. Remove pavement and construct 10" (inch) PCC pavement near the centerline on Dixie Highway, Sta. 40+00 to 43+50. The existing concrete pavement in the said section deteriorated immediately after milling operations and exposure to vehicular traffic.
3. Remove the planned C.B.I. Type A on Dixie Highway Lt. and Rt. Sta. 37+86., which could not be used because of conflict with underground utilities, and, install Drop Box Inlets Type 16G and 15" Slotted Drain pipes to maintain proper drainage.
4. Add a manhole able to withstand traffic and encompass the existing ARTIMIS Junction Box at Sta. 372+50, which was carrying fiber optic cables and was in conflict with the new driving lane on Ramp D.
5. Eliminate a section of the Concrete Barrier Wall Type 14-A-50, where the second race way in the wall would not continue on the adjacent projects or serve a purpose.

This change order resulted in a net increase of five (5) working days.

Increase $32,214.20

This change order involved an inadvertent damage to a fiber optic cable and multi-duct from the ARTIMIS Project, PCN #950142. The damage was sustained during the clearing and grubbing operations and required replacement of the said facilities. However, it was decided to pay for the damages under Change Order #24 under the ARTIMIS Project which resulted in a decrease under this project.

Contact working days remained unaffected by this change order.

Decrease $21,669.12

This change order was issued to increase the target air entrained content from 5.5% to 6.0% +/-1.5% by volume in accordance with the requirements of Section 501.07.01 of the 1994 Standard Specification.

Contract time remained unaffected by this change order.

This change order was approved to implement a Value Engineering proposal which was reviewed and approved by the Central Office. This proposal eliminated boring under I-75/71 by rerouting the 36" (inch) storm sewer and raising the final grade of Orchard road, which eliminated the sag in Orchard Road, hence, providing a more aesthetically pleasing slope. This change allowed use of more shallow trenches which eliminated the concern for possible cave-ins and movement of adjacent properties as well as the potential safety concerns of extremely deep trenches.

Working days were not affected by this change order.

Increase $25,587.70

This change order reflected the emergency work and control of traffic required to repair potholes on I-75 and Dixie Highway to prevent a safety hazard to the motorists. The roadway surface on I-75 from Sta. 402+00 to 423+00 Northbound and Southbound was in very poor condition with numerous potholes of varying size and deteriorating pavement. This section required milling and resurfacing to maintain safe driving surface throughout the rest of the winter season. Included in this change order was also addition of a manhole and fiberglass pipe to allow all deck drainage to flow with the bridge slope to the north end at Abutment #1.This action was deemed necessary to provide a more maintainable drainage system. One (1) additional working day was allowed by this change order.

Increase $109,396.22

This change order was approved to implement a Value Engineering proposal. The proposal eliminated traffic through wall to split southbound traffic. This was warranted by sufficient width on the new pavement which provided for two (2) lanes of traffic.

Contract time remained unaffected by this change order.

Increase $43,580.40

This change order was approved to remit the Department’s share of the cost of the Mediation Conference held on March 23, 1999.

Contract working days were not affected by this change order.

Increase $2,598.94

This change order involved the following activities:

1. Replace granular backfill with Flowable Fill at both bridge ends on the Northbound I-75 Bridge over Orchard Road. This action was necessary due to phased construction which had resulted in settlement cracking in the approach slabs.
2. Add Ground Wire No. 4 per the direction of the Central Office Division of Traffic. This addition was deemed necessary in the concrete median barrier wall raceway along the centerline for the length of the project.
3. Perform special excavation operations in the area of the detention pond to remove and refill unstable material to safely allow mowing equipment for future maintenance activities.
4. Construct 12" (inch) non-reinforced PCC pavement necessary to replace broken and settled pavement adjoining this project on Northbound and Southbound I-75, Sta. 424+68 to 426+50 at the north approaches to River Road Bridge.
5. Provide temporary lighting on southbound I-75 from Kyles Lane to Orchard Road. This was necessary as a means of safety for pedestrians and school children with no bus service who would have to cross the bridge.
6. Add a lane closure which was needed in order to install the guardrail added in Change Order No. 5.
7. Locate ARTIMIS fiber optic line in order to avoid driving posts through the line, in the area where End Treatment Type 3 added in Change Order No. 5, would cross the line.
8. Install Fabric-Geotextile Type III to help stabilize the subgrade in various cut sections on the project where undercutting was not warranted or feasible.
9. Replace Traffic Islands which were not incorporated in the plans but subsequently promised in a Memorandum of Understanding with the owners of Expressway plaza.

Three (3) additional working days were allowed by this change order.

Increase $243,509.79

This change order was primarily issued to protect the traffic from a newly installed Cantilever Sign Structure and its base. 400 LF of guardrail as well as the ancillary items such as Guardrail End Treatments Types 1 & 2A, and Guardrail Connector to Bridge End Type A-1 were employed at Sta. 405+00 Rt. C.L. Northbound I-75. The aforementioned was the result of an oversight in the plans which utilized the

existing cantilever sign structure and base, in spite of conflicts with the new grade, alignment, and a detour. This change order involved repair of a major pothole in the existing 12" PCC at Sta. 425+75 Northbound I-75, while access to the site was facilitated by the traffic phase configuration at the time. Additionally, per the recommendation from Central Office Construction and the direction of District Construction personnel, the slopes of Northbound I-75 from Sta. 421+00 to 423+50 were re-seeded in order to re-establish vegetation. This change order included restoration of areas which contained utilities that were inadvertently damaged during roadway and bridge construction on Orchard and Leslie Roads, as a result of which was the establishment of encumbrance of funds to complete the work .

One (1) additional working day was allowed by this change order.

Increase $94,336.14

This change order was issued to provide drainage to the Northwest corner of Ridge Road and Dixie Highway and upgrade the drainage on Dixie Highway and Orchard Road. This was work was requested by the City of Fort Mitchell who subsequently fully reimbursed the Department.

One (1) additional working day was allowed by this change order.

This change order was approved to remove and reinstall the ARTIMIS 1/10 mile reference markers from the exiting median barrier wall to the new median barrier wall along the length of the project. The ARTIMIS signs had not been addressed on the plans. The existing ARTIMIS Junction Box #119 had to be adjusted to be brought to grade. This change order reflected adjusting the height of the median barrier wall on the Rivard Road Bridge to that of the adjacent median barrier wall north and south of the bridge. This change order included installation of an Interconnect Cable System at the direction of District Traffic Personnel. This System interconnected two new traffic signal systems on I-75/71 at Ramps A & D and at Ramps C & B. Also, at the direction of the Central office Division of traffic, the left turn traffic loop from Northbound Dixie Highway to southbound I-75/71, was replaced with a radar vehicle detector, since it could not be installed on a bridge deck.

A net increase of one (1) additional day was allowed by this change order.

Increase $26,382.94

This change order was approved to replace much of the existing 12" (inch) permanent tape after sustained damage from various traffic changes as well as the weather and snow removal equipment. This change order reflected installation of temporary concrete barrier wall to protect the traveling public and the workers in the work zone throughout the project. This change order authorized removal and replacement of deteriorating curb and sidewalk including traffic control on Dixie Highway north of Orchard Road. This change order included installation of the required thermoplastic markings, crosswalks, left turn skips on Dixie Highway, which were not included in the plans. Temporary detour signs for on I-75 truck ban, which were installed on a previous project on I-75, Northbound and Southbound Tutfway Road at various locations north of I-275 in Ohio, were also removed under this change order. Additionally, the existing 12 " (inch) gore tape on entrance ramps on or adjacent to this project were removed and replaced with broken edge lines (6" skip line) to provide more merging length, and thermoplastic arrows were installed in exit Drop lanes at I-75 Northbound and Southbound between Kyles Lane and Dixie Highway. Replacement of the missing part of stockade fence behind a residence on Orchard road was also performed as a part of this change order in order to provide a tie-in to the R/W fence.

Two (2) additional working days were allotted by this change order.

Increase $111,772.52

This change order was approved to install a sound barrier wall for the property adjacent to the intersection of Northbound I-75 and Rivard Drive.

Working days were not affected by this order.

Increase $1,837.50

This change order was issued to remove the encumbrance of funds as noted in Change Order No. 13, and to provide full and final payment for the repair work performed due to the damages to the utilities on Orchard and Leslie Roads.

Contract working days were extended by one (1) day by this change order.

Increase $2,312.01

This change order was approved to authorize the following activities:

1. Improve visibility and safety on the Dixie Highway Bridge over I-75/71 by installing, removing , and relocating the temporary lighting on the Traffic Control Barrier Wall from Sta. 48+00 to 54+00 on Dixie Highway during all the various traffic phases. This was necessary as the demolition and reconstruction of the old and new bridges had significantly impacted the traffic in the area.
2. Remove and haul to the State Traffic Barn the two ARTIMIS MRVD poles which had been removed by others but left on the project on Northbound and Southbound I-75/71 , Sta. 395+00.
3. Re-align the existing traffic signals with the traffic lanes as they changed during the various construction phases on Dixie Highway.
4. Service and remove temporary lighting added in Change Order No. 12.
5. Remove and place the existing Signal System from the existing utility pole on the Northeast corner of Orchard Road and Dixie Highway to a new pole, so that sidewalk and curb construction could be completed.
6. Finish connecting the 4"(inch) multi-cell ARTIMIS conduit between Junction Boxes along the I-75 Southbound outside shoulder.

This change order reflected relocation of the existing ARTIMIS multi-cell conduit under the new I-75 pavement. The line had been inadvertently damaged and was no longer usable. The new line was installed in the middle of the slope on I-75 Southbound outside shoulder from Sta. 363+72 to 372+70. Two new Quazite Pullboxes were installed and connected to the existing ARTIMIS line at both ends.

This change order included use of a video camera to inspect a clogged house drain at the corner of Ridge Road and Dixie Highway. This was done to investigate a complaint

that the project had interfered with the house drain in the process of installing the storm sewer on Dixie Highway.

This change order added an 8 " (inch) plastic pipe in orderly to properly drain the Dixie Highway bridge abutment along Northbound I-75 to an existing Drop Box Inlet at Sta. 387+95 Rt., C.L. This item was necessary both for drainage and due to the difficulty in performing excavation in rock.

Due to a slide, 600 L.F. of an existing 8 " (inch) chain link fence, which had been called for in the plans from Sta. 502+00 to 508+00 Rt., C.L., I-75 Northbound, was moved back and attached to guardrail posts to prevent further sliding of the fence. The fence could not be re-installed in the proposed location on the plans, due to the presence of the slide on the slope.

One (1) additional working day was allowed by this change order.

Increase $17,476.35

• The need for an appropriate type of drainage control facility during all phase of the project was discussed. In particular during traffic phasing, where lack of drainage maintenance and prevention from entering the road surface can result in adverse consequences. Furthermore, It was pointed out that Load Transfer Assemblies for shoulders, should be included in the pertinent Standard Drawing or a Standard Drawing created to show the details of such devices in the pavement shoulder.

• The significance of a thorough inspection of the existing pavement prior to the letting was discussed. It was emphasized that a careful investigation of the pavement condition, not only in terms of surface but also base courses, should be performed before the project is let. It was pointed out that in many situations, construction of a 1 ½ inch overlay is more cost effective than spot repair of joints, potholes, or deteriorated pavement. It was expressed that this approach provides for less traffic control and a higher degree of safety for the workers.

• It was asserted that in phased construction in particular, flowable fill should be used in lieu of granular fill. It was pointed out that granular fill, unless contained with sheeting against rock wall, would not remain stable and tend to move about causing settlement.

• The issue was raised that roadway plans must match that of the R/W plans. The case in point being one where the R/W plans showed a road that was left out from the roadway plans. It was noted that some mechanism should be in place to keep the District personnel as well as the designer informed of all such details, including the late changes which may be the outcome of ongoing R/W negotiations.

• Temporary lighting and safety of the pedestrians was discussed. The importance of lighting was emphasized, especially in areas where school children without bus service would have to cross a bridge. It was asserted that the design of bridges in urban areas, must fully address the pedestrians with all safety measures such as proper lighting and fences atop the barrier walls, to prevent people from jumping over the barrier wall, only to descend a fatal fall of 40-50 ’ ft. to the ground level, as was the case in a referenced instance..

• The need for the possible revision of a Traffic Standard Drawing titled "Concrete Median Barrier with Light Standards" was brought up. It was expressed that the circular anchor bolts specified at 1 ¼ inch in the drawing, are not readily available, that the standard size is 1" (inch).

The contractor for this project was Central Rock Mineral Co., and the W. L. Harper Co.

The attendance of all participants in this post-construction review is greatly appreciated. Please submit any additional comments to this office by December 4, 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