June 6, 2001

Jim Rummage, P.E.

Chief District Engineer

District 9, PO Box 347

Elizaville Rd

Flemingsburg, KY 41041

Dear Mr. Rummage:

I-64 Rehabilitation

Item No. 9-2005.00

Item No. 9-0155.01

KY 1 Widening

Post-construction Review

Post-construction reviews of the subject projects were held on May 3, 2001 in the District 9 conference room with the following personnel in attendance:

Siamak Shafaghi C. O. Highway Design

James Simpson C. O. Highway Design

Diana Radcliff C. O. Operations

Ronnie Miller District 9, Construction

Joette Fields C. O. Highway Design

Robert Semones C. O. Highway Design

Katrina Bradley District 9, Construction

Larry Taylor District 9, Construction

Robert Trent District 9, Construction

The attendees reviewed the plans and the change orders occurred during the construction of both projects. A total of nine (9) change orders had been issued for these projects with two (2) change orders on the I-64 project pending approval.

The meeting was followed by on-site investigation of the project areas. The I-64 project in Bath County involved pavement rehabilitation of a section of the highway encompassing a distance of 7.2 km--MP 117.00 to 121.50. The Carter County project involved widening of KY 1 for a distance of 0.571 km from 0.2 mile south of I-64 north to AA Highway. The meetings dealt with issues pertaining to Grade, Drain, and Surface. The following is an account of the incurred change orders on each project.

As per the project phasing, the existing outside shoulder of I-64 was to be used to divert traffic. The existing shoulder was to be removed and replaced with full depth asphalt material to provide added stability. This change order was issued to set up the pay item for Asphalt Pavement Milling of the said shoulder area, which had been inadvertently left out from contract.

Contract time was not affected by this change order.

Increase $133,360.92

This change order was approved to authorize the following changes;

1. Establish bid prices for Fabric Geotextile Type III and Backfilling Undercut. These items, integral to the proposed "Bridge End Stabilization", were left out from the contract.
2. Temporary Barrier Wall was proposed as part of the Traffic Control Plan (TCP). However, "delineators", which are used in conjunction with Temporary Barrier Wall, were left out from the contract. This change order established bid prices for "Delineators for Barrier Wall".
3. The project TCP called for the quantity of Temporary Barrier Wall to be delivered from the KY801 interchange in Rowan County and Iron Works Pike in Fayette County. The actual quantity of barrier wall delivered from Iron Works Pike was in excess of that set up in the TCP, hence the contractor incurred additional hauling expenses. This change order established a bid item to reimburse the contractor for the additional hauling expenses.
4. This change order brought the originally planned guardrail end treatments up to the current specifications by replacing a number of Type 4A end treatments to Type 3. As a result, Drop Box Inlet Type 5f, which is used in conjunction with Type 3 end treatments, was also established.
5. The contract specified that all guardrail removed from the project was to be transported to the Bath County Maintenance Garage. However, due to lack of storage space and per the direction of Central Office, all guardrails were hauled to Frankfort Yard, which caused the contractor to incur additional hauling expenses. This change order reimbursed the contractor for the additional hauling expenses.
6. Upon field review of the proposed 100-mm drainage system, decision was made to use the existing median boxes for drainage. This change order established pay items for this work.
7. "Lane Closure" was proposed in this project. However, "Temporary Removable Striping Tape" which is used as an integral part of lane closures, was not included in the plans. This change order established bid items for "Temporary Removable Striping Tape".
8. The contractor worked on eight (8) bridges involved with the project concurrently. Therefore, four (4) additional crash cushions and four (4) additional crash cushion relocations were required. This change order reflected the respective change in the quantities.
9. Upon field review of the substructure of the bridge over Slate Creek and Kendall Springs Road, it was determined that additional bearings needed replacement. This change order established the pay item for additional bearing replacement.

Contract working days remained unaffected by this change order.

Increase $457,733.95

This change order added additional excavation (104,000.00 CU M) of several cut slopes, where the earth material consisting of shales and limestone, was highly unstable and presented a significant safety concern to the travelling traffic with regard to rock falls. This change order included all items such as Clearing and Grubbing, Maintenance and Control of Traffic, etc., necessary to stair-step and lay the unstable areas back in stable slopes away from the highway.

Contract time was not affected by this change order.

Increase $1,714,933.00

This change order was approved to modify the contractor’s approved replacement bearings for the I-64 Bridge over Kendall Spring Road. Added in this change order were also temporary pavement markers Type IV needed for proper one-lane traffic delineation through the four (4) sets of bridges located on this project. This change order added Special Seeding Crown Vetch on slopes steeper than 3:1. This item had been set up in the plans without pay items. Additional items left out from the plans were guardrail bridge end connectors Type A-1 and guardrail terminal section No. 1. These oversight items are indicated in Standard Drawings RBC-001-07 and RBB-002-07.

Contract time remained unaffected by this change order.

Increase $25,663.79

This change order was approved to provide additional leveling and wedging in order to pave the roadway and shoulders according to the profile grades specified in the plans. This change was necessary as the depth of asphalt in certain areas was up to 26". Included in this change order was an agreement with the contractor to add twenty (20) working days to the contract. This time extension settled all claims by the contractor regarding contract time through the issue date of this change order.

Contract time extended by twenty (20) days.

Increase $769,275.00

Due to numerous change orders, this project was prolonged through the construction season and had to be opened to traffic. Consequently, a solid white stripe used to delineate traffic during a lane closure was removed by means of a milling machine. This was necessary to safely accommodate eastbound and westbound traffic throughout the winter months. This change order was approved to reimburse the contractor for pavement striping removal.

Contract time was not affected by this change order.

Increase 410,960.00

This change order was to request approval for reconstruction of existing Drainage Box Inlets within the safety zone. Extension of a 1050-mm pipe and construction of a Sloped & Flared Box Inlet/Outlet was also included in this change order. The aforementioned drainage work alleviated the need for guardrail.

Contact time was unaffected by this change order.

Increase $10,472.63

This change order was submitted to implement cut slope revisions located at eastbound Sta. 26+000 to 26+360 and westbound Sta. 26+080 to 26+280. This action was necessary because of a major safety concern due to the precarious nature of slope material in the project area predominately consisting of highly weathered shales and limestone. This change order included all items necessary to perform the work including maintenance and control of traffic, drainage and erosion control, and excavation.

Contract working days were extended through the effective completion date of the project on August 31, 2001.

Increase $1,261,109.00

The contractor for this project was The Walker Company of Kentucky, Inc.

Total approved change orders..…………….……..$627,718.66

* Does not reflect change orders 7 & 8

* * *

This change was issued to implement the following changes and/or modifications;

1. Add four (4) units of Crash Cushion Type VI-T. These items were needed in safety zones under the bridge along I-64 where sufficient room was not available to flare out and terminate the guardrail sections.
2. Pave the existing unpaved shoulder area to allow three (3) lanes of traffic needed to accommodate the traffic.
3. Provide Traffic Control Signal system due to traffic jams resulting from high volumes of off-ramp and on-ramp traffic of I-64. The installation consisted of five bulb signal heads, trip loops, and all other needed ancillary items to allow protected and permitted left-turn movements.

Eight (8) additional working days were allowed by this change order.

Increase $111,637.05

The contractor for this project was Judy Construction Co.

Total approved change orders..…………….……$111,637.05

The attendance of all participants in this post-construction review is greatly appreciated. Please submit any additional comments to this office by June 25, 2001. 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: M. Hacock. G. Sharpe D. Kratt J. Simpson D. Hite R. Divine J. Stone