Fast Track Rehab
by
Rick Brockman
C t ll IIndustries
Costello
d t i IInc.
TDOT
January 22
22-23
23
Nashville, TN
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Introduction
Why do we need to talk about High Volume
Rehabilitation?
•D O T /Owner’ss Perspective
•D.O.T./Owner
–Increasing Traffic Volumes and Resulting
User Delays
y
–Reduce Project Cost
–Reduce User Cost
–Get more bang out of existing pavements
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Introduction
Why do
Wh
d we need
d to
t talk
t lk about
b t High
Hi h
Volume Rehabilitation?
•Contractor’s Perspective
–Increase
I
S f t
Safety
–Increase Productivity
–Focus
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Common Interests
• Safety
• Quality
• Cost
C t
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Safety of Traveling Public &
Construction Workers
• Reducing Traffic Interruptions &
C
Construction
t ti Ti
Time
– Short Project/Major Disruptions
– Long Project/Smaller Disruptions
• Reducing
g Lane Closure Time
• Speed Management & Traffic
Enforcement
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
2/3 of all
work zone
crashes occur
in daylight
Nighttime
crashes
account for
more than
1/2
/ of the
fatal crashes
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Reducing Costs
• Contracting Procedures
– A+B Bidding
– Lane Rental
– Warranties
– Design/Build
Courtesy of APAC Ballenger
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
FAST TRACK PROJECT A & B BIDDING
Project Title:
JPC Pavement Rehabilitation
Location: Bullitt County
State: KY
Route No. & Project Limits:
I-65 from KY 245 to KY 61
Contractor:
Costello Industries Inc.
Owner Agency:
Kentucky Transportation
Cabinet
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
KENTUCKY DEPARTMENT OF HIGHWAYS
BULLITT COUNTY
I-65 Restoration, Bullitt County, Kentucky
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-WHERE SAFETY WORKS-
I65 Bullitt County, KY
TRAFFIC:
Three lanes in each direction
for entire length of project
AADT:
Trucks:
89,900
39%
Misc:
Primary truck route to southern
states from Louisville and
Indianapolis
UPS located 7 miles from Northern
end of project
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
I65 Bullitt County, KY
Bidding Notes:
• Bid June 23, 2006
• 50 Day Maximum
Schedule
• Drop Dead completion
date of October 1st,
2006
Total Days from Bid Date
to Completion
C
l i
101 Days
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
I65 Bullitt County,
y, KY
Incentives:
• $25,000 per day for
early completion
Disincentives:
• $25,000 per day for
late completion
• $25,000 per day after
October 1st, 2006
• Liquidated Damages
for Lane violations
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
I65 Bullitt County,
y,
Lane Violations
• $5,000 for first
hour or any
y
portion thereof
• $5,000 for 2nd hour
• $25,000 for every
successive hour
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Mixes of Fixes
Quantity of each CPR activity
•
•
•
•
Full Depth Repairs (number)
F ll Depth
Full
D
h Repairs
R
i (sy)
( )
Partial Depth Repairs (number)
Joint/Crack resealing (LF)
397
18 900
18,900
2852
689,788
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Mixes of Fixes
Quantity of each CPR activity
•
•
•
•
•
•
Cross-stitching (number or length)
Retrofit PCC shoulders (length)
Retrofit edge drains (length)
G
Grooving
i (SY)
Diamond Grinding (SY)
Other project items
- Traffic Loops
NA ft
400 fft
887 ft
NA - sy
360,000- sy
4- ea
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Project Item
Total
Total SY of Concrete Pavement
18,900 SY
Total Lane Miles
52.08 mi
Concrete Shoulder
Yes
Dowels - Yes
Pavement Type
Joint Spacing skewed, random 12, 13, 17, 18
Pavement Description
Concrete Thickness 11 inches
Surface Texture Type Diamond Ground
Subbase/Subgrade Thickness/Type 3 to 6 inches Dense Graded Aggregate
During Construction Number 8 tie bars were to installed every 18 inches on all
longitudinal joints
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
I65 Bullitt County,KY
y,
Traffic control as bid:
• Limited
Li i d to two mile
il
closures
• 6 foot buffer zone
between traffic and
workers on mainline
Phasing:
• The
Th Project
P j t can be
b
divided into halves
• North
mm 115 to mm118
• South
mm 110 to mm115
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
I65 Bullitt County,KY
y,
Construction Traffic
Allowed on new
Concrete pavement
when
h strength
t
th
reaches 3,000 PSI
The Traveling Public
Allowed on new
Concrete pavement
when
h strength
t
th
reaches 3,500 PSI
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Traffic Control
Southern Section
•
•
•
Traffic
a c ca
can be s
shifted
ted o
onto
to s
shoulder
ou de
Traffic can be reduced to two lanes throughout the week
Traffic can be reduced to one lane on nights and weekends
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Southern Section Daytime
Southern Section
•
•
•
Traffic can be shifted onto shoulder
Traffic can be reduced to two lanes throughout the week
Traffic can be reduced to one lane on nights and weekends
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Southern Section Nighttime
Southern Section
•
•
•
Traffic can be shifted onto shoulder
Traffic can be reduced to two lanes throughout the week
Traffic can be reduced to one lane on nights and weekends
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Traffic Control
Northern Section
•
•
•
Traffic can be shifted onto shoulder
Traffic can be reduced to two lanes only at Night
8pm to 6am
Traffic can be reduced to one lane on weekend nights
9pm to 5am
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
North Section – Weekday
y nights
g
and weekends
Northern Section
•
•
•
•
Traffic can be shifted onto shoulder
No work from 6am to 8pm Monday through Friday
Traffic can be reduced to two lanes only at Night and weekends
8pm to 6am
Traffic can be reduced to one lane on weekend nights
g
9pm to 5am
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
North Section – Weekend nights
g
only
y
Northern Section
•
•
•
•
Traffic can be shifted onto shoulder
No work from 6am to 8pm Monday through Friday
Traffic can be reduced to two lanes only at Night and weekends
8pm to 6am
Traffic can be reduced to one lane on weekend nights
g
9pm to 5am
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Bid Results from June 23rd, 2006 letting
Contractor
“A” Base Bid
Plus “B” Days Required
Total
at $25,000 per day
not to exceed 50 days
Costello Industries Inc.
Faulkner Construction LLC
g
American Contracting
$ 7,138,697.77
$ 7,907,000.00
$16,407,155.77
$
,
,
50 Days
48 Days
50 Days
y
$ 8,388,697.77
$ 9,106,000.00
$17,657,155.77
$
,
,
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Compared to Engineer’s Estimate
“A” Base Bid
Plus“B” Days
Total
at $25,000
,
per
p day
y
KY Cabinet Budget
$ 6,686,355.00
50 Days
$ 7,936,355.00
Costello
$ 7,138,697.77
50 Days
$ 8,388,697.77
Difference
$
0 Days
$
452,342.77
452,342.77
5.7%
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Award
Awarded: July
y 17th,
2006
Award:
• Delayed by bid protest
• Days from Award to
drop dead completion
77 Days
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Project Challenges
• Multiple CPR activities in process simultaneously
¾ Diamond Grinding
Safety Grooving and Grinding needed 39, 10-hour
shifts using 6 machines
Will generate 400,000 gallons off slurry every weekend
¾ Full-depth/Partial-depth Concrete Patching
Costello needed 31 shifts with pouring at multiple
locations
¾ Joint Sealing
Costello/Huff
C
/ ff needed 36 days to
seal joints behind grinders
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Safety
¾ Steps to Ensure Jobsite Safety
¾ 6 ft buffer zones between the traveling
g public
p
and construction
activities on mainline repairs
¾ 10 Attenuator trucks placed throughout project to protect workers
¾ Off-Duty
Off D t B
Bullitt
llitt Co
County
nt sheriffs on project 24/7
¾ Weekly Safety Meetings – with a $50.00 prize from random drawing for those in
attendance
¾ Production and scheduling meetings held twice a week for all project
participants
¾ Multiple yards, dumpsites, water locations and slurry pits were used to lower
congestion at work zones.
zones
¾ Kentucky State Police enforced work zone speed limits throughout project at
no cost to Contractor
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Safety
¾ Steps to Ensure the Traveling Public
¾ Contractor submitted revised TC plan to better utilize time and
to provide a safer lane for the traveling public
g to
¾ KY Cabinet ((DOT)) utilized three Interstate electronic signs
forewarn motorist of impending and actual construction
activity, up to 25 miles in advance.
¾C
Costello
t ll placed
l
d message boards
b
d att 1,
1 3 and
d 5 mile
il intervals
i t
l
ahead of the construction to warn motorist and suggest
alternate routes
¾ Costello placed advertisements in the local newspaper prior to
construction, informing the public of the scheduled project.
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Safety
¾ Steps to Ensure the Traveling Public, cont’d
¾ Costello attended the Bullitt County Commissioners meeting and the
City of Shepherdsville City Council to inform them of the project
¾ Corridor is heavily used by UPS, which the northern end of the project
was near the Louisville airport, UPS hub. Close communication was
kept with UPS via email with construction schedules and potential
closures to better help with their schedules but to make the drivers
aware for safety
y reason.
¾ Close communication was kept with all establishments in the area by
putting schedules and potential closures on 3 x 5 index cards and
handing them out to the local vendors and shops daily
daily.
¾ Communication was key in preparing for and ensuring safety for the
traveling public and the crews.
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Revised Traffic Control
• No limit on length of closure
¾ Costello was able to set up to eight miles of closure in each direction.
This reduced the amount of setups and takedowns by 176
• The staging was reversed
¾ Original
g
contract had traffic being
gp
put on the inside shoulder originally
g
y in
Phase 1 and the outside shoulder in Phase 2. Under Revised Traffic
Control Plan, the inside shoulder and lane were repair first without
putting traffic on the outside shoulder. Since there was very few patches
on the
th inside
i id lane,
l
thi
this work
k was completed
l t d within
ithi 16 days
d
off start.
t t
¾ When traffic was switched over and placed on the inside lane and
shoulder for the duration of the project
project, the local traffic immediately
noticed the improved ride and commented to the KY Cabinet.
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Revised Traffic Control (cont)
• Elimination of 70% of the temporary striping
¾ Due to the increased length of closure that Costello was able
to leave in place.
• Elimination of 72% of the paint removal item
¾ Work was staged so that the grinders removed existing
striping.
ti i
• KY Cabinet saved $486,000 in the striping line
items
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Revised Traffic Control
Gi d
Grinders
R
Removes E
Existing
i i S
Striping
i i
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Revised Traffic Control (cont)
• Center lane patches in northern section could be
performed
f
d att the
th same time
ti
Costello submitted a 4 hr and 6 hour mix design, so that the
patches could be poured within the same shift on weekend nights
The original contracts requirements had the center lane patches
being performed in halves with DGA used to fill any voids.
voids
• Shutdown for Labor Day weekend
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Slab Removal
•
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Costello Industries Preparing the
Subbase for Paving
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Dowel Drilling
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Dowel Drilling
g
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Drilling in Tight Area
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Epoxy Crew
•
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Slab Replacement
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Slab Replacement
•
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Slab Replacement
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Slab Replacement
•
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Crack Sealing
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Hot Pour
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Safety Grinding and Grooving
363,126 Square Yard
• Pretested prior to
grinding
• Grinders
– 6 machines with 4
foot heads
• Tankers
– 10
• Dumpsites
– 3
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Safety Grinding and Grooving
363,126 Square Yard
• Average
g “smoothness”
before CPR:
– Using IRI,
Inside Lane Average 91
91,
Outside Lane Ave. 104
• Average “smoothness”
after CPR:
– Using IRI,
Inside Lane Average
g 56,,
Outside Lane Ave. 66
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Grinders
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
This is the last time we let a
Safety Grinding and Grooving
borrow our loader…
loader
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Who forgot to put out the
barricades…
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Work Completed in 46
46.5
5 Days
Project Item
Full-depth Repairs
Partial depth Repairs
Partial-depth
Joint/Crack Resealing
Retrofit Edge Drains
Diamond Grinding
g
Total
397
2 852
2,852
689,788 LF
887 L
363,126
,
SY
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
RESULTING
SU
G PROJECT
OJ C SC
SCHEDULE
U
Start Date
Completion Date
Scheduled
Actual
Scheduled
Actual
Entire
Project
8/3/2006
8/10/2006
10/1/2006
10/2/2006
Concrete
Pavement
C
Construction
8/4/2006
8/18/2006
9/23/2006
9/30/2006
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Severe Weather
Weather…
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Severe and Catastrophic Weather
Costello Industries encountered the largest amount of
recorded precipitation in the area. The northern
Kentucky areas and the surrounding states where hit
with tornados and flash flood watches on 4 separate
occasions since year of 1932. A thunderstorm will
occur almost every weekend. The county was
declared an Emergency Disaster Zone.
It was described in national print and television media
as the “largest and most severe weather outbreak in
the month of September in record history that was not
directly
y related to a hurricane”.
(Government of KY declared a State Of Emergency for
Bullitt and surrounding Counties)
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Severe and Catastrophic Weather cont…
Resulting Conditions
ƒ
Flash Flood Warning throughout the weekend
ƒ
P t off I-64
Parts
I 64 and
d II-65
65 closed
l
d due
d to
t flooding
fl di
•
Including a section 5.5 mile south of this project
ƒ
Tornado Warnings and Watches throughout the
weekend
ƒ
Tornado Warning Sirens throughout Saturday
ƒ
4 Deaths attributed to the storm in the area
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Testing Results
Project Test
Required
Average Achieved
Thickness
Compressive Strength
Sample Age:
Slump
Air Content
11 inches
3,500 psi
6 hr to 24 hr mix
5 +/- 2 inches
6 +/- 2 %
5.52 inches
5.63%
Opening strength for construction
6 hours
4.33 hours
11.75
4,733 psi
traffic/traveling public
5 25 hours
5.25
6h
hour mix
i bl
blanketed,
k t d 3000/3500 psii required
i d
Opening strength for construction
24 hours
12.33 hours
traffic/ public
p
24 hour mix blanketed, 3000/3500 psi required
14.16 hours
All patches were inspected 4 months after placement, none were required to be replaced.
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
There were other numerous situations
encountered by the Costello that made this
project a challenge to complete.
1.
1
2.
3
3.
4.
5.
The project
Th
j t was delayed
d l
d 2 weekk due
d tto bid protest;
t t
Preconstruction meeting delayed by 16 days because of the bid
protest;
Project was delayed by 3 days because Costello was picketed for
the first week, Costello Southeast is nonunion;
Additional base preparation approximately 26% of Square
Yardage had Urethane product injected under the slabs, which
was a surprise to Costello
Contract stated not to disturb the underlying soil, but a quantity of
DGA is included for undercutting very poor, soft wet soil…to be
used sparingly. There were several areas that required deep
undercutting
d
tti b
butt one particular
ti l area was 300 ft llong and
d 5 ft d
deep.
The areas could not be be determined until the slabs were
removed that made the actual DGA item overran 175%. DGA
was the only item to overrun the entire project.
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Additional Depth with Urethane
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Mother of all drain holes…
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
I65 Bullitt County,
y, KY
Incentives:
• $25,000
$25 000 per d
day ffor early
l
completion
Received $87,500
Disincentives:
• $25,000 per day for late
completion
• $25,000 per day after
October 1st, 2006
• Liquidated Damages for
Lane violations
Paid $125,000 in Lane
violations
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Restoration of I-65
B llitt County,
Bullitt
C
t Kentucky
K t k
Contractor:
Costello Southeast Inc.
Owner/Engineer: Kentucky Transportation Cabinet
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Restoration of I-65
B llitt County,
Bullitt
C
t Kentucky
K t k
Contractor:
Costello Southeast Inc.
Owner/Engineer: Kentucky Transportation Cabinet
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Appreciation
Professionalism, communication and dedication are the pathways to
performing a project successfully and safely.
Thank you to all the companies and their crews listed below for a job
well done!
American Engineers Inc.
Costello Industries Incorporated
Costello Southeast Inc.
Crafco Inc
Inc.
Faulkner Construction LLC
g Corporation
Huff Sealing
Kentucky Transportation Cabinet
Kentucky Transportation Cabinet - District 5
S f t G
Safety
Grooving
i
and
d Grinding
G i di
LP
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Summary
• Proper
p techniques
q
are available to
repair & maintain pavements
• The techniques are used to correct
pavement distresses and prevent their
occurrence, not cover them up
• Partnering and communication between
Owner and Contractor are essential for
a successful project during design, prebid precon and during pre-construction
bid,
pre-construction.
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Closing
• Get In
• Get Out
• Stay Out!
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
References
•
•
•
•
•
•
“Traffic Management-Handbook for Concrete Pavement Reconstruction
and Rehabilitation,” Engineering Bulletin, American Concrete Pavement
Association, Skokie, IL, 2000
“Fast-Track Concrete Pavements,” Concrete Paving Technology,
A
American
i
C
Concrete
t P
Pavementt A
Association,
i ti
Sk
Skokie,
ki IL
IL, 1994
“Highway Reconstruction/Rehabilitation,” Concrete Pavement
Successes, American Concrete Pavement Association, Skokie, IL 2001
“T ffi Management,”
“Traffic
M
t ” Concrete
C
t Pavement
P
t Successes,
S
American
A
i
Concrete Pavement Association, Skokie, IL 1999
“More Than Just High-Early-Strength,” Lawrence W. Cole and Gerald F.
Voigt ACI Concrete International,
Voigt,
International Detroit
Detroit, MI 1995
Mike Boyle – APAC-Ballenger Paving Division
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-
Any questions?
For a copy of this presentation,
presentation
pictures or general information
rbrockman@costelloindustries com
rbrockman@costelloindustries.com
I-65 Restoration, Bullitt County, Kentucky
-WHERE SAFETY WORKS-