This $22 million dollar job combined a concrete overlay with sections of full-depth reconstruction for 6.94 miles in both directions of I-196 through South Haven, Allegan County. It also included complete demolition and reconstruction of a rest area, culvert installation, permanent signing, bridge deck rehabilitation and installation of median cable barrier.
Schedule and Complexity
The project was on a very close schedule, with no work allowed prior to May 26 and a mandated job complete by November 6. This required some 7 day work weeks, with a few 24-hour work days. In addition to the overlay, 6 sections required full-depth reconditioning; 5 at bridge structures and at the rest area access due to inadequate subgrade. The reconstruction of the 2 interchanges were constrained by the closure of only one off ramp and one on-ramp at a time for a period not to exceed 14 days.
The rest area required complete demolition, beginning with the interesting process of sludge removal from the lagoons and continuing with demolition of the building and all existing facilities prior to the total reconstruction. The new water service began with drilling new water wells and installing new water lines; the new complete sanitary system included reworking and relining the sludge lagoons, new effluent structure, chamber and pump station; a new building, parking area, lighting, landscaping and all new picnic facilities completed the reconstruction.
Construction & Innovation
Construction began by performing concrete patching and placing the asphalt separation layer under traffic on the south bound roadway. Traffic then moved to the SB lanes and complete construction of the NB lanes began. The existing concrete pavement was removed, crushed on-site and recycled as base for the full-depth reconstruction areas. Traffic was then moved to the completed NB lanes. Since the SB asphalt was already in place, concrete paving operations were able to begin within one week of the traffic switch. As a test section, MDOT had the Contractor omit two dowel bars in the wheel path of the NB lanes, while the SB lane dowels were placed in the usual configuration. The NB bridge deck was overlayed in two passes, thus maintaining full access to the entire project length. The SB deck was completed full width.
The Contractor was required to provide a 5 year material and workmanship warranty on the PCCP. To provide assurance and documentation per the Contract requirements, a project-specific Contractor Quality Control Plan, including testing and inspection, was administered by a full-time CQC manager. Additionally, the placement of embeds and the thickness of the pavement was checked continuously during placement, and non-destructive verification tests were performed the following day. The ride was tested every morning with a lightweight profilograph and adjustments were made as necessary.
Traffic was maintained on one roadway in a head-to-head configuration separated with the use of temporary concrete barrier wall. Temporary crossovers were built to access ramps. Changeable message boards in conjunction with temporary signage kept travelers apprised of conditions.