Interstate 77 that runs through Charlotte, NC, has had major traffic problems for years. Currently, a $71-million highway design-build project is underway to help improve the congestion situation. By widening this 8-mi. (13 km) portion of the highway, the I-77 project will solve many of the troubles this busy interstate encounters on a day-to-day basis. The I-77 project is managed by the North Carolina Department of Transportation (NCDOT) and the prime contractor for the project is Rea Construction Company, one of the leading highway, paving and bridge contractors in the Southeast. The work consists of widening I-77 from two to four lanes in each direction, reconstructing part of the I-85/I-77 interchange and installing intelligent transportation system (ITS) components. One new bridge will be constructed, five bridges widened and extensive noise walls installed. The project began December 3, 2001 and, with the hard work of both the subcontractor, F.T. Williams, and Rea’s Design-Build Team, is already two months ahead of schedule. “This is an unconventional project since the road design is not yet complete. That’s how design-build jobs go,” said Benton Payne, division engineer of the NCDOT. “The preliminary designs were completed early on so that construction can begin which speeds up the process. The rest of the design is completed as the project moves along.” According to Kipp Cheek, project manager of Rea Construction, the job is about two months ahead of schedule. Cheek said the major aspect of the project is widening I-77 from the I-85 interchange northward 8.1 mi. (13 km) to just south of Exit 23 – Gilead Road. Work is scheduled to be completed in 2004. The Rea Team will perform design, construction and inspection services on this first-of-a-kind project. The design-build process is much different than traditional highway projects. In the spring of 2001, the NCDOT advertised the project and many contractors submitted qualifications. The NCDOT then selected the three most qualified firms to submit proposals. Once short-listed, Rea’s team had just three months to design, schedule and develop a bid for this project. Once the proposals were submitted, the low bidder was determined by a “quality adjusted price,” with points being awarded for the design, innovation, schedule and strength of the design-build team. Rea received a quality score of 93, leaving the competition in the dust, with the second highest score of 84. That score, in combination with an aggressive lump sum price, won Rea the project. “Our team’s innovative designs and traffic control concepts will allow us to pursue an aggressive schedule, completing the project on June 30, 2004,” said Cheek. “This is 125 days earlier than our competition. Due to the challenging schedule, we had to begin construction well before any designs were completed. Plans for specific activities [i.e. traffic control, clearing, grading, etc.] are being completed just days ahead of planned construction. Final designs will not be approved until the project is almost halfway complete. This process requires intense coordination and communication between our design and construction teams to keep the work flowing smoothly.” When asphalt work begins this spring, Rea will place 500,000 tons (453,593 t) of asphalt in 21 months to open all lanes to traffic by December 2003. Rea will complete the final 60,000 tons (54,431 t) of surface course and thermoplastic markings in the Spring of 2004. This goal can only be achieved through the team’s implementation of new technology and innovative construction techniques. One example of Rea Construction’s operation of new technology is the use of GPS and robotic survey systems installed on dozers, motorgraders and milling machines. Trimble’s Blade Pro 3D system, sold and supported by Spectra Integrated Systems Inc., provides automatic control of the blades elevation and slope in three dimensions (XYZ). The system’s capability allows grading of complex designs such as vertical curves, transitions and super-elevated curves without stakes, stringlines or surveyors. This will provide for increased accuracy, enhanced production and will allow for the elimination of conventional construction staking methods. Access to the median for construction may be the biggest challenge on the project, due to the high volume of traffic on I-77. Rea’s innovative solution will allow workers to construct an earth ramp in the median up to the existing Harris Blvd. Bridge. By tying the ramp to the existing bridge, trucks will be able to exit the median without having to enter the interstate traffic. Traffic will be shifted and lanes narrowed on the bridge to allow room for a provisional construction lane. This provides a direct route to Rea’s portable asphalt plant, staged just off Harris Blvd. Recently, temporary concrete barrier installation has begun next to the northbound lanes, with crews working north from I-85. Soon after, a second crew begins installing barriers next to the southbound lanes. That means only one northbound and one southbound lane will be open overnight while crews are installing the barriers. Once the barriers are in place, most work will be done during the day as crews cut trees and grade the median where the new lanes will be built. Even with all lanes open, drivers face the distraction of seeing workers and equipment behind the barricades. “That could slow traffic,” NCDOT Resident Engineer Jim Cravens said. “You will have the ’I-want-to-watch’ effect - rubberneckers,” he said. Cheek credits the current success of the project to the teamwork and support of the NCDOT, partnered with the efforts of the Rea Team. Rea and the NCDOT are trailblazing North Carolina’s new design-build process with a team of companies that was hand picked, integrating firms specialized in design, inspection and construction. The design effort is led by Wayne Moody, of HDR Engineering. HDR is the lead designer and is assisted by Ralph Whitehead Associates, both based in Charlotte. Inspection services, led by Jimmy Dennis, are provided by Barbara H Mulkey Engineering, with testing and geo-technical services provided by Froehling and Robertson Inc. Mulkey also is providing both design and construction surveying services. The construction team consists of F.T. Williams Company – clearing, grading, erosion control and drainage pipe installation; Driggers Electric & Control Company – lighting, signing and ITS installation; Propst Construction Company – chemical stabilization; Reynolds Fence & Guardrail; Ledbetter Pavement Marking; and GML Contractors – seeding and landscaping. Lockheed Martin provides the ITS design and construction services. Rea’s internal team is led by David Grey, serving as the Design-Build manager of the project. Grey led the proposal effort and is responsible for the overall design-build process. Cheek, who is leading the construction team, is supported by Jeff Turner and Mike Grey, project engineers; Mitch Galyon, David Shinn and Wayne Ailey, project supervisors; and Felipe Mendez, traffic control foreman. The structures effort is led by Dave Wissell, project manager, supported by Kenny Crump, project engineer, and Larry Greene, superintendent. Rea has also added Donna Payne to its team, serving as the administrator for the project. Robbie Robinson, Rea’s plants manager, will be supported by Bays Mitchell Jr., and will produce asphalt for the project using a CMI PTD-400 portable asphalt plant. Trucking services are provided by Asphalt Materials, a division of Rea, and Wayland Trucking, a division of F.T. Williams. Carolina Prestress LLC, another Rea company, will supply the prestress concrete beams for the bridges on the project. Cheek and Grey credit the current success of the construction effort to good weather and the quality work of F.T. Williams Company. F.T. Williams, led by Brent Crisp, vice president and Bob Allen, project manager, is not new to this type of work or to Rea Construction Company. The company is a premier grading contractor in the Charlotte area and is responsible for the clearing, grading, erosion control and drainage on the project. Some equipment on hand for F.T. Williams includes two Cat D300 articulated trucks, seven Volvo A30 articulated trucks, two Cat D6M dozers, two Champion 780 motorgraders utilizing Blade Pro 3D, one John Deere 750 dozer equipped with a GPS survey system, as well as other excavators and scrapers. Jim Price of Propst Construction Company, added that in support of the chemical stabilization operation, CMI mixers and Ingersoll-Rand vibrating drum rollers are being utilized. “Due to specific requirements for the job, we are designing our own equipment to help us perform some of the stabilization work,” said Price. “We are also reviving some old equipment such as a French loader, perfect to cut grade in a narrow area. This project is truly one-of-a-kind since it’s a mix of the latest technology with the variation of old and new equipment.” Cheek added that Propst has been instrumental in finding ways to implement many of the teams unconventional and innovative ideas. For more information visit www.reaconst.com. This story also appears on Construction Equipment Guide.
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