Case Study: I-40 Repair/Paving Project
Lehman-Roberts Co., now in the fourth generation of ownership, continues to build upon a long tradition of quality, trust and strong managerial leadership that sets it apart from competitors in the highway construction industry.
The I-40 roadway was in great need of repairs/paving. Previously, the Tennessee Department of Transportationhad spent a significant amount of resources patching potholes, particularly after the past two years of snow, ice and excessive rainfall. Because this specific project fell between two interchange jobs that were to be finished by the end of 2016, the owner wished to have all work in this important corridor completed around the same time. This was in an effort to relieve the public from construction delays along the I-40/240 inner city area that have been ongoing for the past five years.
This project included a 7.4-mile stretch of roadway that involved milling 3.5” of existing asphalt / filling back with 2” TN 307BM-2 Binder and 1.25” TN 411D Surface. Additionally, there was some concrete pavement replacement on the ramps along with traffic counters cut into the pavement, scoring of pavement, thermoplastic pavement markings, snowplowable pavement markers and guardrail replacement.
This project involved over 100,000 tons of milling and asphalt paving along with a short time frame to complete all items of work. The window of construction was between 8:00 p.m. and 5:00 a.m. Sunday evenings through Thursday evenings. The roadway had to be milled 3.5” deep and filled with 2” binder mix to be able to reopen to traffic each and every night. There were no lane closures carried over to the daytime. The roadway had to be blocked off to traffic during construction allowing two traveling lanes to be opened at all times, milled, paved, striped, temporary markers to be installed and traffic control picked up beginning at 8:00 pm. and opening to traffic by 5:00 a.m. There was a penalty of $1,000 per hour per lane if these time or opening restrictions were violated, along with a ride specification that had to be maintained for smoothness.
Due to a significant amount of liability, it was decided to joint venture this job with another asphalt producer, Standard Construction Company, Inc. Lehman-Roberts Co. would perform all phases of construction on the eastbound side and Standard Construction Co. would complete the Westbound side concurrently to assure the October 31, 2016 completion date. Lehman-Roberts Co. is the managing partner of this joint venture regulating all duties.
Performing this type of work which involves so much exposure to the motoring public, heavy equipment and other hazards, the possibility of injuries or incidents does exist; however, there were no OSHA-recordable or lost time injuries on the I-40 jobsite. Through jobsite planning and the execution of safe work practices, as well as dedicated ownership, supervision, employees and contractors, this job was a tremendous success. The employees put safety first at all times, and the crews conducted pre-job safety meetings, in which everyone’s safety and well-being during all phases of the job were discussed.
Lehman-Roberts Co. completed its portion of the project in early September 2016, almost two months ahead of schedule. Preliminary results indicated a 30.7 HC-IRI Number Per Mile reading on the completed lanes, which falls within the highest category on the IRI Rideability Scale. This was a job that exceeded all expectations for time, rideability and safety.