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September 19 2020
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Vol. XIV • No. 19
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ODOT’s $116M South Side Mega Fix to Complete Next Spring
Ohio Department of Transportation photo
“Once we get to a rough grade, we cement stabilize and fine grade it, and then put a cure on it. It’s a five-day cure for the cement and with that, there is a lot of planning,” said Tim Cunningham, S&S’s project manager.
By Irwin Rapoport CEG CORRESPONDENT
The Ohio Department of Transportation’s (ODOT) two-phase, $166 million South Side Mega Fix project in Columbus, an initiative awarded to Shelly & Sands Inc. (S&S), will be delivered in April/May 2021. The $126 million project is reconstructing and adding a lane in each direction on I-71 between Stringtown Road and I-70; reconfiguring the I-270/71 southbound interchange; replacing 10 bridges and erecting two new ones; and building three noise walls. “A project of this scale can seem unending at times, but we are nearing the finish line,” said Breanna Badanes, ODOT’s public information officer of Central Ohio. Tim Cunningham, S&S’s project manager is very satisfied with the progress of the work, which was temporarily impacted by COVID-19, which led to several hundred bridge and wall crew members being laid off for 30 days. “Right now, we’ve got a completion date
“The soils have been fairly decent — they’re rocky and not a lot of bad soils surprisingly as about two miles pass in a flood plain,” said Ohio Department of Cunningham. “Four times in the last Transportation photo three years, the U.S. Army Corps of Engineers put up the flood gates as part of the city’s flood protection and twice the I-71 northbound and southbound have been shut down in the middle of the project due to flooding at the top of the intersection.” Peak days had up to 120 S&S and subcontractor employees on-site, with between 35 and 50 currently. They have accomplished many Project 2, $126 million, is reconstructing and adding a lane in each direction on I-71 benchmarks, such as completing all between Stringtown Road and I-70; reconfiguring the I-270/71 southbound interchange; 12 bridges; six retaining walls; miles replacing 10 bridges and erecting two new ones; and building three noise walls. of new lanes and reconstruction of existing ones; and other structures. for the end of year, however, due to specifi- continuously since 2018. This project has Equipment, heavy and light, has been cation restrictions and not being able to lay required a lot of double shifts. Over the essential and key pieces have been cranes for top course asphalt through the inclement three-year period, starting in 2017, it has the bridges and dozers and trackhoes for the weather, that has pushed our scheduling to probably been 60 percent 24/7 work.” excavation. next spring,” said Cunningham. “We’ve The work area encompasses 13 lane mi. see FIX page 2 been on a seven-day work week schedule of highway, including six on I-71.
Page 2 • September 19, 2020 • www.constructionequipmentguide.com • Ohio State Supplement • Construction Equipment Guide
Shelly & Sands Nears Finish Line on South Side Mega Fix FIX from page 1
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“We have 12 to 13 dozer and trackhoes — Cat, John Deere, Kobelco and Komatsu — running around the project,” said Cunningham. “They are moving material. If you take a six-mile, six lane highway, you can break it down into Ohio Department of Transportation photo five different sections and Excavation for the new lanes and reconstruction of the each section kind of existing ones was continuous in order to clear the becomes its own job. It’s just area for the placing of a moving material from one chemically stabilized subgrade. place to the other and getting rid of them. On one occasion I-71 and build the outsides of we had six trackhoes in one the bridges.” section swinging at the same Several of the bridges at time. Machine controls have the I-270 interchange been essential to help meet retained parts of their subspecifications and we have structures. GPS, UTS and ATS.” “They were torn down to Excavation for the new the piers and the pier caps lanes and reconstruction of were rebuilt and minor the existing ones was continrepairs were done on the uous in order to clear the abutment structures,” said area for the placing of a Ohio Department of Transportation photo Cunningham. “We then chemically stabilized sub- Tiebacks for the ramps rebuilt the superstructure, grade. were drilled through the “When you have a big sheet piling, with some placed the beams and poured the decks.” section, you chemically sta- being 45 ft. long. Bridge demolition was bilize the whole work space done at night with the help of prior to putting any underdrain or stone base,” said Cunningham. lane closures. Much of the demolition “You have to let that sit for five days and process was based on slab removal, which nobody can be on it. We may have a spread were cut into squares and removed. For the bridges north of I-270 — those of 15 to 18 guys doing this and we have them go to another area. Once we get to a rough approaching downtown — traffic was grade, we cement stabilize and fine grade it, detoured so that the demolition operations and then put a cure on it. It’s a five-day cure could be done without interruptions. Some for the cement and with that, there is a lot of bridges were built in 90 days, while others took 110 to 120 days. planning.” Good days saw crews lay 2,500 tons of Removal of the excavated materials has asphalt per-day for the road work. been efficient as they have been placed in “All of the concrete ramps were total clotwo old quarries on either side of the project sures or half phased construction,” said that are being filled to reclaim the space. “Some of this work was done with off- Cunningham. “We had four different ramps, road articulating dump trucks, but 85 percent that were not phased and each one was a 30was done with on-road dump trucks,” said day total closure.” Four noise walls were built along residenCunningham. The last of the bridges was completed last tial areas — a mile north and south of the of June. Ten were reconstructed, and two were the I-270 and I-71 interchanges – in 2018. ‘We prepped the working bench and startnew ones. “We had multiple span and slab bridges ed drilling shafts on one end,” said and most were pretty similar in construction Cunningham. “It was a continuous cycle types, lengths and widths,” said with the drill crew completing the shafts and Cunningham, who pointed out that the con- the next crew would come in behind with struction of the bridges began with the mid- trackhoes and cranes setting the post and dle section. “We then did all the excavation panels.” There were several types of retaining and road prep, followed up with 14,000 lineal feet of new median barrier wall. This walls — reinforced cast-in-place, deadman allowed us to switch traffic to the middle of see FIX page 4
Construction Equipment Guide • Ohio State Supplement • www.constructionequipmentguide.com • September 19, 2020 • Page 3
Page 4 • September 19, 2020 • www.constructionequipmentguide.com • Ohio State Supplement • Construction Equipment Guide
Columbus Project Includes Rebuilding Bridges, Noise Walls FIX from page 2
anchor tenons and tieback sheet piling. “As part of this we had a 700-foot section of Army Corps floodwall to build between 2017-18,” said Cunningham. “This came with its own unique challenges because it had federal oversights, ODOT funding and city of Columbus maintenance. From design to construction, there had to be agreement from the different entities. It took a lot of cooperation and we did not take this lightly as flood protection comes with life and limb possibilities.” The ramp reconstruction and retaining wall construction were often linked and phased construction helped to maxi-
mize the efforts of the crews. With the help of lane closures, it allowed crews the room to work ramp and wall work simultaneously. Tiebacks for the ramps were drilled through the sheet piling, with some being 45 ft. long. Cunningham is joined by Ryan Porter, Eric Griffin and Faour Alfaour with countless others in the field to make up the management staff required on this large of a project. “We have all been here from the start,” said Ohio Department of Transportation photo Cunningham. “We have a lot of great help in the Equipment, heavy and light, has been essential and key pieces field and Eric is keeping track of the budget and have been cranes for the bridges and dozers and trackhoes for the excavation.
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administrative issues.” The major subcontractors are The Ruhlin Co. for building part of the bridge structures; Complete General for electrical/ITS communications and concrete paving; Griffin Pavement Striping for permanent and temporary striping; Paul Peterson Co. for maintenance of traffic; Cembase for cement stabilization; Lionel Construction for aggregate base and asphalt; M.P. Dory for permanent signage; and Lake Erie for temporary and permanent safety features. The excavation and demolition will generate 5,000 tons of steel; 100,000 cu. yds. of concrete; 100,000 tons of asphalt; and 315,000 cu. yds. of earth and rock. New materials should include 6,000 tons of steel; 80,000 cu. yds. of concrete; and 415,000 tons of asphalt. Equipment-wise, S&S is using cranes — Link-Belt and Grove; excavators — John Deere, Cat and Komatsu; dozers — Cat, John Deere and Case; loaders — John Deere, Volvo and Cat; dump trucks — Volvo and Cat; rollers — Bomag, Hamm and Cat; and pavers — Vogele and Volvo. “Most repairs, as long as the material and parts are available, are done either the same day or overnight so that we do not have any down time,” said Cunningham. “We have an extensive maintenance and mechanical division that makes sure we have very little down time. Our company is adamant about getting equipment fixed and back in service. One of the major items we had here was buckets breaking concrete — they tend to experience a lot of wear and tear. We also had some broken undercarriages with the tractors [dozers] as some of them had to travel back and forth along a stretch of three miles.” S&S purchases and rents equipment from dealerships such as Columbus Equipment (Komatsu), Ohio CAT (Caterpillar) and Murphy Tractor (John Deere). “Buying the volume of equipment that we do, they’re obviously happy to help us as we are such a good customer,” said Cunningham. “Due to the size of this job, we’ve been able to demonstrate some of the new technology and machines. They wanted us to run Komatsu equipment with integrated machine controls and John Deere and Cat models — dozers and motor graders — with machine controls. They wanted live feedback so that they could develop better and faster machines.” The testing included universal tracking systems (UTS) where the machines are controlled with a robotic survey instrument. “The tightness of the tolerance on the UTS is supposed to be ¼-inch and under and GPS tends to be an inch plus or minus,” said Cunningham. “GPS is really good for getting a rough end fast and then it’s time to bring in the road graders with UTS and cut everything down to be fine-tuned.” S&S uses Trimble and Topcon GPS systems, which has served the company well. CEG
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Construction Equipment Guide • Ohio State Supplement • www.constructionequipmentguide.com • September 19, 2020 • Page 5
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Page 6 • September 19, 2020 • www.constructionequipmentguide.com • Ohio State Supplement • Construction Equipment Guide
Alliance, Ohio, Receives Community Facelifts Courtesy On paper and in practice, the Alliance Water and Sewer Distribution Department is exactly what the name implies. At various job sites throughout the city however, the department’s employees also are a skilled construction team working on a wide range of projects to enhance the city.
While maintenance of the city’s water mains and sanitary sewers is the primary focus of the Water and Sewer Distribution Department, it also seeks out ways to employ skills, equipment and resources toward contributing to the city’s ongoing development. According to Doug Hastings, Alliance Water
and Sewer Distribution superintendent, most of the crew working for the department have a construction background and are extremely proficient at the construction work they’ve taken on throughout the city. An example can be seen in the department’s construction of a
(L-R): Charlie Vance, construction foreman of Alliance Water and Sewer Distribution Department; Tom Seefried, machine sales representative of Ohio CAT; Doug Hastings, superintendent of Alliance Water and Sewer Distribution Department; and Chris Harris, Con/Agg manager of Ohio CAT, review the work being done at the site of the future soccer complex in Alliance, Ohio.
The Alliance Water and Sewer Distribution Department crew, joined by Ohio CAT’s Tom Seefried (2nd from R) and Chris Harris (R) on the work site at the city’s future soccer complex.
municipal soccer complex on a former industrial site donated by the Jim Wallace Company of Sagamore Hills, Ohio. Prior to being converted into an open lot, the 15-acre site was home to the Transue and Williams Stamping Co. plant. Significant site work was required to get the property into shape for the soccer complex, including the separation and removal of 4 ft. of slag, bricks and rocks from the lot as well as treating the soil in preparation for the grass playing field. In all, the department has taken out and processed 5.5 ft. of materials at the site to level the field. According to Hastings, the department is uniquely suited to the task. As he explained it, by converting biosolids, a by-product from the city’s wastewater treatment facility, into usable materials to create topsoil, Alliance realized a savings of approximately $350,000
per year in avoided landfill disposal costs. The process is a win/win for the municipality, operation cost savings plus a product to be used at the department’s various projects, including the new soccer complex. To process the topsoil, the Water and Sewer Distribution Department maintains a 25-acre field where the materials are prepared for use. To blend the biosolids with dirt to create the topsoil, the department purchased a Screen Machine 612W portable trommel screen from Ohio CAT. The Screen Machine 612W trommel is a portable screening plant designed to separate green waste products, including topsoil, compost and wood chips, making it highly effective for the machine’s primary service at the wastewater treatment facility. The unit’s portability also makes it ideal for jobs like the one it’s currently performing at the soccer complex. Ultimately, when the soccer complex is completed, topsoil produced by the department will top off the final surface layer, providing a rich base to grow the field grass. Hastings stated that the top-
The city’s recently acquired Woolley transportable conveyor proudly displays an American Flag and Ohio CAT banner at the soccer complex work site.
Piles of screened dirt from the site are ready to be blended with topsoil mix produced from wastewater biosolids.
Construction Equipment Guide • Ohio State Supplement • www.constructionequipmentguide.com • September 19, 2020 • Page 7
of City’s Water, Sewer Department, Screen Machine
The Screen Machine 612W portable trommel screen feeds the Woolley transportable conveyor to create a stack of material to be used on site.
soil is so rich, the city’s maintenance department claims they have trouble keeping the grass cut at locations around the city where it’s been used. Always on the lookout to make the most of the resources they have to work with, the department plans to use the 612W portable trommel screen’s tailings generated at the soccer complex site as a base for a roadway leading to the city’s police shooting range. Hastings estimated that the soccer complex will be under seed this September and will be ready for games by the 2021 spring season at the latest. Hastings is highly impressed with the 612W portable trommel screen, saying he appreciates the way everything folds up to move from site to site and once placed, set up is accomplished in a matter of 15 to 20 minutes. He said controls for the unit are easy to understand and the accessibility of the grease fittings make maintenance a simple and quick task. Hastings finds the production of the 612W portable trommel screen impressive as well, stating that it keeps up with all the material that the department’s Caterpillar 320 excavator can feed it. On the soccer complex job site, the setup includes a Woolley transportable conveyor, also purchased from Ohio CAT, which, paired up with the Trommel, can create a full stack within a couple of hours. The 612W trommel screen is self-contained, diesel-powered and features a direct open feed hopper with a large 6- by 12-ft. (1.8 by 3.6 m) rotating drum delivering 160
Work is in full swing at the future site of the Alliance, Ohio, soccer complex.
This Caterpillar 308 Next Gen excavator stays busy trying to keep up with the Screen Machine 612W portable trommel screen. Overs from the trommel screen are carried off by the city’s new Caterpillar 289D3 compact track loader.
At the Alliance Wastewater Treatment facility, construction also is under way on the biosolids processing operations with the installation of this stationary conveyor system supplied by Ohio CAT.
sq. ft. (48.7 sq. m) of screening area. The pile heights created by the side discharge conveyor and oversize conveyor offers operators hours of high-capacity processing time without interruption. The fact that the trommel screen was manufactured by Screen Machine, an Ohio-based company, is an added bonus. Charlie Vance, the Alliance Water and Sewer Distribution Department’s construction fore-
man, also is impressed with the Screen Machine 612W portable trommel screen. Vance said that with Ohio CAT as Screen Machine’s authorized dealer, they get the whole package. The department has a great deal of experience working with Ohio CAT, as the city has purchased a wide range of Caterpillar equipment from the company. Vance added that the combination of outstanding equipment, a
knowledgeable and dedicated sales team and unparalleled service are the reason they choose to do business with Ohio CAT. In Vance’s view quality always pays off in the long run. According to Vance, Tom Seefried, Ohio CAT’s machine sales representative, is one of the best in the business. For his part, Seefried has found working with the Alliance Water and Sewer Distribution Department extremely rewarding. He stated that the department has an incredibly positive attitude and work ethic and is always eager to tackle whatever tasks are required to get the job done. Chris Harris, Ohio CAT Con/Agg manager, agrees with Seefried’s assessment. Working with Seefried, Harris recently designed a new conveyor system for the Alliance Water and Sewer Distribution Department, which combines the Woolley transportable conveyor currently in
service at the soccer complex with a stationary conveyor system to be installed at the plant. When Harris stopped in to provide advice on installing the stationary conveyor system, he was surprised to see that the department crew had much of the installation already completed. As well as the recently-acquired Screen Machine 612W portable trommel screen and conveyor system, the city of Alliance recently took delivery of a new Caterpillar 289D3 compact track loader and a new Caterpillar D5K2 dozer. These recent purchases add to the department’s fleet, which includes a new 308 Next Gen excavator; a new 320 Next Gen excavator; a new 24DTA Interstate trailer; and a 926M wheel loader out of the rental fleet all acquired in the past year. The city also owns a Caterpillar IT14G wheel loader and Caterpillar 924Gz wheel loader. CEG
Page 8 • September 19, 2020 • www.constructionequipmentguide.com • Ohio State Supplement • Construction Equipment Guide
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