I-65 from State Road 44 to State Road 252, Patching and Rehabilitation
Johnson and Shelby County, Indiana
This design-build project includes patching and rehabilitation of two lanes in each direction separated by a grass median, resulting in four lanes of roadwork. The original roadway consisted of continuously reinforced concrete (CRC) pavement. The guidelines for this contract are to full-depth patch the existing roadway, continuing with the CRC pavement, which includes full reinforcement of each patch. The roadway will then be topped off with new stone matrix asphalt (SMA) surface on the entire mainline and new HMA surface on the shoulders. Also included in the project are new underdrains on both sides of the mainline traveling lanes in both southbound and northbound directions.
The original plan for the patching was to patch the obvious road deterioration with either full-depth or partial-depth patches, depending on the extremity of the area, but INDOT has since brought in a GPR expert, which resulted in a complete change of scope. The expert was able to pinpoint areas where the original CRC reinforcement was missing from the current pavement, which proved to be vastly more extensive than the surface displayed. Our patching quantities have all but tripled due to this. There are three bodies of water passing through our project limits, resulting in six bridge rehab projects within the contract. The first two (Big Blue River) are being almost completely reconstructed. Both end bents and bearings on each end of each bridge are being torn down and rebuilt, and there are full deck and bridge rail replacements in the plans as well. The next body of water heading north is Sugar Creek. These two bridges will also have their end bents completely reconstructed, along with a portion of the deck at each end. They will have their existing latex-modified overlays milled off, with the remaining surface hydrodemolished. The bridges will be patched with partial- and full-depth patches depending on the quality of the deck after demolition. The third body of water is Amity Ditch. The bridges over Amity were not in the original contract, but prior to construction, our project engineer advised they be added due to visible deterioration. The Amity Ditch bridges pair will be milled/hydrodemolished and a new overlay applied, just like Sugar Creek. New joints will also be constructed at the deck/approach interface, but there will be no end bent reconstruction. Work is being performed for INDOT Seymour District through an on-call inspection agreement. Approximate construction costs are $21 million (Contract R-33860).