This $203 million project, constructed over three separate contracts, involved the complex reconstruction of 8 miles of I-41, including the full reconstruction of three separate interchanges.
Kapur provided the overall administration of the contract along with inspection, material testing, erosion control compliance, traffic control compliance, utility coordination, project record keeping, and inter-agency coordination. Our staff helped oversee the construction of more than 1.3 million cubic yards of common excavation, over 800,000 square yards of concrete pavement, over 180,000 tons of asphalt pavement, 80,000 lineal feet of culverts and storm sewer, four stormwater ponds, four signalized intersections, and two roundabouts.
The project also included 25 concrete girder bridges, 27 wire-faced mechanically stabilized earth retaining walls with concrete tip-up panels, 46 sign structures, seven noise barriers, and multiple temporary retaining walls, all built using staged construction. Challenges associated with this project included managing numerous stages while maintaining high traffic volumes and mitigating traffic impacts of off-site roadway closures.
Poor subsurface soils were identified during this project, requiring coordination between the project team and WisDOT Bureau of Technical Services and the use of various geotechnical monitoring devices, strip drains, and staged embankment construction. Coordination from Kapur with the contractor and WisDOT was especially instrumental in reaching a resolution after a global stability failure under a retaining wall, which required alternative solutions and an expedited schedule.
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