Concrete Structures

I-40, San Mateo to Pennsylvania (Award Winning Project)

New Mexico Department of Transportation
Project Location: Bernalillo County, NM
Contract Total Value:  $21,653,150.00

This reconstruction project involved the widening and improvements of I-40 through Albuquerque.  The limits of the project, both eastbound and westbound, were I-40 from just east of the San Mateo Boulevard interchange to just west of the Boulevard interchange.  Accommodating interstate traffic was a challenge with weekday traffic flows that exceeded 155,000 vehicles per day through the construction zone.  A large flood channel exists between the eastbound and westbound lanes which eliminated the ability to shift traffic into oncoming lanes.

A large quantity of retaining walls and sound walls were constructed on the project.  AUI set up its own certified precast yard to supply the 83,000 SF of precast walls.  The walls required drilled shafts for foundations and pilasters to support and connect the walls.   Over 8,200 VF of drilling was required for the 120 drilled shafts, 48” in diameter and 22’ deep.  Precast pilasters were bolted on each of the drilled shafts for sound walls to support the wall panels above the surface.  Over 500 wall panels were placed, typically in 10’ sections.

Retaining walls were built for support of the properties involved.  The foundations for the retaining walls consisted of 36”drilled caissons with a 14” x 89# steel H-pile placed (not driven) inside to enhance the integrity of the wall support system.   AUI installed approximately 30,000 SF of sheet piling to facilitate this work.

The paving operations consisted of 3600 SY or 1350 CY of Portland-Cement Concrete Pavement and 137,500 SY or 68,000 tons of plant mix bituminous pavement.  Over 18,500 LF of 42” cast-in-place concrete barrier wall was constructed.  Drainage improvements were included in the project consisting of 5,200 LF of 24”and 36” storm drainage pipe, and 35 drop-inlet structures.

NMDOT CN HE204, HSIP-082

New Mexico Department of Transportation
Project Location:Otero County,NM
Contract Amount: $1,417,898

 

 

 

 

 

 

 

This project originally consisted of five phases of construction.  Four involved removal and replacement of existing concrete wall barrier (CWB), and/or gabion baskets utilizing the existing gabion rock.  The fifth phase entailed removing several large boulders that loomed over the existing highway and had the potential, after heavy rains, to roll off the hillside and impact the traveling public and roadway surface.

The first phase included the construction of three extended shoulder areas.  AUI constructed these areas first to facilitate the subsequent detour of traffic to the newly widened roadway in order to better accommodate the removal and replacement of the gabion baskets and/or CWB.  AUI’s Project Management Team opted to incorporate the three separate shoulder widening areas into one traffic control setup.  This enabled the traveling public to be inconvenienced only one time versus the three times under the original Traffic Control Plan.

The fifth phase, which called for the removal of the ominous boulders, was completed under a separate Traffic Control Plan that required a total closure of the roadway for short scheduled periods of time.

Originally, the intent was to utilize the existing gabion rock in the new baskets.  However, shortly after AUI started the removal of the gabions, it was clear that new gabion rock material would be required to complete the gabion baskets per the intent of the construction drawings.

In addition to the gabion rock, other major bid items included 9,600 SY of rock scaling; 1,100 CY of rock excavation; 4,700 CY of unclassified excavation; 2,274 SY of detour pavement; 3,300 CY of gabion removal and replacement; and placement of 1,150 LF of state-furnished CWB.

For this contract, AUI also retained the services of a Public Awareness Officer, just as we did for the otherUS82 project (foregoing listed Project No. 2).  In addition, AUI implemented an extensive flagging operation which included runaway truck spotters in conjunction with trained and certified flagpersons.

NMDOT CN HE203, TPZ-(HSP)-082-1(24)03

New Mexico Department of Transportation
Project Location:Otero County,NM
Contract Amount:  $1,633,142

 

 

 

 

 

 

 

This project was broken up into two different phases.  The first was to re-slope or layback an area adjacent to the highway that had experienced a lot of rock falls.  AUI was able to accomplish this without blasting by using a large excavator with a hydraulic hammer and transporting material to an area requiring fill beside the highway.

The second phase of the project was at the tunnel area on the highway. The work included the scaling down of loose rock, building a large retaining wall with colored patterned concrete and rock retaining fence for future protection of the roadway and the complete rebuilding of the visitor parking/turn out area adjacent to the tunnel (concrete sidewalk, curb and gutter and new pavement).

Both of these phases utilized many different traffic control setups and flagging operations to maintain continuous traffic movement as well as safety for the public and workers.  Due to the extent of public relations activities needed for this project, AUI retained the services of a Public Awareness Officer.  This Officer coordinated with and/or maintained continuous communication channels with Cloudcroft businesses, the US Forest Service (high fire danger), highway trucking traffic, the media and other agencies concerning construction activities, scheduling and traffic interruptions.

The project consisted of over 13,000 CY of both rock and unclassified excavation also including 4,000 CY of rock scaling.  The new lookout area was constructed when approximately 1,200 SY of detour paving was placed to detour travelers away from the 2,140 SY of permanent minor paving needed to complete the lookout area.  The major portion of the retaining wall was constructed using over 312 CY of structural concrete and over 27,000 pounds of rebar.  By eliminating the blasting operations, the project was able to save over $ 61,000.

Amador Avenue Improvements

City of Las Cruces
Location of Project:Las Cruces,NM
Contract Amount: $2,290,038.67

Amador Avenueis a main thoroughfare for both pedestrian and vehicular traffic for businesses and residences, in addition to regularly scheduled train crossings. This four lane road was reduced to two lane traffic on many occasions for the paving and utility work being performed. A pedestrian refuge island was built to accommodate those trying to access the Community of Hope and area businesses. Sidewalks, drive pads and drop inlets were removed and replaced as necessary and rebuilt in accordance with the American with Disabilities Act compliance.

This Project scope involved the removal and replacement of over 13,000 SF of sidewalk, drive pads and valley gutters, approximately 2,000 LF of concrete curb and gutter, and over 22,000 SY of asphalt paving.  The rehabilitation of utilities included approximately 4,000 LF of high and low pressure gas lines and services in addition to 3,900 LF of new water line, valves and hydrants, and approximately 1,000 LF of SDR-35 sewer line, with 5 new manholes, and new inlet grates.

AUI worked closely with businesses and residents utilizing the city and our own door hangers to notify anyone that could be directly affected during this project. At times when traffic needed to be diverted away from the project site, the flow was sent through less inhabited residential areas so as to not create a heavy flow of traffic into more highly developed residential areas. The safety of both AUI employees and local residents was key, as traffic control measures were revisited regularly to assure that both vehicles and pedestrians were kept a safe distance from any area of construction in addition to the walking paths that were created for pedestrians while sidewalks were being replaced.

Angel Fire PID 2007- Roadway and Infrastructure Improvements

Angel Fire PID (Owner)
Location of Project: Angel Fire, NM
Contract Amount: $24,541,188.31

AUI’s work in Angel Fire, NM on the Angel Fire PID 2007 – Roadway and Infrastructure Improvements Project was a Design-Build Project. The overall scope of this design/build contract could be broken into two categories:  (1) Roadway improvements, and (2) utility infrastructure improvements.  Due to sub-phasing tied to project funding, this was a multi-year contract spanning from 2009 through anticipated completion in 2012.  Roadway construction (approx. 18.5 miles) included widening, grading, bank stabilization and surfacing in addition to trenching of approximately 291,000 LF for electrical and telephone lines. The site utilities scope of work included approximately 98,100LF of C-900 waterline (82,72LF of 8” and 15,380LF of 6” respectively) in addition to 2,700LF of 4” DI pipe. This project also included placing approximately 38,590LF of 8” SDR 35 PVC sanitary sewer pipe.  AUI was also contracted to include two water storage tanks; a booster station; gravity collection lines and service stub outs in addition to three lift stations.

In consideration of the project location, AUI completed this project in phases that correlated with seasonal changes to ensure a safe working environment and a quality end product.

Exit 102 Acomita I-40 Interchange at MP 102.000

New Mexico Department of Transportation (Owner)
Contract Amount: $3,851,057 (AUI Subcontracted portion)

This project is one of the first bridge/interchange projects that utilized roundabouts at the on and off ramps.  The newly constructed bridge over I-40 was built approximately 1000’ west of the existing interchange.  The two-span, 200’ long twin bridges contained many aesthetic features from custom formliners to custom-stained concrete.  Traffic was never interrupted during the construction of the new bridge or during the widening of the existing bridges.   This was a very challenging portion of the project as the existing interchange bridges had to be partially demolished and widened without disrupting traffic on either I-40 or Old NM 124 running underneath the bridge.  AUI devised a method utilizing steel beams and heavy duty shoring to accommodate this unique challenge.  AUI was a subcontractor to Kirkland Construction who was responsible for the paving and earthwork on the project.  AUI constructed all of the concrete flat work on the project along with all concrete structures on the project including but not limited to curb and gutter, sidewalk, drop inlets, PCCP, colored/ patterned median paving, bridges, concrete box culverts and concrete slope blankets.

A major challenge on the project was the location.  The Acomita area is well known for its harsh winters.  The majority of this project was constructed during the winter months.  AUI fought through numerous snow storms and many days where the wind chill factor brought temperatures down into the single digits; however, the project progressed and was never suspended due to weather.  AUI made provisions to accommodate cold weather concrete to the satisfaction of the NMDOT.  This project was been a great success and a fine example of collaboration between the contractors, the NMDOT and the Pueblo of Acoma.

I-10 Hidalgo, Luna And Dona Ana County: CN 1100021

New Mexico Department of Transportation
Project Location: I-10 MP 22.550 to MP 146.680
Contract Total Value:  $117,386.00 (AUI Subcontracted portion)

AUI was subcontracted under two different subcontractors for this project. AUI worked as a 2nd tier subcontractor for San Bar Construction to complete 5 drilled piers for the “ITS” camera poles along I-10,  48” in diameter and ranging in depth of 12’ to 14’. Subsequently, AUI was a 3rd tier subcontractor to McDade Woodcock, Inc, for the construction of 9 drilled shafts to be utilized for Overhead signage along I-10, 54” in diameter and ranging in depths of 14’ to 22’’ deep.

As in previous projects requiring this scope of work, AUI used a “Lo-Drill” mounted on a 330 Hitachi Excavator to excavate the drilled shafts and placed Sonotube to maintain the shaft shape above existing grade. Rebar was placed inside of the drilled shaft and was supported by the Excavator. Type G concrete was placed in the drilled shaft using drop chutes until it was 4’ from the top of the shaft.  A pattern jig was placed on top of a form and the anchor bolts and nuts were placed using the line and grade provided by the surveyor. Once this was complete, the placement of Type G concrete continued up to the top of the form.  AUI has a history of projects involving this type of work, both as a prime and as a subcontractor, in addition to a crew that is well versed in the installation of drilled shafts.

Paseo Del Volcan (Northern Section) Stage II, IRIS to US 550

City of Rio Rancho
Location of Project: Rio Rancho, NM
Contract Amount: $8,796,959 (AUI Inc.’s subcontract amount)

The project called for a 3.1 mile extension of Paseo del Volcan from Iris Road to US 550 consisting of the addition of a two-lane roadway, drainage crossings, roadway intersections with traffic signals, three bridges, and the raising
of Enchanted Hills Boulevard.  Once again AUI was a subcontractor to Mountain States Constructors, Inc., the prime contractor for this City of Rio Rancho project. Under AUI’s $8.7 million subcontract, AUI constructed four bridges (two single-span and two double-span), a seven-barrel box culvert , a two-barrel box culvert , approx. 10,000 SF of soil nail walls , 3,000 SF of pre-cast sound walls , approx. 50,000 SF of MSE wall, and 2,000 LF of concrete barrier wall. AUI also placed over 2,500 LF of RCP storm drain ranging from 72” to 96” in diameter, in addition to 2,000 LF of 12” sanitary sewer and approximately 800 LF of 16” waterline.

This American Reinvestment and Recovery Act (ARRA) funded project began construction in August 2009 and was scheduled for completion by February 2011; however, AUI successfully completed its construction activities by the end of 2010.

I-10, Las Cruces to Texas State Line

New Mexico Department of Transportation (Owner)
Location of Project: Dona Ana County, NM
Contract Amount: $5,092,543.51 (AUI Subcontracted portion)

AUI was subcontracted by Mountain States Constructors, Inc. to assist in the new construction and rehabilitation of I-10 from Las Cruces to the Texas state line. The overall project scope involved the lane expansion of I-10 northbound and southbound lanes from two to four lanes. AUI’s portion of this project included the construction of a 4,800LF permanent concrete wall barrier, a new Gateway Sign for visitors entering the state of New Mexico, and construction of a 42,000SF precast concrete sound wall held in place by drilled piers. Scheduling conflicts were kept to a minimum as the project progressed smoothly with AUI placing over 13,000LF of culvert pipe extensions in addition to approximately 20 drop inlets of various sizes, to provide the necessary drainage for the lane expansion of I-10. The installation of culvert pipe and box culvert extensions; cleaning and or filling existing culvert pipe and box culverts; in addition to preparing the area for Mountain States paving portion by backfill and compaction over these installations, had to be done in an efficient and timely manner to assure that all contractors and subcontractors involved could stay on schedule.
AUI’s success on this project was dependent upon positive working relationships with both NMDOT and the prime contractor, Mountain States Constructors, Inc. The quality of the final project was enhanced by AUI’s commitment to the safety of their employees as there were no lost time accidents on the project and in large part to the dedication of our employees who take great pride in their work. Every effort was made to work together on this project and share resources when necessary; while efficient productivity allowed the project to stay on schedule and on budget.

Camino De La Placita Phase II, TT91-119, BID NO. 02-03-10; MAP-6005(900)00 CN 9582

Town of Taos
Location:  Taos, NM
Contract Price:  $1,634,147.64

The jobsite was located on Camino de la Placita, which is a main thoroughfare bypass for the Plaza area and is a combination arterial/residential collector street. AUI’s contracted scope of work included reconstruction of Camino de la Placita to include new roadway (subgrade prep, base course, pavement fabric, asphalt pavement, curb and gutter, sidewalk, handicapped ramps, drive pads), installation of new water, sewer, and storm sewer lines, manholes, drainage structures, fencing, removal and replacement of CMU walls, signalization, and traffic control.
The biggest challenge AUI faced while constructing this project was impact planning in order to minimize the effect on tourist-based businesses.  The AUI project team worked closely with the Town of Taos project representatives and the owners of businesses affected by the construction activity to schedule roadway, curbside parking, and sidewalk impacts so that business access was maintained for local and tourist traffic.
By being reasonable, cooperative, and working well with the owner’s representatives, AUI met the Town of Taos’s expectations on this project. AUI responded to the project site restrictions and existing site conditions resulting in a project completed within the time expected by the owner.

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