Hot job summer: The asphalt pavement process

 

By Tim Potter, 
District Five Public Affairs Manager 

Imagine this: You’re under a blinding sun along U.S. 50 near the town of Walton, and the combined heat and humidity makes it feel like around 106 degrees. It’s suffocatingly hot, the kind of conditions that trigger a heat advisory.

Not just that: You’re laying down asphalt cooking at around 250 degrees when you first apply it. The stiff south wind feels like more of a blast furnace than a cooling breeze. You’ve worked through lunch because overlaying a side road at a highway is one of those jobs where it’s not real practical to take a normal 30-minute break. The equipment has been strategically positioned, and the different tasks involved must click right along. The asphalt -- and the process for applying, shaping and finishing it -- is demanding, unforgiving.

That is what it was like for a combined team of crew members – from the Newton Subarea, District Special Crew and El Dorado Area and El Dorado Subarea -- the afternoon of July 28. If you had to visit one of the hottest KDOT jobs on an extra sweltering day, this was it. They had been overlaying side roads for almost two weeks.

Sweat beads covered the reddened face of Bobby Jones that afternoon as he matter-of-factly explained the work being done and the reality of enduring merciless weather.

“The hotter it is, the nicer it lays,” Jones said of the asphalt. “You have to work it while the asphalt’s hot.” The Newton Subarea Supervisor watched a massive roller compact the new surface. Even though they had paving machines, some of the finishing and clean-up tasks must be done by hand, by bending over a shovel and pushing and lifting.

Through it all, “You have to drink lots of fluids; otherwise, you’ll be laid out on top of the asphalt,” Jones said. “If you don’t keep hydrating, this heat will take it right out of you in a heartbeat.”

Everyone had a different role in the overlay job, and part of it was paying attention to their co-workers – operators making sure they didn’t drive over someone, everyone staying aware of the semis barreling past only feet away, everyone making sure that the next person wasn’t overcome by the heat.

“This is a team effort,” Jones said. “We all have to watch out for each other.”

Did you ever wonder? How do KDOT crews stay cool?

On June 15, workers from Wellington and Hutchinson crews repaired a spot on U.S. 81 between South Haven and Caldwell. The job included a milling and overlay

For days in advance, the National Weather Service sent alerts warning people to prepare for a dangerous combination of heat and humidity on Thursday, June 10. And, of course, there have been and will be other days like that during the rest of the summer.So on a dangerously hot day, how do KDOT employees who have to work in the elements deal with the heat hazards? A common theme was - prevention is crucial. Here is what they shared about coping with the heat and humidity on June 10: 

Dennis Senters, Beloit Subarea Supervisor, District Two: “I made sure they (his crew) had their water with them” – meaning extra water. “You could tell it was the first big heat of the year,” Senters said. “And it was hard on ‘em. When they came in, their tongues were hanging out. I tell them: When you need a break, you take a break.” He also reminds his crew that some people can endure heat better than others, and not to assume that because you feel OK, your co-worker does as well. “We got a great crew in Beloit. We keep a close eye on each other.” 

Daryl Dougherty, Engineering Technician, Phillipsburg Construction Office, District Three: His June 10 work schedule centered around inspecting a grading project north of Osborne on U.S. 24/281. Even with a breeze, at 2:24 p.m. the temperature where he was working was 94 degrees. But the “real feel,” factoring in the humidity, was 103 degrees, Dougherty noted. He had been in the heat for about six hours at that point, but he was making sure he stayed hydrated. “Every time I go back to the pickup, I make sure I drink a glass of water.”

Burke Koehn, Scott City Subarea Supervisor, District Six: Koehn tried to steer his crew to jobs where they could avoid the heat and sun that day. He noted that his area of southwestern Kansas had been unusually humid after weeks of regular rainfall. “The humidity is definitely something that makes it harder to cope with,” Koehn said.

Mike Lorett, Facilities Specialist, part of the District Five HVAC crew: “My biggest trick is a spray bottle of water.” He works outside in sweltering conditions so others can stay cool inside. So he sprays his face, head and neck -- sometimes every five minutes. “I spray my beard, and I call that my portable air-conditioning,” he said, laughing. “I’ve got a big ol’ hat, big ol’ brim on it. I don’t care what I look like -- I keep cool. You got to keep cool, and you got to keep hydrated.”

Dan Acridge, Wichita Area Crew Supervisor: Because of the extreme heat on June 10, Acridge had his crew finish painting stop bars by 2 p.m. “That’s enough -- they’ve been out in the heat all day,” he said. While they worked, he had them take breaks in an air-conditioned truck. “It was really humid this morning, and the humidity burned off a little.” Working directly over pavement intensifies the heat, Acridge noted. “Then, of course, we’re always working in teams so we can keep an eye on each other.”

Remember to slow down and pay attention in work zones and help our crews get their work done so they can make it home to their families. 

Geometric Improvement project in Coffeyville reconfigures a major intersection

The intersection of 11^th  Street and Willow Street in Coffeyville is feeling the summer heat as construction is underway and will be widened with new turn lanes and traffic signals. The City of Coffeyville is reconstructing U.S. 166 at the intersection between Spruce and Elm streets as part of a Geometric Improvement (GI) project. 

Earthwork continues on the eastbound lanes of 11th Street (U.S. 166) in Coffeyville. Two-way traffic is flowing on the westbound lanes.

Restaurants and businesses line both sides of the roadway, which is also known as U.S. 166. In the midst of it all, two-way traffic flows on westbound U.S. 166, workers grade and dig and pour concrete on the eastbound lanes.

Coffeyville Public Workers Director Chuck Shively said the completed project would result in smoother traffic flow. 

The city of Coffeyville is reconstruction U.S. 166 at the intersection between Spruce and Elem streets. 

"The old signals were becoming obsolete and the detector loops did not function correctly,” Shively said. He explained that the intersection of 11th Street and Willow Street is used as a detour route several times a year when U.S. 169 (South Walnut Street) south of 11th Street is closed for railroad crossing repairs or other construction activities.

KDOT is funding 90 percent of the project cost. The city’s share is 10 percent, plus any costs above $1 million. The GI project was awarded to Mission Construction Company, Inc., of St. Paul. The cost of construction is approximately $1.3 million. 

KDOT is funding 90 percent of the project cost of the Geometric Improvement project.

Shively said that work is progressing well as weather permits. Officials anticipate an October completion.

The process of a bridge repair

U.S. 81 over Kyle Railroad in Ottawa County is in the process of being repaired.
The project is expected to wrap up next spring. 

By Ashley Tammen

North Central Kansas Public Affairs Manager

We often receive comments and questions about how long it takes to repair bridges. To properly explain the repair process, we must explain what makes up a bridge.

Bridges are composed of three basic elements: the foundation, the substructure that holds up the bridge deck and the superstructure or bridge deck. The superstructure is made up of several layers of reinforced steel with steel girders throughout. Bridge repairs can encompass repairing one of those elements or even up to all three — including the concrete surface and guardrails can break down over time.

One example of a bridge repair is on U.S. 81 over Kyle Railroad in Ottawa County. The superstructure needs repaired due to the wear and tear of concrete.

“Where there is damage on the bottom side of a bridge, you risk moisture coming in underneath. When maintenance staff goes to patch potholes on top, it doesn’t last long due to the moisture and the movement of the bridge,” said Phillip Nelson, Engineering Technician Senior in Salina. 

There are several steps that must be taken so the bridge deck can be replaced, which occur in multiple phases.

During the first phase, two temporary median crossovers are installed with drainage structures and inside shoulders so traffic can be rerouted to the opposite bridge while one bridge is being repaired.

Next, the existing U.S. 81 bridge will get an temporary asphalt overlay to help prevent damage while the two-way traffic is driving on the bridge and temporary guardrails will be installed.

During phase two, traffic will be reduced to one lane and temporarily detoured to the southbound U.S 81 bridge using both crossovers. Once traffic has been rerouted off the bridge under construction, the contractor will remove all the old concrete leaving only the steel girders.

The steel girders will then be repainted, and new concrete will be replaced above them. After repairing the bridge, permanent guardrails will be installed on the south ends with temporary guardrails on the north ends for two-way traffic.

Finally, during the last phase, traffic will be moved over to the newly-repaired south bridge using median crossovers. Once traffic has been rerouted, the last bridge will get repaired. 

The last step is to repaint the stripes on the repaired bridge, and U.S. 81 will be open for traffic. It is expected to be completed next spring.

We urge all motorists to slow down in work zones and give our crews room to work. 

Road construction and detour technology innovations

KDOT crew members from Garden City installed a temporary detour sign for the
U.S. 50/83 bypass project earlier this year. 

Road construction season is here and those orange barrels and cones seem to be popping up everywhere. While some may be frustrated by this season, road construction is essential to effectively and efficiently maintain our highways. Thanks to technology and innovation, today’s drivers can navigate road construction and detours much easier than drivers in the past. 

For example, 50 years ago when a driver encountered a detour, the driver had two options— follow the detour signs and most likely arrive late to their destination or get out the paper map and find an alternate route.  Eventually, road construction, detour routes and traffic updates became available on the radio and in the newspaper, making it easier for drivers to anticipate detours and delays and choose an alternate route if possible. 

Drivers today can access detour information in many ways, making it possible to avoid road construction and detours altogether. This makes it easier to prepare for and navigate road construction and detours when necessary.  Social media apps like Facebook, Twitter and Instagram give cities, counties and states the ability to communicate current information on road construction and detours to drivers with minimal delay, so that drivers can better plan their travel.

In addition, apps like Mapquest, Googlemaps and Waze provide a variety of tools including live traffic updates, road closure information and even alternate routes.

In metro areas, drivers will often find smart work zones that are designed to predict travel time and delays or speed through the construction zone in real time.  Alternate routes and travel times using those routes may also be predicted by allowing drivers to make informed decisions ahead of work zones. 

These smart zones help prevent driver frustration, encourage drivers to take alternate routes, reduce congestion and keep traffic flowing. They also help make work zones safer for both travelers and highway workers.

In addition, many state DOTs have their own websites and/or apps that provide detailed road construction and detour maps and current road conditions.  Kansas road conditions are available by visiting www.Kandrive.org. 

KDOT encourages drivers to take advantage of these and other technology and travel innovations. Remember to “know before you go,” in order to make travel as enjoyable and safe as possible during this road construction season.

Pothole patrol

KDOT crews clear debris and dirt away.

By Lisa Mussman, 
Northwest Kansas Public Affairs Manager

After a long season of battling snow and ice, KDOT crews are starting to shift their focus to repairing the damage winter weather has left behind on the roads. Among that damage is a plethora of potholes dotting the pavement in all parts of the state.

Potholes are formed when moisture left over from snow and ice seeps into cracks in the pavement. When the temperature drops, water freezes and expands the pavement, causing it to bulge and crack. Cars driving over these trouble spots eventually cause the pavement to break up, forming a pothole.

KDOT has a variety of methods and tools available for pothole patching, one of them being spray patching. Spray patching is done with a specialized trailer mounted machine, reducing the need for many different pieces of equipment. Crews recently utilized this method on a portion of U.S. 36 in Norton.

The process begins with clearing any debris and dirt out of the hole.

One of the ways crews can repair a pothole is using the spray patching technique. 

 

A tack coat may then be applied, followed by a layer of emulsified asphalt and aggregate. The emulsion is essentially the glue that will hold the asphalt together in the hole.

Finally, the hole is topped with a layer of dry rock and excess materials are swept up. After a short curing period, the patch is ready to withstand traffic.

The final step of filling a pothole is by adding a layer of dry rock that will help the
 patch be able to withstand traffic. 

As KDOT begins to ramp up its pothole patrols, motorists are reminded to slow down and move over for crews working.

Reminder: Speed Limit Enforcement Blitz this weekend

TOPEKA, Kan. – The Kansas Department of Transportation has partnered with law enforcement agencies across the state to launch a tough new speed enforcement blitz statewide. The intensified enforcement effort against speeding drivers underscores the severity of the problem in cities and towns across Kansas.

“Speeding greatly reduces a driver’s reaction time,” said Chris Bortz, KDOT Traffic Safety Program Manager. “A speeding driver puts everyone on the road at a greater risk of a crash.”

On average in Kansas, 25 percent of fatal crashes are speed-related. Nationwide, speeding was a contributing factor in 27 percent of all fatal crashes, leading to more than 9,500 deaths, according to the latest data from the National Highway Traffic Safety Administration (NHTSA).

During campaign from July 21-23, officers will intensify enforcement of posted speed limits on Kansas roads, highways and interstates, targeting and ticketing speeding drivers.

“We’ll stop and cite anyone caught speeding—especially in construction zones and on interstates—where most of our speed-related crashes occur,” said Lt. Adam Winters with the Kansas Highway Patrol.

As speed increases, the severity of crashes increases, leading to a rise in fatalities and/or serious injuries. According to NHTSA, a crash on a road with a posted speed limit of 65 miles per hour or greater is more than twice as likely to result in a fatality than a crash on a road with a speed limit of 45 or 50 miles per hour, and nearly five times as likely to result in a fatality than a crash on a road with a speed limit of 40 miles per hour or below.

“On the drive to zero fatalities, you are in the driver’s seat,” Bortz said.