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Improving Heavy Construction

Projects

I-74 Interstate Reconstruction

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Big bridge projects don’t come around very often in the Midwest, despite having the Mississippi running through it.  They change the landscape distinctively.  It has been that way with our I-74 Reconstruction project, and we were excited to add this to milestones in McCarthy’s long community history.

This Interstate Reconstruction project extends from the banks of the Mississippi River north to the Middle Road interchange. This project, of the I-74 River Bridge Corridor, necessitated a lot of coordination. Included were five different prime contractors, two Departments of Transportation, and two local city governments. There were many traffic control changes in the overall project, and the traveling public did a good job navigating the shifts.

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The pavement section of the interstate expanded to six through lanes with auxiliary lanes and a center median barrier. Altogether, this project required over 73,000 SY of new pavement and aggregate subbase. It also required another 225,000 CY of dirt to be moved in tight spaces. Around the project, there were two new noise walls, a precast MSE wall, and a temporary soil retaining wall at the centerline of the interstate.

In addition to work that is standard to us, this project had several features that are one of a kind.  The DOT installed 9 “Identity Elements” through the project which were 30’-40’ tall precast and steel structures. These identity elements include painted steel panels, acrylic sheets, lighting, and reflective panels. Our McCarthy Improvement work was consistently ahead of schedule and we completed all critical closure and call completion date requirements on time. This project was a one-of-a-kind experience and a truly important project for our area.  We are proud to be able to leave a lasting impact on our community and home. This project was a runner-up for the Iowa DOT Interstate Project of the year in 2023.

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Check out more photos here! https://i74riverbridge.com/newsroom/gallery.aspx

Linwood Mining & Minerals Smokestack Replacement

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An aging smokestack at Linwood Mining & Minerals was partially blocking the stack’s gas outlet. The rotary kilns could not run without an open outlet, so Linwood commissioned McCarthy Improvement’s help to demo the stack, perform a site inspection then investigate the soil surrounding the stack’s stump so that the sub-base and concrete base could be properly designed.

After engineering created new blueprints, McCarthy Improvement:

  • removed and disposed of unsuitable soil and replaced it with aggregate fill to strengthen the ground for the foundation.
  • placed crane pads to accommodate the erection of the smokestack.
  • installed and leveled a custom anchor bolt assembly ring.
  • installed over 25,000 lbs. of reinforcing steel and placed 260 CY of concrete in a continuous pour to complete the foundation.
  • Stripped the forms and backfilled the foundation after the stack was replaced to reduce the time the kiln needed to be shut down.

Installation of the smokestack took just two days and was a highly coordinated effort by Linwood, McCarthy Improvement and Oertel Metal Works who fabricated the smokestack.

Augusta Regional Airport Apron Rehabilitation

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The Augusta Regional Airport apron rehabilitation project removed and replaced deteriorating asphalt on both the North and South ends of the airport with Portland cement concrete pavement. The project was broken into five phases to utilize smaller closures to limit obstruction for airport traffic. The original contract was allotted 11 months to construct the project, 60 days were added prior to the start due to an owner survey control issue, however, the final phase was opened for airport use nearly two months ahead of the expected opening date. A change order was granted by the airport, which included a new connector between Runway 17-35 and Taxiway A. Only 90 days were supplemented to the contract for the construction of connector A3. The use of the connector will cut wasted time and fuel for extended taxiing by commercial aircraft carriers & general aviation.

Over 3,000 SY of 6” PCC, 14,100 SY of 8” PCC, 7,600 SY of 10” PCC overlay, 39,000 SY of 11” PCC, 11,500 SY of 14” PCC, & 5,200 SY of 18” PCC paving along with grading, drainage, pipe and asphalt demolition, markings, sealing, and lighting were finished in this tight project timeframe. Overall, more than 27,500 CY of PCC were batched for this project.

Project Facts 

  • A $1.9 million change order was issued with the savings from the original contract
  • All work was completed 45 days early, under budget, and with no outstanding punch list

Augusta Airport Taxiway, Augusta, GA

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The $16.7 million Augusta Airport Taxiway project hit another Milestone date! Taxiway Charlie and Delta were officially opened in time for The Masters Tournament. Inclement weather has affected the progress from the start; however, due to determination, a lot of hours, pre-planning and effective implementation of the operations, the tasks necessary to achieve the goal were met.

As the Prime on this project, we are responsible for several key subcontractors, such as earthworks, electrical, HMA paving, and striping. Coordination of the subcontractors and completing the concrete pour sequence were paramount to this success. The airport has been supportive of alternate work plans to assist with the schedule as well. As a team, we are continuously seeking ways to be cost-effective and expedite the schedule to be fully complete.

Hartsfield-Jackson Atlanta International Airport Runway Replacement

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This project consisted of two separate construction time segments: a spring segment, which consisted of completion of three taxiway phases, and a fall section, which consisted of the Runway 8L-26R keel replacement section, and four other different taxiways’ work. The fall section was limited to 29 days of construction and was comprised of concrete paving approximately 9,100 LF of 100ft wide, 20 in deep, keel section of the Runaway, as well as complete replacements of 22 in thick PCC on Taxiways B3, Ramp 2 North, and a portion of Taxiway B11.

There were significant Liquidated Damages associated with any construction delay: approximately $700/minute. There were also significant penalties associated with the smoothness of the final concrete surface. Despite five days of excusable delays, we finished the job approximately six hours ahead of the original deadline, incurred no penalties due to smoothness and needed no corrective grinding.

All runaway pavement was fully reinforced with WWF, and placed in two lifts through the use of an intricate paving train. There were two separate paving trains to accommodate the work between the Runaway and Taxiways, as well as two central batch plants, and approximately 50 dump trucks a day. This project won a first-place award in the paving category from the GA American Concrete Institute. It also garnered a Gold award from the American Concrete Pavement Association.

Runway 8L/26 R opened ahead of schedule and approximately 61,000 CY of concrete was placed over 19 paving days.

Greenwood Airport – Runway 9-27

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The Greenwood Airport project consisted of runway and taxiway paving and lighting rehabilitation work. The project held:

  • approximately 55,586 SY of 5 inch thick concrete overlay of Runway 9-27
  • approximately 4,800 SY of taxiway asphalt overlay

In addition, there were 13,230 SY of asphalt shoulder transition pavement, 71,300 SY of asphalt pavement milling, adjustment of existing runway edge lights, adjustment or relocation of existing taxiway edge lights, new pavement marking and minor sediment and erosion control measures. The runway edge lights were also replaced with new LED runway edge lights and new guidance signs.

Approximately 2,100 SY of Taxiway “C” pavement milling, asphalt overlay and pavement marking completed this project.

Davenport Municipal Airport Runway 3/21 Reconstruction

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The Davenport Municipal Airport project consisted of 44,383 SY of 8″ PCC Paving, and over 20,000 SY of 10″ PCC Paving. The scope of work included: PCC Removal, Earthwork, PCC Paving, HMA Paving, Wire Fencing, Storm Sewer Installation, Pavement Marking, Airfield Lighting Installation, Erosion Control, and Seeding/Mulching.

Eastern Iowa Community College District

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The Eastern Iowa Community College project included an excavated and graded field and constructed a new concrete road. McCarthy Improvement installed underground utilities and built concrete foundations and parking facilities.

I-20 / Lee Road

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The I-20 project included 0.739 miles of widening and reconstruction on Lee Road (CR 817) beginning south of Monier Blvd. and extending north of Sweetwater industrial connector. In addition, the construction of the bridge and approaches over 1-20/SR 402 and the installation of intersection video detection systems (VDS) were apart of this project.

I-16 Laurens County

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I-16/SR 404 was a project that held 29.727 miles of concrete pavement rehabilitation, milling, inlay, plant mix, resurfacing and ramp reconstruction beginning at SR 26 and extending to SR 29.

  • 491,747 SY of 11” PCC paving was put down
  • 168,000 tons of concrete was crushed and used in the shoulders
  • 626,000 SY of shoulder paving, 1,188,466 SY of CTB and pavement interlayer fabric
  • PCC shoulders were jointed and sealed every 15 feet

I-16 and I-95 are the main corridors to the port in Savannah and Brunswick, and this improvement allowed for the heavier truck traffic that was anticipated with the new distribution centers developing along the I-16 corridor.  It also is a major tourist route to the Golden Isles in the summer.

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