In Lucas County, Ohio, work continues on multiple phases of the I-475 improvement project.
(ODOT photo)
In Lucas County, Ohio, work continues on multiple phases of the I-475 improvement project. The Ohio Department of Transportation (ODOT) is overseeing the latest effort, a $102 million undertaking that includes building a highly anticipated interchange at U.S. Route 20A in Maumee in northwest Ohio.
"This project is one of several identified in a strategic plan by the Toledo Metropolitan Area Council of Governments [TMACOG] in the late 2000s, to prioritize improvements for the entire length of I-475 in the Toledo Metropolitan Area," said ODOT District 2 spokesperson Kelsie Hoagland. "The study laid out certain recommendations, some of which have been constructed, and some that are yet to be developed."
This segment of I-475 overlaps U.S. Route 23, connecting travelers north to Michigan and serves as the major interstate alternate to I-75 and I-280.
"The route is also a major thoroughfare for local traffic, connecting several suburbs in greater Toledo," Hoagland explained. "The project is constructing a new interchange at U.S. Route 20A, which will provide better access to a developing commercial/business/industrial corridor. Daily traffic on this segment of I-475 is more than 70,000."
I-475 improvements include the widening of I-475 from two to three lanes and covering a 5-mi. stretch between Airport Highway and the Maumee River crossing. In addition to constructing a diverging diamond interchange (DDI) at Route 20A and I-475, crews must resurface a portion of U.S. Route 24 and improve access to the industrial corridor.
"Construction is going well, but there have been challenges," said Hoagland. "Challenges with conflicts in the constructability of maintenance of traffic plans designs have been a factor, but also with crashes. We have had many crashes in this zone, and regular traffic delays as a result. The primary cause is high speeds and following too closely. There is no room for error in this zone."
The existing configuration provided two lanes in each direction, which is maintained most of the time, but during construction, shoulders are eliminated, and lanes are narrowed. Various short- and long-term ramp closures are necessary and under way.
Work began in July 2022 and should be completed by December 2024. Kokosing Construction Company Inc. serves as the prime contractor.
"Kokosing is a hub in the northwest Ohio region, allowing them to be familiar with the area, and they have completed other large projects with ODOT in the past," said Hoagland. "ODOT also tries to entertain the most competitive bid, which in this case was Kokosing."
According to Craig Wing, Kokosing senior area manager, the overall schedule of the project is challenging, because of the number of intermediate Maintenance of Traffic (MOT) phases required to keep the existing ramps open to the public as much as possible.
"There also are several utilities in the vicinity of the new 20A interchange. Through good communication and cooperation between ODOT, Kokosing and the various utility companies, conflicts and schedule impacts have been avoided."
Currently, the new northbound 475 pavement is being constructed, along with one of the new bridges for the 20A interchange. In addition, the reconstruction of U.S. 20A is under way and scheduled for completion before Thanksgiving.
"The keys for the 2023 construction season are finishing the work on U.S. 20A, along with the completion of the new NB 475 roadway so that traffic can be moved from the existing southbound pavement to the new northbound by the end of the season," said Wing.
Building the new DDI is a major part of the ongoing construction.
"A large amount of dirt embankment is required to construct the new interchange ramps," Wing explained. "In addition, the new interchange features two separate bridges for the diverging diamond."
Regarding efforts to widen approximately 5 mi. of I-475 between U.S. 24 near Maumee and Airport Highway, said Wing, "Maintenance of traffic and minimizing the impact that ramp closures create for the traveling public are big concerns on the project. To that end, a large quantity of temporary pavement will be utilized on the project to keep closures and impacts to a minimum."
The pavement on the project is being completely replaced. This includes removal of the existing pavement and installation of new drainage features, followed by cement stabilizing the subgrade for the new pavement. Once that is completed, underdrains are installed, and aggregate base is placed and graded in preparation for the new asphalt pavement.
Wing said the bridges over Monclova Road and the Norfolk Southern Railroad will be replaced in phases, with one bridge being removed and replaced each year. A Value Engineering Change Proposal (VECP) was submitted and approved for the replacement structures. As part of the VECP, the new structures were changed from three span structures with spill through slopes, to a single span bridge on capped pile abutments behind MSE walls. The VECP eliminated two piers from Norfolk Southern right-of-way and reduced a potential utility conflict with the TransCanada gas pipeline.
As for construction to resurface approximately 3 mi. of U.S. 24 from Waterville-Monclova Road to just east of the I-475 interchange, "This is a heavily traveled section of U.S. 24, so again, disruptions to the traveling public is a main concern," said Wing. "The work of performing pavement repairs and resurfacing the highway will be performed with temporary lane closures at night to keep impacts to a minimum."
For now, the elements have not been a problem for crews.
"We have been fortunate with the weather so far in 2023, but wet weather and cooler temperatures this fall will have a detrimental effect on the overall schedule," Wing said.
Several pieces of equipment have been used on the project to date. They include Cat D6 and D7 dozers; Cat 330, 336 and 349 excavators; Cat 730 and 740 articulated trucks; Komatsu PC228 and PC490 excavators; a Cat 16G grader; various rollers; Cat 815 and 825 compactors; a Vermeer T758 trencher; Volvo water trucks; a John Deere 624K loader; and a Manitowoc M-85 crane.
The reconstruction of I-475 and the addition of the new interchange at SR 20A involves moving in excess of 475,000 cu. yds. of dirt and placing 16,000 cu. yds. of concrete. It also requires installing more than 550,000 tons of reinforcing steel and placing more than 400,000 tons of asphalt pavement.
Wing said the most time-consuming part of construction will be the replacement and widening of 5 mi. of pavement on I-475. He added that working on a project that will serve so many for years to come is extremely rewarding.
"Kokosing is proud to be a part of a project that will continue to expand the economic development of western Lucas County and provide several safety upgrades and improvements for the people who travel on this section of I-475 each day." CEG
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