RH Roadways Highway H 365 Realignment For NSWC Crane Division Crane Indiana April 29 2004 April 2 2004 Mr Dave Burrus Naval Surface Warfare Center Crane Division Engineering Design Branch Bldg 2516 Crane IN 47522 5082 Dear Mr Burrus Since we first met RH Roadways has been working intensely to develop a solution to your traffic navigation problem Roads H 365 and H 367 are very difficult to maneuver for large tractor trailers due to varying slopes multiple railroad crossings and the curvature of the road This route is a crucial one in that it connects a major highway H 101 to a large ordinance storage facility Building 3333 RH Roadways has been asked by NSWC to design a road that will make travel easier and safer for tractor trailers In our approach to find a solution we completed a site assessment examined the subsurface and closely followed all codes and regulations The final decision as discussed in January was to design the alternative for realignment to the south of the existing road The final design includes horizontal and vertical alignments pavement and hydraulic designs construction alternatives erosion and sediment control plans and a cost analysis As requested our recommended design alternative accomplished all of the goals set forth in the beginning of this project Vertical grade was reduced to a maximum of three percent possible railroad crossings were limited to four and cut and fill quantities were minimized The total cost of the final design is estimated to be 365 000 We would like to take this time to express our appreciation for the project This was a great opportunity to use what we have learned and apply it in all of the aspects of design Your time was greatly appreciated and we hope future seniors will have the opportunity to work with NSWC If you have any questions or comments feel free to contact us Sincerely Tim Brown Project Manager Drew Furry Project Engineer Jim Walter Project Engineer Tabatha Doughty Project Editor CC Robert Houghtalen Enclosure Final Report Executive Summary The Naval Surface Warfare Center NSWC Crane Division is located in southern Indiana NSWC Crane Division is a major source for countless electronic and technical services including ordinance development testing and storage Therefore efficient ordinance movement is critical to the NSWC mission However one specific building does not allow for easy access to the main highway This key facility Building 3333 is located only 0 6 miles from the highway Its existing access roads are narrow full of sharp curves and cross several active railways Given these conditions the roads HWY 365 367 are very difficult to navigate for commercial semi trailers The goal of RH Roadways is to provide NSWC with recommendations to re align or relocate the roadway for easier navigation of tractor trailers while limiting railroad crossings Five alternatives were assessed in a matrix of client developed criteria to identify the best solution The best solution was designed and includes horizontal and vertical alignment hydraulic design construction planning erosion control measures plans and specifications and final cost analysis RH Roadways recommendation includes construction of a new route that uses a portion of the existing roadway The eastern half of the road H 365 will be moved south to allow for a straighter road with reduced vertical grades All design goals were met using this alternative including a reduction in railroad crossings from seven to four a reduction of grade from twelve to three percent and a decrease in degree of curvature from 100 feet to 500 feet The total cost of construction was estimated to be 375 000 Construction will be done in two stages utilizing flexible pavement The first stage will be the realigning of the eastern half located to the south of H 365 and the second stage will involve tying into the existing concrete slab near Building 3333 Erosion will be minimized during construction and natural grass cover will be the main control Table of Contents 1 Project Description Client Information Project Background 1 1 2 2 Design Requirements Objectives Constraints Deliverables 3 3 3 5 3 Project Approach Site Assessment Existing Subsurface Conditions Codes and Regulations Alternative Solutions and Assessment Engineering Design of best Alternative Solution 6 6 6 6 6 7 4 Design Solution Site Assessment Existing Subsurface Conditions Codes and Regulations Alternative Solutions Assessment of Alternative Solutions Horizontal and Vertical Alignment Design Pavement Design Hydraulic Design 8 8 8 9 9 10 11 12 12 5 Cost Construction and Maintenance Considerations Construction Cost Maintenance 13 13 13 14 6 References 15 Appendices A Site Assessment B Existing Sub Surface Conditions C Codes Regulations D Design Options E Horizontal Vertical Design F Pavement Design G Hydraulic Design H Construction Planning I Cost Analysis J Preliminary Design of Alternative 4 and Alternative 5 Figures 1 2 3 4 5 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 Location of NSWC Site map with 10 ft contour intervals Example of a frog railway switch View of on site storage area Design Matrix of the five alternatives 1 2 4 4 10 State of Indiana Shaded area of Martin County South central Indiana highlighting the NSWC Base and the site location A1 NSWC Base highlighting the project road Site map including contour lines Site map with critical area highlighted Site map with existing project road highlighted Site map with railroad lines labeled with R number and crossing on the project road circled Floodplain and wetlands in the Northern Martin County area with the project site circled Expanded view wetlands and floodplains do not exist in the project area Site map with location photographed pictures Railroad crossing SW Railway switch or frog S Site map with location photographed pictures A13 A2 A3 A4 A5 A6 A7 A8 A9 A10 A10 A10 A11 Trees and vegetation SW A14 A15 A16 A17 Stockpiled materials on site E Road markings NE Employee parking E Site map with location photographed pictures A18 A11 A11 A11 A11 A12 Current Road E A19 A20 Current Road SW A12 A12 B1 Soil survey of site with project road highlighted B1 Figures Cont C1 C2 C3 Load Equivalency Factors Typical Details of Sub grade Drainage Installations Typical Details of Base Drainage Installations C4 C6 C9 C4 C5 C6 C7 C8 C9 C10 C11 C12 C13 CBR Thickness Design Chart Flexible Pavement Flow Diagram for Design Design Chart VI 11 Design Chart VI 12 Design Chart VI 13 Design Chart VI
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