Lake and Porter Counties SR 249 Bridge Superstructure

April 25, 2017

Indiana Department of Transportation - LaPorte District315 East Boyd BoulevardLaPorte, IN 46350

Re: Project Development Services - SR 249 Bridge Superstructure Replacement over US 12 and two railroads in Porter County Dear Selection Committee:

Primera Engineers, Ltd. (Primera) is pleased to submit our Letter of Interest and our qualifications to provideprofessional engineering services to INDOT in regards to the above-referenced project.

Why Select PrimeraPrimera is a full-service engineering firm with a staff of nearly 200 professionals dedicated to sustainabledesign and the pursuit of excellence using the latest technologies. Primera offers a wide range of professionalservices on both single and multidiscipline projects in a host of different markets. Primera staff are quality-drivenprofessionals who are proud to be a part of a culture in which the entire existence of the company is based onearning clients’ satisfaction at every opportunity.

As you will see highlighted throughout our proposal, Primera is strongly committed to delivering cost effective,high quality projects that are completed on time and within the budget. Since Primera’s inception nearly 30years ago in 1987, we have built an exceptional record of successful projects. Primera has been a longstandingleader in the engineering industry, with projects ranging from schools and roadways to utility infrastructure.Strengthened by the experiences gained during the design and construction of thousands of projects, thePrimera team has the expertise, skills, experience and capacity to deliver the project while exceeding INDOT’sexpectations in the process.

Our CommitmentPrimera is strongly committed to delivering cost effective, top quality projects that are completed on time and onbudget. On our projects, we maximize our productivity by:

• Providing the appropriate resources and effort to complete projects on schedule

Responsible OfficePRIMERA ENGINEERS, LTD. 9200 Calumet Avenue, Suite N301Munster, Indiana 46321219/513.8715 • F 312/606.0415

Authorized NegotiatorBRAD MINNICK, PE Senior Project Manager219/961.1241 [email protected]

Primera’s INDOT Annual Contracting CapacityOver $34 Million as of September 2016, includes over 10% increase over the last quarter.

Our Proposed TeamPRIMERA ENGINEERS, LTD. [Munster, IN]CATEGORIES: 3.1, 8.1, and Utility Coordination

BEAM LONGEST & NEFF [Indianapolis, IN]CATEGORIES: 5.2, 6.1, 11.1, 12.2

K & S ENGINEERS [Highland, IN] CATEGORIES: 7.1

SATISFACTION GURANTEED

Lake and Porter Counties – SR 249 Bridge Superstructure Replacement over US 12 and two railroads in Porter County

100%

7%

86%

7%DBE

PRIMERA ENGINEERS // 2PROJECT DEVELOPMENT SERVICES - SR 249 BRIDGE SUPERSTRUCTURE REPLACEMENT OVER US 12 AND TWO RAILROADS IN PORTER COUNTY

• Developing efficient projects (more “bang for the buck”) which saves money for our clientsand their constituents; and

• Utilizing innovative design techniques in order to deliver timely, quality projects

Primera will provide professional services that are timely, fair and extremely beneficialto the INDOT LaPorte District, building upon Primera’s three decades in business as a pre-ferred provider of consultant engineering services in Indiana, Illinois and Wisconsin. Thank you for your time and consideration of Primera’s team. Strengthened by their experience, the Primera team has the strong skill set needed to deliver this project while exceeding expecta-tions. We look forward to the opportunity to work with INDOT on this project.

If you have questions or need additional information, please contact me directly at219/961.1241 or [email protected]. Sincerely,

Brad Minnick, PE, Senior Project Manager Authorized Negotiator

Providing the appropriate

resources and effort to complete projects

on schedule.

+

Developing efficient projects (more “bang for the buck”) which

saves money for our clients and their

constituents.

$

Utilizing innovative design techniques in order to deliver

timely, quality projects.

!!

PROJECT UNDERSTANDING

This two-phase contract will include two primary elements:1) Perform an Engineering Assessment/Engineer’s Report (EA) - approx. 6 weeks2) As the scope of work is better defined, Primera will perform the bridge design and plan development work to produce the construction documents for FY 2020 bid letting.

Furthermore, the design and plan development will include the following activities:

Task 1 Environmental Services

Task 2 Topographical Survey Data Collection

Task 3 Geotechnical Services

ON OUR PROJECTS WE MAXIMIZE OUR PRODUCTIVITY BY:

Task 4 Road Design and Plan Development

Task 5 Bridge Design and Plan Development

Task 6 Utility Coordination Services

Task 7 Construction Phase Services


Our proposed Project Manager, Brad Minnick, and bridge design engineer, MikeZelisko, for this project, performed a site visit to assess existing bridge, roadway,and roadside conditions, and potential traffic safety and operational issues. Theyfound the following key items that require design consideration and attention:

BRIDGE CONDITION AND ALTERNATIVES:

The ten-span bridge is comprised of four precast prestressed concreted bulb-Tbeams supported by nine concrete hammerhead piers. The most significantfinding from a previous Fall 2016 inspection indicated the beams are in poorcondition, rating 4, due to advanced deterioration on beams 1, 2 and 4 in span8 that exhibited cracking into their top flanges. However, after a load rating ofthe bridge in November 2016 in which the bridge was instrumented with straingauges, it was agreed to raise the superstructure rating to a 5 instead of a 4 withthe State Program Manager. Further test results revealed a curing deficiency dur-ing the construction process of the beams. The presence of delayed ettringite for-mation (DEF) was cited in the beams at various locations and predicted to con-tinue to worsen over time.

Several alternatives were presented for the proposed scope of work to meet theprimary goal of superstructure replacement to eliminate the DEF condition of thebeams, which included:

Building a bridge adjacent to the existing structure while the existingsuperstructure is replaced, estimated cost $16.8 Million

Widening the existing superstructure to accommodate traffic while thesuperstructure is replaced, estimated cost $15 Million

Closing the bridge and constructing an at-grade crossing for traffic whilethe existing superstructure is reconstructed at an accelerated schedule,estimated cost $8.45 Million

Do nothing

There are many factors that complicate these alternatives, primarily how to handle the maintenance of traffic (MOT) during construction. There are sev-eral nearby plants that are heavily serviced by truck traffic. Also, staged

construction of the proposed superstructure is not allowed due to the pres-ence only four beams per span. Additional beams would be required to ac-commodate the staging to allow one lane of traffic during construction. De-tour routes may also need to be utilized while this work is performed. An-other alternative could be to "fiber wrap" the existing beams in order to ex-tend the lifespan of the superstructure without causing any impacts to traf-fic. However this would not resolve the DEF issue that exists in the beams.

An additional alternative for consideration could involve utilizing AcceleratedBridge Construction (ABC) techniques that would involve use of prefabricated bridge elements that could significantly reduce the impact on traffic and the timerequired to perform the work. One such method could include a bridge slidewhich would consist of constructing a new structure adjacent to the existing thensliding it into place once the existing is removed. There are a growing number of projects nationally that have utilized this method, including one currently under construction in Indiana on I-70 over SR 121. It is anticipated that by utilizing this ABC methodology, the innovations will improve the conventional practice in the following ways:

• Reduction of time that traffic is affected by the construction zone: Withconventional construction methods, the construction zone would be requiredfor 6 to 9 months. It is anticipated that through these innovative methods,the maintenance of traffic on the State Route could be reduced to a fewweeks of impacts at the most. This would dramatically reduce contractorrisk, exposure of construction personnel to traffic, and inconvenience to thetraveling public.

• Innovation Performance• Improved Construction Quality: By building the superstructure in a temporary

location, the entire superstructure can be built at once, eliminatingconstruction joints in the deck, and enhancing long-term performance of thebridge asset

Alternative #1, a twin or “sister” bridge, could be constructed adjacent to theexisting bridge. This would help lower the accelerated construction costs andstill provide a new bridge that would greatly extend the lifespan than any otheralternative. This could be advantageous for the local area businesses if trafficvolumes continue trending up. Interchange design and work would still need to

1

2

3

4


be included due to the construction of a new bridge adjacent to the existing. This approach would likely be well received by the Port, due to its significantly reduced impact to the movement of goods in and out of the sprawling Port campus. Monitoring of the progress of the I-70 ABC project, which began construction last week, will provide additional cost data and lessons learned as the SR 249 design evolves. Extensive coordination will be a hallmark of Primera’s design effort, specifically with the Port Authority and the railroads. As Indiana’s only deep-water port, it receives ocean vessels carrying international shipments between Indiana and ports around the world. This port is included as a priority in a recent study conducted by the Indiana Blue Ribbon Panel on Transportation Infrastructure submitted to the Governor.Regardless, a life cycle cost analysis for each alternative would need to be performed to justify these various alternatives and make a comprehensive recommendation.

MAINTENANCE OF TRAFFIC / DETOURSThere are limited options available to safely accommodate the ADT of 10,200, based upon 2009 data, due to the abundance of railroad tracks under and running parallel to US 12 at this location. This ADT contains a disproportionately high truck volume at 40%. To the west of the SR 249 bridge, the Midwest Highway offers access to the west side of the Port of Indiana. However, select roadway improvements would be necessary to make this a viable detour alternative. To the east, Main Entrance Drive offers a lengthy alternate route into the east end of the Port of Indiana facility. Similarly, existing road conditions and traffic counts would need to be evaluated for suitability as an MOT option. The Following represents proposed construction sequencing

Phase I - Build “sister” bridge to the west with existing bridge open Phase II - Construct tie-in to existing SR 249 ramp network


Phase II - Short Term Detour - US 12 East to Main Entrance Drive

Phase III - Construction of SR 249bridge superstructure replacement

“sister” bridge in-service

bminnick

Text Box

Potential alternative for SR 249 bridge superstructure replacement.


Key Staff

Brad Minnick, PE – Senior Project Manager. 20+ years of construction experience in Highway Planning, Study and Design including project engineering/management; reconstruction/ rehabilitation; traffic studies/engineering; geometric design; preliminary/Stage I studies; Stages II & III design and contract preparation; permit reviews; government agencies/stakeholders coordination;

application of national and state design standards and policies. Former INDOT Construction Director, managed Construction Inspection of over $1 Billion worth of Construction, including 500 contracts. Additionally, Mr. Minnick is an INDOT Certified Utility Coordinator.

Mohammad Husain, PE, SE – Structural Lead. More than 35 years of experience in the design of railroad and highway structures such as QA/QC, structural analysis/design, TS&L plans, as well as final design of a wide range of transportation structures.

Michael Zelisko, PE – Structural Engineer. 5 yearsof experience including structural design, constructioninspection and planning of various projects with state, cityand county agencies. Worked on highway and pedestrianbridge structures, retaining walls, junction chambers andculverts (steel, prestressed concrete, reinforced concrete),and has compiled several IDOT bridge condition reports.

Chad Dillavou, PE, PTOE – Phase I Project Engineer / Traffic& Geometric Studies. Geometrics Specialist with 8 years ofexperience in Phase I and traffic design/studies, includingCSS and public involvement experience.

Matt Villanueva, PE – Phase II Project Engineer / Roadway & MOT. 8 years in planning, study, and design. Experienced in development of contract plans and documents: highway geometrics, traffic control/staging plans, signing, traffic analyses, special provisions, quantities/cost estimates, and public meetings.

Mark Johnson, PE – Railroad Coordination / QAQC. 37 years of experience in planning, study, design and maintenance of highways and bridges; railroad coordination; developing project scopes, budgets, and schedules; analysis and design; and quality management.


While the majority of Primera’s comparable bridge superstructure replacement design work has been completed for the Illinois Tollway, the Illinois Department ofTransportation, and various counties in Illinois, Primera has a growing body of work with INDOT and LPAs as detailed below. All of Primera’s projects, regardless of where they were completed, have three overarching tenets: ON TIME, ON BUDGET, and NO SURPRISES. The SR 249 bridge design project offers a unique opportunity to build upon INDOT’s partnership with Primera, and showcase our design skills on a larger scale. As INDOT project managers become increasingly frustrated with other consultant’s challenges meeting milestone deadlines and maintaining their commitment to the project delivery budget, Primera welcomes this design project to deliver on both fronts. Additionally, with concise, timely communication with the INDOT project team and stakeholders, Primera ensures no surprises during the de-sign process. Primera routinely attends monthly meetings with other clients, offering project updates. As noted later in our LOI, Primera has completed nearly twenty (20) Engineering Assessments in last fall alone for the Illinois Tollway on Interstate 355, followed by the associated design work and contract document preparation.

Firm Experience

INDOT Contract R-35969-A; East Chicago, Lake County, Indiana LPA Contract – Stage 1, 2, 3, and Final Tracings Design for Bridge Removal, IntersectionImprovement, RoundaboutMichigan City, LaPorte County, Indiana Local Contract – Stage 1, 2, 3, Final Tracings Design and Construction Inspection for One-Way to Two-Way StreetConversionINDOT Contract B-34011-A; Hammond, Lake County, Indiana – Construction Inspection for Kennedy Avenue over I-80/94, I-80 WB Ramp to Kennedy Ave.Bridge Deck Overlay, Bridge Rehab/RepairINDOT Contract B-38550-A; Hammond, Lake County, Indiana – Construction Inspection for I-80 over US 41: US 41 over I-80; Kennedy Ave. over I-80;Columbia Ave. over I-80 Bridge Maintenance and RepairINDOT Contract B-38392-A; Michigan City, LaPorte County, Indiana – Construction Inspection for Bridge Painting, SR 212 Bridge over US 35 and WB US 20INDOT Contract R-39773-A; Michigan City, LaPorte County, Indiana – Construction Inspection for Roadway Contract on US 20, from US 421 to US 35/SR212Indiana Toll Road Concessionaire Company, Lake Station, Lake County, Indiana - Construction Inspection for Structure BHX-B ReplacementINDOT Des # 1601161 & 1601162 Kouts, Porter County, Indiana LPA Contract – Stage 1, 2, 3 and Final Tracings for Sign Head Replacement: Regulatoryand Warning Sign; and Pavement Marking project (awarded)

IL 64 over Mill Creek & Ferson Creek, IDOT, Kane Co., IL. Phase I Roadway, Drainage & Structural Engineering Services for culvert improvements. Servicesprovided: Roadway, Drainage and Structural Engineering.Illinois Tollway. Interstate I-355, IL. Phase I Engineering including 18 bridge Engineering Assessments, followed by Roadway, Drainage and Structural Engi-neering for Contract Document preparation.IL 102 Over Ryans Creek, IDOT, Will Co., IL. Phase I Engineering Services for Bridge Improvements. Services provided: Roadway, Drainage and StructuralEngineering.

IL 120 over US 41, UPRR, & Old Skokie, IDOT, Dist. 1, IL. Phase II Engineering Services for deck removal and replacement of bridges SN 049-0050 and SN049-0051.79th St. over B&OCT & IHB Railroad, IDOT, Bridgeview, IL. Phase II Engineering Services for bridge rehabilitations at multiple locations including removaland reconstruction.IL 53 over St. Joseph’s Creek, IDOT, Lisle, IL. Phase II Engineering Services to develop Contract Plans and Specifications, and Construction Cost Estimates forproposed bridge replacement.

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PROPOSED STAFFING FOR THE SERVICES

Primera Engineers, has assembled a highly-qualified team for the White County bridge replacementproject. Primera’s proposed Project Manager, Brad Minnick, PE, will lead all aspects of theproject from our Munster, Indiana office. Primera’s team of professionals will be responsible forthe bridge replacement designs, permitting and hydraulics analysis. In addition, Primera’s teamwill be supported by highly-qualified sub-consultants, including: Beam Longest & Neff to providetopographical survey data collection and environmental permitting; and K & S Engineers to providegeotechnical exploration. An organization chart depicting our team structure is included below.

Brad MinnickProject Manager

Primera

Mohammad Husain, PEStructural Lead

Primera

Mike Zelisko, PEStructural Engineer

Primera

Chad Dillavou, PE Phase I Project Engineer

Primera

Matt Villanueva, PE Phase II Project Engineer

Primera

Mark Johnson, PERailroad Coordination

Primera

Geotechnical Services

Environmental, Topographical Survey,

Right of Way, Title Research

ANTICIPATED SERVICES TO BESUBCONTRACTED

TOPOGRAPHICAL SURVEYENVIRONMENTAL PERMITTING

BEAM LONGEST & NEFF//7%Full service firm, we have been designing comprehensivesolutions for all facets of infrastructure projects—fromlocal intersection improvements to statewide QualityAssurance & Quality Control programs—for over 60years. This wide variety of experience, combined withour knowledgeable staff, allows our clients to rely on usfor their complete engineering needs. Services includeTransportation, Bridge, Environmental Engineering,Survey, Environmental Services, Right-of-WayEngineering, Right-of-Way Services, and ConstructionInspection

GEOTECHNICAL INVESTIGATION

K & S ENGINEERS (DBE) //7%Since 1984, K & S Engineers, Inc., (K & S), hasbeen a professional engineering consulting firmactively engaged in Geotechnical Drilling Services,Environmental Drilling, Construction and MaterialsEngineering, Design of Foundations for various types ofstructures, Testing of Soils, Construction Inspection andEnvironmental Engineering (Phase I & 11). In addition,K & S performs Drilled Shaft Construction and ForensicInvestigation of construction materials. At K & S, wecontinue to maintain our reputation as a leader in thefield of Geotechnical, Environmental , and ConstructionInspection Services.


Bridge Removal // Aldis Avenue RoundaboutEAST CHICAGO, INDIANA

Primera Engineers was selected to provide Stage I, II and III Engineering Servicesfor the replacement/rehabilitation of Inland Steel Overpass over Aldis Avenue.Bridge 00386, known as Inland Steel Overpass (Michigan Avenue) over AldisAvenue, was built in 1952 and reconstructed in 1982. The existing structure is a3-span concrete structure supported by columns and piers with an overall lengthof 191 feet and an overall deck width of 85.3 feet. Primera prepared a BridgeCondition & Assessment report; geometric study which includes an analysis ofthe roadway and bridge vertical and horizontal alignments; a TS&L plan whichwill investigate different replacement/rehabilitation options; developed a ProjectDevelopment Report and set of contract documents and prepare the finalcontract documents.

Owner City of East ChicagoServices Provided Structural Analysis, Civil Design, Drainage DesignPermittingPerformance Period 08/2013 - 02/2017Project Value $3 million

One-Way to Two-Way Street ConversionMICHIGAN CITY, INDIANA

This project involved the conversion of vehicular traffic flow from a northbound only configuration on Pine Street, southbound only configuration on Washington Street, and an eastbound only configuration on 9th Street between Pine and Washington Street. In its new configuration, both northbound and southbound vehicular traffic are allowed on Pine and Washington Streets from 2nd Street to 11th Street. Additionally, 9th Street between Pine and Washington Streets was converted to accommodate E/W vehicular traffic. The goal of this project was to improve traffic flow, accessibility and the business district’s curb appeal.

Owner Michigan City Redevelopment CommissionServices Provided Roadway Design, Decorative High Mast and Pedestrian Lighting Design, Decorative Traffic Signal Design, and Construction InspectionPerformance Period 05/2015 – 09/2016Project Value $3.6 million

EXPERIENCE ON SIMILAR PROJECTS


Primera is providing Design Section Engineer services (DSE) to prepare contract plans and specifications, and project related permits for the proposed roadway and bridge rehabilitation on the Veterans Memorial Tollway. The project is located between MP 12.3 (I-55) to MP 22.3 (Butterfield Road) in DuPage County. Primera will also identify potential utility conflicts per ISTHA’s DSE Manual requirements. The Tollway’s design criteria and policies, standard specifications, materials and construction requirements will apply to all portions of the improvement that is under the ISTHA’s jurisdiction. Those outside of the ISTHA’s jurisdiction will follow IDOT standards, policies and requirements.

The DSE’s tasks include identifying utility impacts on construction, ROW, costs and project schedule; conducting surveys; developing MOT and staging; performing a field review and report on barriers that do not meet standards; reviewing flooding/drainage issues and potentially perform studies; determining need for ditch cleaning/re-grading, new culvert lining, and other repairs that may be needed; and reviewing if the previous Barrier Warrant Analysis accounted for all existing items.

Primera is responsible for Design and Plan Preparation for the rehabilitation of existing mainline and ramp pavements, shoulder resurfacing, bridge rehabilitations, drainage modifications, crossroad structure rehab/

reconstructions, landscape and soil erosion/sedimentation control, signage and pavement markings, MOT, lighting updates, BWA and guardrail, terminal and anchor installation per AASHTO and Tollway criteria, and utility protection/relocation.

This project also calls for structural rehabilitation and modifications requiring the preparation of a Bridge Condition Report per bridge. Primera will assess the need for repairs or replacements to various structure components, as well as assess the conditions of overhead sign structures, retaining walls and noise walls in order to recommend/design the necessary improvements.

Field surveys will be required. Coordination with all agencies will be conducted through ISTHA and the DSE will assemble the necessary information for the Tollway, while railroad coordination will be conducted through the DSE.

Owner: Illinois State Toll Highway AuthorityServices Provided: Roadway Design & Planning, Structural Design & Planning, Utility CoordinationPerformance Period: 05/2016 - OngoingProject Value: 9.2 million

I-355 Roadway and Bridge Rehabilitation – MP 12.3 to MP 22.3, DUPAGE COUNTY, ILLINOIS


Illinois 64 over Mill Creek and Ferson Creek LILY LAKE, ILLINOIS

Primera provided preliminary engineering services for two culvert improvements: the removal and replacement of a single box culvert and double box culvert over Mill Creek and Ferson Creek, respectively. The improvements required profile adjustments related to the adjacent and transverse floodway. The adjacent properties are wooded one-acre residential lots, open prairie grass and farmland. The project required the preparation of two culvert technical memorandums, hydraulic reports, geometric studies, crash and safety analysis, scour analysis, transportation management plans, environmental coordination, public involvement documentation and a project report.

Owner Illinois Department of TransportationServices Provided Drainage Design, Roadway Design, Structural DesignPerformance Period 10/2013 – 02/2015Project Cost $1 million

IL 120 over US 41, UPRR, and Old Skokie RoadLAKE COUNTY, ILLINOIS

Primera provided Phase II professional engineering services to developconstruction contract documents, specifications and estimates for therehabilitation of the bridges carrying Illinois 120 over US 41, UPRR, and OldSkokie Road (SN 049-0050 & SN 049-0051). Design work consists of removaland replacement of the deck along with repair of abutments and piers withformed concrete repairs for both bridge structures, SN 049-0050 and SN 049-0051. Both structures’ existing structural steel needed to be cleaned, re-painted, required type F parapets and the conversion of all spans from non-composite spans to composite design spans.

Owner Illinois Department of TransportationServices Provided Structural Design, Roadway Design, Drainage DesignPerformance Period 02/2011 – 12/2015Project Cost $4,000,000


Primera appreciates your time and effort in reviewing our Letter of Interest. If awarded this project, Primera isconfident that this will continue our great long-term working relationship with INDOT. We look forward to hearingfrom the LaPorte District soon.

REFERENCES

Craig Phillips, Michigan City Planner, 219-873-1419

Chris Reynolds, INDOT LPA Area Engineer, 219-325-7524

Mark Pittman, INDOT Bridge Engineer, 574-993-0691

Jon Kruger, INDOT Construction Director, 219-325-7562

PRIMERA IS THE RIGHT PARTNER

The Primera team adds significant design Cost Re-duction Incentive (CRI) and Change Order (CO) review experience to the INDOT team.

Recent Examples: East Chicago plan review to incorporate a differentlight pole design in the field saved the Client over$130,000 while accelerating the construction schedule by 4 weeks.

Michigan City has received a CRI proposal fromPrimera to save in excess of $600,000 (nearly 20% ofthe $3.6 Million project), through the substitution of an approved equal for decorative light poles.

Michigan City saved approximately $150,000 on a pro-posed Change Order, due to Primera’s meticulous review and rebuttal of proposed Contractor costs.

Primera saved INDOT $270,000 or 81% of the proposed budget for Construction Inspection on Contract B-38550.

Primera saved INDOT $76,180 or 58% of the proposedbudget for Construction Inspection on Contract B-34011.

INDOT PREQUALIFICATIONS3.1. Non Complex Traffic Capacity and

Operations Analysis

3.2 Complex Traffic Capacity and

Operations Analysis

8.1 Non-Complex Roadway Design

8.2 Complex Roadway Design

9.1 Level 1 Bridge Design

9.2 Level 2 Bridge Design

10.4 Lighting Design

13.1 Construction Inspection

14.1 Regular Bridge Inspection

Documents

Lake and Porter Counties SR 249 Bridge Superstructure