GRANITEROCK

Graniterock Performing Repair and Overlays on Highway 1 and Highway 101 Simultaneously

Graniterock crews performing repair and overlay on Highway 1 near Big Sur while working six feet apart with mandatory face covers as part of the company’s response to Covid-19.

By Brian Hoover, Senior Editor

Graniterock is in the midst of significant repair and overlay projects on two heavilytraveled California roads: Highway 101 between Salinas and Chualar and Highway 1 from Carmel to Big Sur. Both projects are part of a $1.1 billion allocation for 133 projects recently approved by the California Transportation Commission (Caltrans), and part of the SB 1 Road Repair and Accountability Act passed in 2017.

Highway 1/Big Sur Overlay Project

Highway 1, known as the Pacific Coast Highway, runs 750 miles from Capistrano Beach in Orange County to Leggett in northern Mendocino. Billed as one of the most beautiful drives in America, this epic roadway leads to everything from secret beaches and soaring cliffs to the giant redwood trees and famous Monterey Bay Aquarium. The constant heavy traffic, of course, takes its toll on this highway and one particular 35-mile stretch is now undergoing long-overdue repairs. The section under reconstruction stretches from Torre Canyon in Big Sur to San Luis Avenue in Carmel. Graniterock was contracted by Caltrans to see the $21.9 million project to completion. The work includes removing and replacing failed asphalt, resurfacing, repainting, and upgrading guardrails.

Graniterock’s crew utilized a Wirtgen milling machine for removing around four-inches of existing material when repairing sections of the asphalt roadway where it has deteriorated on the Highway 1 repair and overlay project.

Chris Sveum, construction manager for the construction division at Graniterock, is overseeing all of the details on this overlay project. The job started in early April and is scheduled for completion by July 2021. “We will have most everything wrapped up later this summer and then just have some miscellaneous work going on into 2021,” says Sveum. “We are essentially removing around four-inches of existing material when repairing sections of the asphalt roadway where it has deteriorated. When that is complete, we will begin overlaying the entire 35-mile section with rubberized hot mix asphalt. So, just over 70 lane miles of paving by job’s end.” Sveum explains the failing asphalt sections are removed and replaced with new asphalt, followed by a 1/16” to a 1/4” smoothness grinding of nearly the entire section. “The asphalt remove and replace portion will utilize approximately 11,000 tons of asphalt from our A.R. Wilson plant in Aromas,” continues Sveum. “We will follow this up by installing 68,300 tons of rubberized hot mix asphalt in a 1.8-inch lift.”

The Highway 1 project includes removing and replacing failed asphalt, resurfacing, repainting and upgrading guardrails.

Sveum points out weather is always a challenge when working in coastal areas. “A unique aspect of this particular project is that we are now in the middle of working on the asphalt repair portion, and normally we would do this work at night so as not to disrupt traffic patterns. However, due to Covid-19 conditions, traffic is down enough that Caltrans is allowing us to get this work done during the day, and that will mean better quality.” Sveum says other challenges include communication issues with weak or intermittent cell service. “Communication issues on the job site require everyone to plan and coordinate even more than in normal conditions,” says Sveum. “It’s not like paving a freeway system where you can burn through tonnage on each shift. When you consider the logistics, distance, and trucking challenges on this Highway 1 project, we estimate that putting down 68,000 tons of overlay should take around two and a half months to complete. Our crews are doing a great job on this overlay project. It is important to recognize every team member, along with our area manager Karl Philipovitch, senior project manager, Dave Olivas, project engineer, Ella Giordano, and job site superintendent, Robert Lauderdale.”

Highway 101/Chualar Repair & Overlay Project

California U.S. Route 101 runs nearly 800 miles from San Diego, to the Oregon border. Many travelers consider 101 to be a nice balance between the mundane Interstate 5 and the slow and curvy coastal Highway 1. Because of its popularity, 101 is worn out in many places, including the 14-mile section Graniterock is working on in Monterey County. Graniterock construction crews are performing an asphalt overlay in an area of 101 that runs through the agricultureheavy cities of Salinas, Chualar and Gonzales – known as the salad bowl of the world. The work stretches from ½ mile north of Gonzales to East Market Street in Salinas. The job started in summer 2019 and is scheduled for completion by September 2020. “There are two major components to this project that include some remove and replace repair work, followed by a complete asphalt overlay. The overall pavement section was constructed from both concrete and asphalt,” says Sveum. “There were around 1,300 individual concrete panels that were removed and replaced with just under 6,000 cubic yards of rapid set concrete.”

Subcontractor, Eagle Rock, Inc. performed the concrete construction portion, completing 30 to 40 of the eight-to-nine-inch thick concrete panels every night. “After the concrete sections were repaired, our Graniterock crews began asphalt remove and replace work, similar to what is being done on the Highway 1 project. We are also profiling and preparing the entire 14-mile stretch (56 lane miles) for the rubberized hot mix asphalt overlay. We put down around 14,000 tons of asphalt on the remove and replace sections in 2019,” continues Sveum. “Over the last couple of weeks, we started the overlay work, which consists of around 67,000 tons of rubberized hot mix asphalt. The difference in these two overlay projects comes down to 0.6 of an inch with the Highway 101 project being a bit thicker at 2.4”

Graniterock construction crews are performing an asphalt overlay in an area of 101 that runs through the agriculture-heavy cities of Salinas, Chualar and Gonzales.

Highway 101 work is being done at night, making the traffic lighter and conditions safer for everyone.

Sveum says the Highway 101 work is being done at night, making the traffic lighter and conditions safer for everyone. “We have worked well through all of the challenges on this project. Most every paving project has its material and trucking challenges. We were able to keep things moving smoothly with the addition of our new Weiler remixing transfer vehicle,” says Sveum. “Covid-19 has had an impact on this project as well, as we got creative and rented a 19-passenger van to shuttle three or four team members at a time. We have remained adamant about no carpooling and the passenger van has been a great tool in getting our people back to their cars after completing their shifts. Safety is always our number one concern at Graniterock. I want to thank and recognize our area manager Karl Philipovitch, project manager, Martin Canning, and our project engineer, Rick Guerrero, along with all of the other hardworking crew members.”

Graniterock’s construction division is a proven leader in heavy civil infrastructure construction. With 120-years of experience, Graniterock continues to work as a trusted partner with other general contractors and public works agencies. Their team of professionals is proactive in seeking cost-effective solutions to even the most complex projects. For more information on Graniterock, please visit their website at www.graniterock.com or call their Watsonville headquarters at (831) 768-2000. Cc

Above & Below: Graniterock employees shown working six feet apart following Covid-19 orders on the Highway 101 project.