Located in the Shenandoah National Park, Skyline Drive provides opportunities for picturesque scenery of the treasured Blue Ridge Mountains. Running along the crest of the mountains from Front Royal to Rockfish Gap in Virginia, the rehabilitation project included work on Skyline Drive from Mile Posts 5.63 to 28 and 65.20 to 97.10, along with intermittent overlooks and parking areas adjacent to Skyline Drive. Skyline Drive runs from north to south through the park and throughout the project limits pavement experienced cracking and severe pavement deterioration, in addition to the deterioration of wearing surface due to continued use over time on both Skyline Drive and the various overlooks.

As the lead designer and provider of quality control services for the MC3 led Design-Build Team, ELR worked closely with the Contractor, National Park Service (NPS) Denver Service Center (DSC), Shenandoah National Park Staff, along with their Construction Management Representative (CMR), to assess the deteriorated pavement in order to complete the final design and prepare the release for construction plans. ELR as the engineer of record was responsible for pavement design, pavement markings, work zone traffic control, and quality control inspections to successfully deliver the project.

Skyline Drive Rehabilitation

The Project is part of VDOT’s $2.3B improvement program for the 330 mile I-81 Corridor and is located near Marion, Virginia. The purpose of the project is to improve safety and operations by extending the existing I-81 Exit 47
northbound on ramp approximately 3,900 feet from MM 48.1 to MM 48.8. The project improvements include mill and overlay existing lanes; extend existing ramp lane, shoulders, and ditches; install a rock fallout zone; grade slopes; and installation of signage.

To accomplish this, approximately 75,000 cyds of material were excavated with the use of explosives while staying within the existing right-of-way and
maintaining traffic in the heavily travel north-south interstate. A significant portion of the cut was in rock, while a smaller portion is in soil, with less-
weathered blocks suspended in a matrix of soil. Major risk on the project was presence of this site in karst topography with sinkholes. To mitigate the risk
rock catchment ditch was provided, and ELR engineering geologist and
engineers visited the site regularly to monitor the features exposed as the
pre-splitting continued. As the rock splitting continued, and slope was exposed, rockfall hazard analysis was revised and recommendations were made for talus
maintenance.


The design-build project was awarded to the Team in July 2021 with all
permitting, design approvals, and construction completed early in less than 12 months.

I-81 MM 48 NB Acceleration Lane Extension Design-Build Project

This is a Locally Administered Project (LAP) by Loudoun County to extend Northstar Boulevard as a 4-lane median divided minor arterial roadway, from John Mosby Highway (US Route 50) to Tall Cedars Parkway, in Loudoun County, Virginia. The roadway has 10-feet shared use paths on the both sides of the roadway and has additional turn lanes and traffic signals with pedestrian controls installed at US Route 50, Marrwood Drive and Tall Cedars Parkway. The project budget of $45.8M was funded by Loudoun County, NVTA, and VDOT.

As the lead designer for the Bridge, ELR supported the project by providing the County with Stage-II Final Design and ultimately Stage-III Construction engineering services for the Northstar Boulevard Bridge over South Fork Broad Run. This included structural design /detailing, scour analysis, developing final plans, specifications, special provisions, and a cost estimate. The bridge is a 150-feet long single span pre-stressed concrete bulb-T beam bridge at 45-degree skew on tall wall abutments, with long wing walls, on spread footing foundation.

Working closely with Loudoun County and VDOT as part of the Stage-III post-design efforts, the bridge foundation was redesigned because of the variable bedrock encountered at depths different from the estimated bedrock depth which was based on the original subsurface investigation. ELR also assisted the County with reviewing RFIs and shop drawings throughout the construction of the Bridge.

Northstar Boulevard

ELR provided the NCDOT and Summit Design and Engineering
Services with construction inspection staff to perform duties including
but not limited to the following:

Asphalt paving oversight, recording, and documenting NCDOT
and QMS standard specifications while maintaining current
certification status.

Bridge construction and concrete placement installation
inspections of application, recording, and documenting work
items throughout the construction process. Girder installation,
elevation checks, and overall monitoring while maintaining
current concrete certifications for applied techniques and
different mixes of approved concrete as per NCDOT.

Erosion control measures project wide were inspected for proper
construction installation and performance using the approved
plans to assure jurisdictional streams, permitted sites, and any
sensitive areas are protected using the current regulatory
specifications.

Work Zone Traffic Control supervision of devices installed using
the approved transportation management plans which are
checked and inspected. This is to address the safety of both the
traveling public and construction personnel in the active work
zones with protection using best industry practices.

I-40 Exit 300-319

ELR was hired by US Developments to complete site planning for a 22.7 Ac site commercially zoned site in Union County, NC adjacent to the City of Waxhaw, NC. The area is a rapidly growing bedroom community outside Charlotte, NC and has very restrictive growth ordinances that made development challenging. Development of the site is constrained by has large elevations changes throughout the site, federally and locally protected waters and associated tree buffers through the heart of the site, limited sewer capacity for the site, and very restrictive development requirements for the conditionally zoned property that required special use permits for each activity.

ELR valued engineered several already designed features including redesign of a 30’ tall MSE wall, reducing the height and improving the grading around the wall to reduce cost and footprint of the wall, adjusting grading for more applicable uses of the property including cut and fill balance and reduction of rock excavation to improve the project.

Specific site designs included a commercial spine road through the site, development of four commercial lots along Providence Road which is the main entrance to the site, and a rear upscale townhome development including 75 units blended into the protected stream and buffers.

Under construction in the development is a Caliber Collision facility, a PEP Boys Tire Service Center, and a 100,000-sf climate control storage facility. Other developments that will start soon are the 75 townhome units and a medical office building. All infrastructure is being designed by ELR.

Providence Road Project

Staff now at ELR held key design roles for all roadway, hydraulics, structural, signing, pavement marking, and transportation management elements of the I-77 HOT Lanes P3 project. This was the first P3 design-build executed by NCDOT, providing the addition of managed lanes along a 26-mile corridor of I-77. Staff was responsible for design criteria, and final plans, and oversaw location & surveys, geotechnical investigation, right-of-way, and utilities. The project included 18 bridges and interaction with key developer staff, stakeholders, local municipalities, and private utility companies.

Following construction completion, ELR entered into a Master Services Agreement (MSA) with I77 Mobility Partners, to provide various design-related services, during their period of operating and maintaining this highway.

In 2021, ELR staff provided post-design services for reconstructing and rehabilitating 16 ramps and loops at Exit 16 Sunset Road, Exit 18 W.T. Harris Blvd., Exit 25 Sam Furr Rd., Exit 30 Griffith St., and Exit 33 Williamson Rd. The plans included roadway design, erosion control, transportation management, and pavement marking.

Other services have included mobile scanning for the entire managed lanes corridor, static toll sign design for when the dynamic tolling signs are not functioning, revisions to the managed lanes signing, and bridge inspection and rehabilitation plans.

I-77 HOT Lanes P3 - Master Services Agreement

This project involves the major pavement rehabilitation of I-71 from State Route 665 to Stringtown Road. The project involves full depth pavement and an additional third travel lane in each direction that will be added to the median. ELR completed a MOTAA where several concepts were evaluated, leading to the selection of a part-width MOT plan. The FRA-71-0903 L/R structures over White Road will be replaced with single span prestressed concrete I-beam structures. All existing signs and guardrail will be replaced and the drainage was evaluated for replacement, repair, or reuse. In addition, the project involved 5 noisewalls and lighting design.

FRA-71-5.29

The proposed Exchange Road Waterline Extension Phase I project is being implemented by the Flatwoods-Canoe Run (FCR) Public Service District and is necessary to provide quality and dependable potable water and fire protection service to approximately 59 residences in the Holly and Otter Magisterial Districts of Braxton County, West Virginia. This project will be supplied via the FCR PSD’s Water Treatment Plant. The project includes upgrading an existing booster pump station and the construction of a water storage tank that will be sized to provide water to future phases of expansion of the system.

The Exchange Road Phase I project would tie-in at the existing Pressure Reducing Station near the intersection of State Route 4 and County Route 19/22. The Exchange Road Phase I project would serve residents along County Routes 19/22, 19/26 and 19/16.

The proposed project is estimated to cost $3,136,600 and is being funded by a $1,853,500 Appalachian Region Commission Grant; a $570,000 USDA Rural Development Grant; a $570,000 USDA Rural Development Loan and $142,500 in private contributions.

This Phase I Project will provide water to the planned Phase II Project that will serve an additional 39 customers. The Phase II Project is estimated to cost $2,498,027 and will be funded by an already committed $1,698,027 Abandoned Mine Lands Grant and a requested Small Cities Block Grant in the amount of $800,000.

Exchange Road Waterline Extension Phase 1

Project involved the replacement of the SR 109 over the Maumee River. As part of the project, alignment alternatives were developed to realign SR 109 to eliminate the existing offset intersection. The intersection with SR 109 with CR 424 was designed to change SR 109 to the predominant movement and make CR 424 a stop condition. The proposed bridge will be a 12 span prestressed concrete I-beam structure and will have aesthetic enhancements including bicycle friendly railing. The project also involved design of guardrail to provide access to a future bikepath, drainage improvements, ROW plans, traffic control, and MOT. Extensive environmental coordination was completed as the Maumee River at this location is classified as a recreational river.

HEN-109-18.02

The Village of Cadiz, Ohio is located in Harrison County, Ohio. The village is in the midst of the shale oil activity in Ohio. Two shale oil plants have been constructed in the village, along with two new motels. In June of 2012, Ohio EPA mandated the village make improvements to their wastewater system. A tight timeline was included in the mandate from Ohio EPA.

The village’s wastewater system was constructed in 1939. No significant improvements or extensions were made to the system before issuance of the Finding and Orders by Ohio EPA. The system consisted of 197,684 linear feet of gravity lines ranging from 4-inches to 15-inches, 22,069 linear feet of 1.5-inch to 6-inch force mains, 794 manholes, 14 cleanouts, and 9 pump stations. The collection system was constructed primarily of clay pipe. The system surcharged during wet weather events. Resulting untreated wastewater flowing into nearby creeks and onto private properties.

Ohio EPA required the village to submit monthly reports and to participate in a monthly conference call with staff from Ohio EPA’s Columbus and Southeast District offices. E.L. Robinson Engineering staff drafted monthly reports for the village and participated in the conference calls. The reports and calls focused progress made on wastewater system improvement. The village was placed under a “connection ban.” No new wastewater customers were permitted to connect to the village wastewater system without approval from Ohio EPA. E.L. Robinson Engineering developed a report that tracked elimination or reduction of inflow and infiltration to the wastewater system. As I&I was eliminated by the village, Ohio EPA granted credits for new connections. It was critical for the village to maintain report and document elimination of I&I. The credits generated permitted new shale oil industries and supporting businesses locating in the village to connect to the wastewater system.

The North Trunk Collection System project is the third project completed by the village in an effort to improve their wastewater utility. This project involves replacement or rehabilitation of the many of the most problematic collection lines, manholes and other appurtenances. Work includes nearly 3,700 feet of pipe lining, 1,200 linear feet of 8-inch gravity line and 1,400 linear feet of 4-inch service laterals.

This project has a budget of $870,000. Funding for this work was provided by Ohio EPA’s Water Pollution Control Loan Fund (WPCLF). E.L. Robinson Engineering staff is currently completing planning and design of the next phase of collection system improvements. This phase is significantly larger in scope than the current project. Anticipated cost for the next phase is expected to be $8-milllion. A funding package is being developed at this time for those improvements. It is anticipated that funding will be provided by USDA-Rural Development, USACE, Appalachian Regional Commission and possibly Ohio EPA’s WPCLF program.

E.L. Robinson Engineering staff has worked with the village to complete a rate analysis to appropriately set wastewater user charges at levels that provide adequate revenues to cover operation, maintenance, capital improvements, debt service and reserve accounts.

North Trunk Collection System Improvements

E.L. Robinson Engineering, working as the designer for The Ruhlin Company, was successful in winning the $40,000,000 Design-Build Willow Island Power Plant Site Development Project. The project, currently under construction, involves diverting water from the locks and dam through a powerhouse to generate an average annual output of approximately 195 GWh. ELR Engineering designed and coordinated the layout and arrangement of the cellular and land-slide earthen cofferdam, perimeter slurry cut-off wall, powerhouse excavation, instrumentation, dewatering system, and temporary roads.

In addition, ELR was responsible for the preparation of all design criteria, analyses and design calculations, specifications, construction drawings, and quality control and quality assurance. The design includes construction, operation, and maintenance of the necessary facilities, including groundwater seepage cut-offs, required for dewatering the construction areas, and insuring that the completed excavation is free from running or standing water. The system incorporates pumping wells, sumps and drainage ditches to allow all work within the cofferdam to be accomplished in the dry.

The design also includes an instrumentation system to monitor the performance of the cofferdam excavation and dewatering system. During the drilling for establishing the base elevations for the dam structure within the first stage of cofferdam, a fault under existing Pier 9 and weir area was discovered resulting in changes in the footing design of the pier. The fault-shattered rock was removed, excavation was cleaned and backfilled with concrete, and the concrete gravity monolithics were replaced with circular sheetpile cells and connecting arcs. Slush grouted rock berms were placed downstream for stability and a grout curtain constructed under the weir.

Willow Island

E.L. Robinson Engineering was contracted by the Logan County Development Authority to provide project planning and site design including approximately one half-mile of access road design, site grading plan, sediment and erosion control, water and sanitary sewer layout; and upgrade to the existing wastewater treatment plant. This development includes 52 acres of land located near the Southwest Regional Jail and US 119 Corridor G. ELR is able to provide clients, like the Logan County Development Authority, with a full range of civil engineering and construction management services. ELR’s goal is to provide convenience and make the job of their clients as easy as possible.

ELR is committed to providing maximum efficiency in the completion of every project. The Earl Ray Tomblin Industrial Park and Access Road utilized the full depth of ELR’s quality services, including stormwater drainage, preparation of bid/contract documents, participation in the solicitation and evaluation of bids received, construction administration and inspection, assistance with easement/property acquisition, surveying and mapping, and preparation of all necessary permit applications

Earl Ray Tomblin Industrial Park and Access Road

This award winning design build project with Schirmer Construction and Cleveland Metroparks was prompted by the necessary removal of the original Fort Hill steps due to severe erosion of the over 100’ high cliff adjacent to the Rocky River, next to the Rocky River Nature Center. ELR proposed a unique set of timber stairs connecting landings set on “tree” like support navigating the popular trail to 100’ above the valley. The stairs feature 2 overlooks and singular column foundations to minimize the impacts to the surroundings and view shed. This design won the 2018 ABCD award for Outstanding Special Purpose Bridge.

Cleveland Metroparks Fort Hill Steps Wins ABCD Award

E.L. Robinson Engineering teamed with the joint venture of the Beaver Excavating Company and Mosser Construction, Inc. to develop a Value Engineering Change Proposal (VECP) for the LUC-24-1272 (US 24 over Norfolk Southern Railroad) and LUC 24-1293 (US Route 24 over Ramp D) structures for the LUC-24-6.19 project in District 2. This VECP resulted in a project savings of over $3 million dollars. The VECP included the realignment of Ramp D closer to the Norfolk Southern Railroad. This allowed for the elimination of the 306 foot long precast concrete arch structure over the Norfolk Southern Railroad and the 330 foot long precast concrete arch structure over Ramp D.

The two eliminated structures were replaced with a two span rigid frame/slab structure with a 57 degree +/- skew and average length of approximately 213 feet. The structure was then classified as a buried structure and was no longer classified as a tunnel as it was now less than 300 feet in length. Tunnel lighting was replaced with standard underpass lighting and the fire suppression system and advance tunnel signing was eliminated. A strut and tieback system was provided for the two span structure to provide footing lateral stability thereby permitting the footing size and pile pattern to be reduced.

The main slab reinforcing steel was designed and detailed to be perpendicular to the substructure units. The roadway barrier was designed to be integral with a substantial reinforced concrete edge beam. The two span structure was designed for overloads as applied per the contractor’s earth moving equipment. In addition, the area of mechanically stabilized earth walls was reduced by approximately 21,000 square feet. This VECP resulted in a savings of just over $3 million dollars.

I-64 Cable Median Barrier (Kentucky State Line to Milton I/C)

More Highlighted Projects