This five-level interchange connecting the I-10 Freeway and the SR 303L Freeway is a critical component of the 40-mile SR 303L, as it provides system continuity to I-17 to the north. The project constructed four flyover bridges and an embedded frontage road system, a unique design in Arizona that increased the overall footprint to yield the largest system traffic interchange in Arizona. Ultimately, as part of the five-level system traffic interchange, 14 bridges; including multi-span freeway ramps 75-feet above existing grade, were constructed.

The System TI generated over two million cubic yards of export which was used to provide two adjacent ADOT SR 303L corridor projects (concurrently under construction) with borrow material and other private development such as Dick’s Sporting Goods distribution warehouse.

A complex project in both size and scope, both ADOT and the design and construction team went above and beyond typical project management to truly partner with all stakeholders.

There were no serious safety incidents throughout the project. Throughout the duration of the project, the Project Team had a high percentage of YTD supervisor safety audits averaging at 68%, and the project completed 666,000 manhours with zero injuries. The Project Team also went four consecutive quarters incident-free. The project OSHA recordable incident rate finished at 2.72, compared to the industry average of 6.0.

The Project Team analyzed the project phasing and proposed an alternative phasing that eliminated a final phase. This phasing approach shifted I-10 traffic and eliminated the need for temporary asphalt and utilized the final PCCP pavement for the interim traffic conditions. Additionally, the Project Team re-phased the McDowell Road detour that traveled under falsework for two sections of the fly-over ramps. The fly-over bridge frames were built ahead of the detour being shifted. This avoided the need for falsework altogether under one ramp while the other was built with less falsework and better temporary clearance. The Project Team worked with ADOT, City of Goodyear, and the design team to develop a crossroad closure plan and detour route to minimize the amount of travel through a work zone. This allowed for the full closure of Cotton Lane, which separated the work zone and live traffic, increasing safety while decreasing overall construction duration.

The Project Team efficiently phased the earthwork despite the challenging conditions on the project. The project involved over 3.4M CY of earthwork with multiple phases in different job stages. Several of the structural excavations for the fly-over pier foundations were over 40’ deep from existing grade. This resulted in phasing an additional 1M CY of earthwork excavation to accommodate substructure construction that included pier columns with 100’+ deep drilled shafts and pier columns over 90’ tall. Additionally, to meet the critical path work, the Project Team built most bridges on soffit fill as well as falsework grading to limit the overall falsework height to not exceed 70’. Overall, the Project Team moved nearly 5.5M CY of heavily phased earthwork with minimal double handling of dirt – any dirt moved was to build embankment, structural excavation, bridge soffit fill or for other project-specific tasks. The careful phasing of the earthwork benefited the schedule and the budget. Along with phasing dirt internally, they coordinated the export of nearly 1M CY to two other projects on the SR 303L corridor (one of which was a concurrent Pulice project, from Camelback Road to Glendale Ave.) and to surrounding developments in the area, including the Dick’s Sporting Goods distribution center.

Building a high-profile, multi-level interchange drew a lot of attention from the public, and the Project Team received many requests from the public for tours of the project. The Project Team also had the privilege of providing guided tours to students from Metro Tech High School Construction program and Air Force Engineers at Luke Air Force base. In Spring 2013, the Project Team took each group to the top of the largest flyover bridge, giving them an aerial view of the entire project and most of Phoenix. They were able to see the construction of the I-10 WB Bridge, formwork being installed on McDowell Road Bridge abutments, excavation of Loop 303 subgrade, and a view of the falsework on Ramp WS. While on the bridge, a brief overview of the project was given and the Project Team answered questions from tour groups.

They also viewed the newly paved I-10 WB roadway between Sarival and Loop 303 where they saw firsthand the installation of barrier footings and a ground view of the falsework on-ramp WS. In Spring of 2014, students from Metro Tech High School Construction program came out again and suited up in essential safety gear to experience a full day on a live construction site. Project Engineers Reece Green and Tyler Reynvaan worked with the head of the Construction Program at Metro Tech, Rick Schapler, to coordinate the tours for the students. The opportunity to see the phasing integration of such a complex project as the I-10/SR 303L TI gave the students perspective on the reasons they practice measurement, construction blueprint reading, safety procedures, and problem solving. According to Rick, tours like this improve student focus and dedication in the classroom because they have experienced construction in

Together, from project development through construction, the Team successfully worked across multiple agencies and stakeholders in executing this unique and innovative project. Design, environmental clearances, and construction were delivered on time, and ahead of schedule. I-10/SR 303L  Team highly won the 2014 AGC Build AZ Award.