US-12 & STH 11 Improvements (including stream realignments)

Diligent communication and proactive collaboration were essential for overcoming the environmental complexities of this infrastructure project.

The Wisconsin Department of Transportation (WisDOT) selected Batterman to oversee the US-12 and STH 11 improvements project, which involved resurfacing 7.25 miles of roadway, reconstructing the Sugar Creek Bridge and Bakers Creek box culvert, and upgrading the US-12 and County ES intersection with new traffic signals. The most complex aspect of this project was managing the realignment of two environmentally sensitive streams under challenging conditions, while strictly adhering to the plans and regulations established by the Wisconsin Department of Natural Resources (WDNR) and the U.S. Army Corps of Engineers. Through extensive planning and open communication with WisDOT, WDNR, and the contractor, effective solutions were developed to ensure the project’s successful completion with minimal environmental impact.

PROJECT SCOPE

Batterman provided construction oversight for the resurfacing of approximately 7.25 miles of pavement, the reconstruction of the Sugar Creek Bridge on US-12, the replacement of the Bakers Creek 60-year-old box culvert on STH 11, and improvements to the intersection of US-12 and County ES, which incorporated new traffic signals.

CHALLENGES FACES

The project site required strict adherence to environmental regulations due to the presence of marshland and active waterways. The realignment of two streams, the Sugar Creek Tributary and Bakers Creek, was necessary to accommodate the new roadway and culvert structures while maintaining natural water flow and ensuring effective stormwater management.

Sugar Creek Tributary Realignment:

• Required work in wet conditions and a marsh area.
• Managing water bypass pumping while minimizing erosion and sediment displacement.
• Stabilizing heavy equipment in marsh conditions.

Bakers Creek Realignment and Box Culvert Construction:

• Heavy rainfall in June and July caused water levels to rise, overwhelming bypass pumping efforts.
• Wet conditions and marsh soils created productivity and efficiency challenges.
• Ensuring erosion control and protection of the existing water channel during construction.

SOLUTIONS IMPLEMENTED

Sugar Creek Tributary Realignment:

• Direct communication with WDNR and the contractor resulted in the use of crane mats to stabilize heavy equipment during stream excavation.
• Crane mats were leapfrogged as the excavator progressed through the channel to maintain stability.
• Large steel plates were used to separate construction activities from Sugar Creek and bypass pumping operations. Additionally, the outer and upper stream banks were protected with straw wattles, while the inner stream bank was used for contractor access. Once the stream excavation was complete, a heavy-duty silt fence was installed on the inner bank.
• To prevent bank erosion, plywood and cinder blocks were used to extend and distribute water flow, while a sump system of corrugated pipe and clear stone filtered out eroded material before water returned to the creek.

Bakers Creek Realignment and Box Culvert Construction:

• To mitigate the impact of unexpected high-water levels, the project team modified the excavated area to protect the existing channel and prevent erosion.
• With coordination from WDNR, work was temporarily suspended until water volumes decreased.
• After approximately two weeks of monitoring weather and water conditions, additional bypass pumps were deployed.
• Extended work hours were implemented to avoid further delays due to detrimental weather events.

FINAL OUTCOME

Despite facing environmental and weather-related challenges, the project successfully upgraded roadway infrastructure, improved traffic flow, and strengthened environmental stewardship in contemporary infrastructure development. Both stream realignments were completed with high praise from the state agency officials, and the goal of minimizing environmental impacts while promoting habitat growth for plants and wildlife was achieved.

STH 11 / Bakers Creek

US-12, Sugar Creek Tributary and Bridge