Hunter Contracting widens "The Widow Maker"

North Mountain, in the Phoenix metro area, is both a popular recreation area and an ideal location for television and radio towers, but was treacherous to ascend.

Known as “The Widow Maker” for its blind spots and steep grades, the access road leading to the construction site was in disrepair. Further complicating the project’s safety considerations was the 200,000 pound crane needed to erect the tower, which the access road wasn’t wide enough to accommodate. The city tasked Hunter Contracting, a heavy civil construction company based in Gilbert, Ariz., with renovating and extending the 4,400 ft winding road, making it safe to travel and ensuring there would be enough surface area to accommodate the crane.

This overhead view of the mountain gives an idea of some of the construction challenges Hunter Contracting faced.

A speed limit of five miles per hour was established and a mandatory spotter put in place for all concrete and haul trucks. Additionally, crews were required to make eye contact with an equipment operator before passing. “The original concrete supplier’s safety lead was unwilling to have its drivers haul material up the mountain,” Osborne said. “A second supplier, who was willing to do the work, hand-selected drivers with enough experience to safely drive the trucks up the mountain.” Additionally, a controlled-access zone was maintained three feet from the edge of the mountainside.

During construction, the project team faced the risk of falling boulders, some as large as automobiles. “Our crews monitored the terrain and, in one instance, discovered a 12-foot-tall boulder that had delaminated two feet from the mountainside, meaning that it could fall at any time,” Osborne said. “Fortunately, we cleared the area and dislodged the boulder without incident.”

The terrain also created safety risks and obstacles to overcome when installing the shotcrete drainage outlets that would direct rainwater along the road’s switchbacks. “There isn’t a piece of equipment that can grade and spray the concrete on the side of the mountain,” Obsorne said. “To create the outlets, we had to rent an 85-foot-tall manlift. Our crews were literally hanging off the side of the mountain, tied off to a water truck and using a fire hose to grade the mountain.”

Correctly building new retaining walls to ensure they'll last was a priority on the project.

With safety as a top priority, the decision was made to terminate the subcontract. “The legal challenges associated with taking over work on a proprietary product and diverting our crews to perform the subcontractor’s work required extra documentation and created new obstacles to overcome,” Osborne said. “Our crews observed how the subcontractor constructed the walls and through that observation and supplemental research, not only completed the wall, but also rebuilt and raised the portion of wall that was already built. We safely constructed the wall as it was originally designed and with higher quality. With the unexpected addition of taking on the subcontractor’s work, as well as rework from a storm that washed out most of the subgrade prior to paving, we still completed the project on schedule and within budget.”

With the road wide enough to safely accommodate the crane, the team began pioneering a road for the last 200 feet of unpaved access road and creating a staging area for the crane while the pad was under construction. Once work concluded, crews moved the crane into position on the pad. A forklift delivered tower pieces to the crane, and it was successfully erected, meeting the loading requirements needed to house new, heavier equipment.

Additionally, the improved access road is a safer environment for repair personnel and others headed up the mountain, including the many hikers who visit the trail each year.

With this insight, we were able to dig deeper and determine that the concrete trucks were taking too long to get to the site because they were taking turns driving up and down the mountain. To solve the problem, we created staging areas that allowed trucks to pull over when needed and as a result, increased from one to four trucks on the mountain at the same time.”

Hunter Contracting relied on Viewpoint's Spectrum construction management solution to get more accurate data and real-time insights into the project's progress.

Closely tracking data such as job costs, change orders, material and equipment usage and worker productivity from its projects also helps Hunter Contracting deliver smarter bids and forecast future work.

“Looking at the data in Spectrum, we can find opportunities to work more efficiently on future projects and better understand what we’re capable of delivering and within which budget and timeframe,” Osborne said. “It’s easy for our estimating team to run a report across similar projects and see how we perform on a certain type of work.”

While many companies already do some version of this, having more complete and relevant data can provide a fuller picture of how jobs fare and where improvements can be made. Furthermore, analyzing that construction data with modern business intelligence tools also ensures bids are more accurate for future projects, while the increased efficiencies and on-time, on-budget delivery of projects leads to a solid reputation and helps land more work.

Taking advantage of data and building reliable, productive workflows requires a connected construction management suite that provides a single source of real time data across contractors’ people, projects and processes. With a better understanding of accurate construction data, contractors can make actionable financial business decisions in real-time, on both current projects and for future work.