Attch_02_-_Fishhook_FSSS_2018_01_12.pdf

SPECIAL PROJECT SPECIFICATIONS

FISHOOK TUNNEL

Table of Contents

PREFACE

SECTION 101 – TERMS, FORMAT, AND DEFINITIONS

SECTION 102 – BID, AWARD, AND EXECUTION OF CONTRACT

SECTION 103 – SCOPE OF WORK

SECTION 104 – CONTROL OF WORK

SECTION 105 – CONTROL OF MATERIAL

SECTION 106 – ACCEPTANCE OF WORK

SECTION 107 – LEGAL RELATIONS AND RESPONSIBILITY TO THE PUBLIC . 12

SECTION 108 – PROSECUTION AND PROGRESS

SECTION 109 – MEASUREMENT AND PAYMENT

SECTION 153 – CONTRACTOR QUALITY CONTROL

SECTION 155 – SCHEDULES FOR CONSTRUCTION CONTRACTS

SECTION 156 – PUBLIC TRAFFIC

SECTION 157 – SOIL EROSION CONTROL

SECTION 214 – TUNNEL SCALING

SECTION 261. — CEMENT-GROUTED UNTENSIONED ROCK DOWELS

SECTION 566 — SHOTCRETE

PREFACE

Delete all but the first paragraph and add the following:

The Forest Service, US Department of Agriculture has adopted FP-03 for construction of National

Forest System Roads.

SECTION 101 – TERMS, FORMAT, AND DEFINITIONS

101.01 Meaning of Terms

Delete all references to the TAR (Transportation Acquisition Regulations) in the specifications.

101.03 Abbreviations.

Add the following to (a) Acronyms:

AFPA

MSHA

NIST

NESC

WCLB

American Forest and Paper Association

Mine Safety and Health Administration

National Institute of Standards and Technology

National Electrical Safety Code

West Coast Lumber Inspection Bureau

Add the following to (b) SI symbols:

mp Milepost ppm Part Per Million

101.04 Definitions.

Delete the following definitions and substitute the following:

Bid Schedule--The Schedule of Items.

Bridge--No definition.

Contractor--The individual or legal entity contracting with the Government for performance of prescribed work. In a timber sale contract, the contractor is the “purchaser”.

Culvert--No definition.

Right-of-Way--A general term denoting (1) the privilege to pass over land in some particular line

(including easement, lease, permit, or license to occupy, use, or traverse public or private lands), or http://www.nist.gov/

(2) Real property necessary for the project, including roadway, buffer areas, access, and drainage areas.

Add the following:

Adjustment in Contract Price--“Equitable adjustment,” as used in the Federal Acquisition

Regulations, or “construction cost adjustment,” as used in the Timber Sale Contract, as applicable.

Change--“Change” means “change order” as used in the Federal Acquisition Regulations, or

“design change” as used in the Timber Sale Contract.

Design Quantity--“Design quantity” is a Forest Service method of measurement from the FS-96

Forest Service Specifications for the Construction of Roads and Bridges. Under these FP specifications this term is replaced by the term “Contract Quantities”.

Forest Service--The United States of America, acting through the Forest Service, U.S. Department of Agriculture.

Neat Line--A line defining the proposed or specified limits of an excavation or structure.

Pioneer Road--Temporary construction access built along the route of the project.

Purchaser--The individual, partnership, joint venture, or corporation contracting with the

Government under the terms of a Timber Sale Contract and acting independently or through agents, employees, or subcontractors.

Protected Streamcourse--A drainage shown on the plans or timber sale area map that requires designated mitigation measures.

Road Order--An order affecting and controlling traffic on roads under Forest Service jurisdiction.

Road Orders are issued by a designated Forest Officer under the authorities of 36 CFR, part 260.

Schedule of Items--A schedule in the contract that contains a listing and description of construction items, quantities, units of measure, unit price, and amount.

Utilization Standards--The minimum size and percent soundness of trees described in the specifications to determine merchantable timber.

Add Figure 101-1—Illustration of road structure terms:

Figure 101-1—Illustration of road structure terms.

SECTION 102 – BID, AWARD, AND EXECUTION OF CONTRACT

102 Bid, Award, and Execution of Contract

Delete Section 102 in its entirety.

SECTION 103 – SCOPE OF WORK

103.01 Intent of Contract.

Add the following:

This project is to improve tunnel stability and reduce rockfall hazard for Fishhook Tunnel near Avery, Idaho. The north portal of the project is located in SE ¼ of NE ¼ of Section 32, Township 45 North, Range 5 East, in Shoshone County, Idaho.

The work includes but is not limited to the following:

(a) Pressure washing the inside rock surfaces of the tunnel and portal areas,

(b) Capture, haul, and land application of water generated during the pressure washing to prevent it from entering Fishhook Creek

(c) Rock scaling,

(d) Disposal of rock debris,

(e) Furnishing and installing cement-grouted untensioned rock dowels,

(f) Installation of drainage mat material,

(g) Application of shotcrete, and

(h) All other incidental items necessary to complete the project in accordance with the plans and specifications.

SECTION 104 – CONTROL OF WORK

Deletions

Delete Sections 104.01, 104.02, and 104.04.

Add the following subsection:

104.06 Use of Roads by Contractor

The Contractor is authorized to use roads under the jurisdiction of the Forest Service for all activities necessary to complete this contract, subject to the limitations and authorizations designated in the Road

Order(s) or described in the contract, when such use will not damage the roads or national forest resources, and when traffic can be accommodated safely.

SECTION 105 – CONTROL OF MATERIAL

105.02 Material Sources.

105.02(a) Government-provided sources.

Comply with the requirements of 30 CFR 56, subparts B and H. Use all suitable material for aggregate regardless of size unless otherwise designated. When required, re-establish vegetation in disturbed areas according to section 625.

105.05 Use of Material Found in the Work.

Delete 105.05 (a) and (b) and the last sentence of the second paragraph and substitute the following:

Materials produced or processed from Government lands in excess of the quantities required for performance of this contract are the property of the Government. The Government is not obligated to make reimbursement for the cost of producing these materials.

SECTION 106 – ACCEPTANCE OF WORK

106.07 Delete

Delete subsection 106.07.

SECTION 107 – LEGAL RELATIONS AND RESPONSIBILITY TO THE PUBLIC

107.05 Responsibility for Damage Claims.

Delete the entire subsection.

107.06 Contractor’s Responsibility for Work.

Delete the following from the first paragraph.

“except as provided in Subsection 106.07”.

107.09 Legal Relationship of the Parties.

Delete the entire subsection.

107.10 Environmental Protection.

Add the following:

Design and locate equipment repair shops, stationary refueling sites, or other facilities to minimize the potential and impacts of hazardous material spills on Government land.

Before beginning any work, submit a Hazardous Spill Plan. List actions to be taken in the event of a spill. Incorporate preventive measures to be taken, such as the location of mobile refueling facilities, storage and handling of hazardous materials, and similar information. Immediately notify the CO of all hazardous material spills. Provide a written narrative report form no later than 24 hours after the initial report and include the following:

(a) Description of the item spilled (including identity, quantity, manifest number, and other identifying information).

(b) Whether amount spilled is EPA or state reportable, and if so whether it was reported, and to whom.

(c) Exact time and location of spill including a description of the area involved.

(d) Containment procedures.

(e) Summary of any communications the Contractor had with news media, Federal, state and local regulatory agencies and officials, or Forest Service officials.

(f) Description of clean-up procedures employed or to be employed at the site including final disposition and disposal location of spill residue.

When available, provide copies of all spill related clean up and closure documentation and correspondence from regulatory agencies.

The Contractor is solely responsible for all spills or leaks that occur during the performance of this contract. Clean up spills or leaks to the satisfaction of the CO and in a manner that complies with

Federal, state, and local laws and regulations.

SECTION 108 – PROSECUTION AND PROGRESS

108.00_nat_us_02_16_2005

108 Delete.

Delete Section 108 in its entirety.

SECTION 109 – MEASUREMENT AND PAYMENT

109 Deletions

Delete the following entire subsections:

109.06 Pricing of Adjustments.

109.07 Eliminated Work.

109.08 Progress Payments.

109.09 Final Payment.

109.02 Measurement Terms and Definitions.

(b) Contract quantity.

Add the following:

Contract quantities will be adjusted only when there are errors in the original design of 15% or more.

Change the following:

“(b) Cubic yard” to “(c) Cubic yard”.

Add the following definition:

(p) Thousand Board Feet (Mbf). 1,000 board feet based on nominal widths, thickness, and extreme usable length of each piece of lumber or timber actually incorporated in the job. For glued laminated timber, 1,000 board feet based on actual width, thickness, and length of each piece actually incorporated in the job.

SECTION 153 – CONTRACTOR QUALITY CONTROL

Add the following.

153.07. Project Submittals

At a minimum, the contractor shall provide project submittals to the Contracting Officer as shown on the Submittal Log below.

Submittal Log

Item

No.

Incidental to

Pay

Item(s)

Description of Submittal Type of

Submittal

Requirement found in Specification No.

/Drawings

Additional

Specificati on

References

1 151 Weed Free Material Source

Certification

Material

Certification

FSSS 105 FSSS 151

2 151 Hazardous Spill Plan Plan FSSS 107.10

3 151 Contractor Quality Control Plan Plan 153.02 552.09

4 151 Erosion Control Plan Plan FSSS 157

5 214 Handling of Wash Water Plan Plan FSSS 214

6 214 Tunnel Scaling See FSSS

214.03

FSSS 214

7 261 Rock Dowels See FSSS

261.03

FSSS 261

8 261 Rock Dowels Testing Results Testing

Results

FSSS 261.08

9 566 Drainage Mat Material

Certification

FSSS 566.04, FSSS

566.09

10 566 Shotcrete See FSSS

566.06

FSSS 566

11 566 Pressure washing surface prep Inspection

Report

FSSS 566.09

12 566 Shotcrete Testing Results Testing

Results

FSSS 566.19

FSSS

566.18

SECTION 155 – SCHEDULES FOR CONSTRUCTION CONTRACTS

155 Delete.

Delete Section 155 in its entirety.

SECTION 156 – PUBLIC TRAFFIC

Description

The Forest Service will close the roadway adjacent to Fishhook Tunnel (St. Joe’s National Forest Road

301/Fishhook Creek Road) for the entire duration of the construction project. Staging locations will be along the closed roadway areas on either end of the Fishhook Tunnel. The Contractor shall coordinate with the Contracting Officer regarding construction schedule and anticipated duration, prior to the start of construction.

SECTION 157 – SOIL EROSION CONTROL

157.02 Materials

Provide bales, wattles, logs and rolls from a certified noxious weed free source.

157.03 General.

Delete the first two paragraphs and replace with the following:

Submit an Erosion Control Plan detailing permanent and temporary control measures to minimize erosion and sedimentation during and after construction in accordance with the plans and storm water permits. Do not modify the type, size, or location of any control or practice without approval. Submit the erosion control plan proposal at least 7 days before operations begin to the CO for approval.

Reflect in the Erosion Control Plan special concerns and measures necessary to protect resources and government improvements. Include:

(a) The construction activities and sequence of implementation relating to specific erosion control measures.

(b) The location and type of permanent controls to be implemented during construction.

(c) The location and type of temporary controls to be implemented during construction.

(d) For work in stream channels with running water a detailed dewatering plan.

(e) For work in stream channels without flowing water describe level of ground and vegetative disturbance and measures to reduce potential sediment delivery.

(f) Description of the monitoring plan.

Add the following to the third paragraph:

Upon completion of construction at the site, remove all temporary erosion control devices, dewatering materials and equipment from Government property.

157.08 Water Crossings.

At any channel crossing where there is running water, dewater by rerouting water flow around the site before and during excavation and embankment operations.

Measurement

The Erosion Control Plan is incidental to other items in the contract.

SECTION 214 – TUNNEL SCALING

214.01 Description. Furnish a scaling crew(s) and associated equipment to pressure wash the tunnel crown and sidewalls and scale loose rock blocks from the perimeter of the tunnel as shown on the drawings and as directed by the Contracting Officer or his Representative. The work will include the removal of the scaled rock material from the tunnel and disposal of it in designated locations within 2 miles of each tunnel portal. The work will also include the capture, haul, and land application of water generated during the pressure washing to prevent it from entering Fishhook Creek.

214.02 Definitions

(a) Pressure washing – Pressure washing is the process through which the rock surface is cleaned to provide a sufficiently clean surface capable of forming a strong bond between the rock and the shotcrete and to assist with identifying loose rock for removal by scaling.

(b) Scaling – Scaling is the process by which loose rock is removed from the crown, arch and sidewalls of the tunnel.

(c) Scaling Crew - A scaling crew is defined as a minimum of two qualified rock scalers, a working foreman and all required equipment. The foreman shall be on-site with the crew a minimum of

40 percent of the time during each working day. The type, configuration, and quantity of scaling crew and equipment type shall be selected by the Contractor. At a minimum, scaling equipment shall consist of one work platform, one loader, two light towers, and all miscellaneous tools and equipment necessary for the Contractor to complete the work.

214.03 Materials

Not Used.

Construction Requirements

214.04 Submittals. Not less than 14 days prior to beginning tunnel scaling, the Contractor shall provide to the Contracting Officer or his Representative the following submittals. Allow 7 days to review. Do not begin work until submittals have been approved.

(a) Qualifications of the Contractor’s personnel. The Contractor shall provide written evidence that the rock scaling foreman and rock scalers have performed satisfactory work in similar capacities and for a sufficient length of time to be fully qualified to perform their duties. The foreman shall have a minimum of 5 years of demonstrated experience as a rock scaling foreman. The rock scalers shall have at least 2 years of demonstrated experience on similar projects.

(b) The Contractor shall submit a detailed work plan for the tunnel scaling. The plan shall detail:

1. The types of equipment and tools to be utilized in the scaling work.

2. The number of rock scaling crews, as defined in Section 214.01.

3. A rock removal and disposal plan for rock debris generated from the rock scaling work, including provisions to protect the existing tunnel invert surface.

4. A Health and Safety Plan. The plan shall include, but not be limited to, a description of the project and potential hazards, emergency action procedures, air monitoring equipment and procedures, contacts for key project personnel, communication methods between foreman and crew, between other crews, and with emergency personnel, contacts for nearest emergency facilities (police, fire, medical, Life Flight), personal protective equipment, and spill containment plans.

214.05 Preparatory Meeting. Prior to commencing any work on the scaling, the Contractor, including all field personnel to be involved in scaling, shall meet with the Contracting Officer or his

Representative to review the Health and Safety Plan, plans and specifications, work plans, and submittals. Scaling may commence upon approval of the scaling plan and procedures described in

Section 214.04, SUBMITTALS and after the Preparatory Meeting.

214.06 Equipment Requirements. Equipment used for tunnel scaling operations shall be selected by the Contractor. Equipment selected and employed by the Contractor shall be appropriate for tunnel scaling operations and shall provide a working configuration to perform scaling at all points around the tunnel perimeter.

Operation of equipment inside and outside of the tunnel shall be in accordance with applicable Local, State, and Federal Regulations. For situations where there is a conflict between regulations, then the most stringent shall apply. No gasoline-powered equipment shall be allowed to operate within the tunnel or at the portals.

214.07 Pressure Washing. Prior to scaling, all rock surfaces shall be pressure washed with water to remove accumulations of dust, clayey coatings, and other foreign materials. Do not allow wash water to enter Fishhook Creek. Capture, haul, and land apply water generated during pressure washing at a private site to be selected by the Contractor to prevent the wash water from entering Fishhook Creek.

Work with the Contractor Office to select the site for land application. One possible location is at the junction of Forest Roads 201 and 301, approximately 5.25 miles upstream of the tunnel.

214.08 Scaling. The work shall consist of removing loose rock blocks from the tunnel perimeter. Upon completion of the first rock scaling pass, the tunnel perimeter shall be observed by the Contracting

Officer or his Representative to assess whether or not tunnel scaling has been completed. If other rock blocks are identified that require removal, the Contractor shall continue to scale until the tunnel perimeter has been scaled to the satisfaction of the Contracting Officer or his Representative. Site safety and construction means and methods shall remain the sole responsibility of the Contractor.

Work shall proceed according to the work plan and schedule submitted by the Contractor and approved by the Contracting Officer or his Representative prior to the beginning of the work. Changes to the work plan must be approved by the Contracting Officer or his Representative.

Any crew member who must leave for any reason shall be replaced immediately by a qualified replacement.

All rock and debris produced during the rock scaling operation shall be removed and disposed of by the

Contractor at locations approved by the Contracting Officer or his Representative and within 2 miles outside of each tunnel portal. Access by vehicles to and through the tunnel shall be maintained at all times.

A minimum of two light towers shall be provided by the Contractor for each scaling crew to illuminate the work area. The light tower shall have a telescoping and rotating mast (360-degree rotation) so that the lights can be readily adjusted for the work conditions. Each light tower shall have a minimum of four (4)

1,000 Watt metal halide lamps. Replacement lamps shall be available on site.

When requested by the Contracting Officer or his Representative, the Contractor shall make the work platforms and lighting systems available to the Contracting Officer or his Representative for the purpose of inspecting the tunnel perimeter. During inspections, the equipment shall be operated by the Contractor.

For estimating purposes, the Contractor shall assume that the tunnel shall be inspected by the Contracting

Officer or his Representative and Scaling Foreman for one hour prior to beginning scaling and for one hour upon the completion of scaling operations.

During removal of scaled rock from the tunnel perimeter, the Contractor shall take appropriate actions, to the maximum extent practical, to reduce loss of surface aggregate and damage to the tunnel invert.

Measurement

214.09 The method of measurement for labor and equipment is designated in the Schedule of Bid Items and discussed below.

Labor

Labor to perform the pressure washing work defined in Section 214.01, including the capture, haul and land application of wash water, shall not be measured and is incidental to the scaling work.

Labor to complete the scaling work defined in Section 214.01 shall be measured to the nearest half-hour for each scaling crew. Time in excess of 40 hours per week shall be measured at the same rate as that rate used for the first 40 hours per week. Labor of less than one-half hour per work day for reasonable work interruptions, such as minor repairs, shall be measured. Labor that is dependent on broken equipment and therefore cannot be accomplished, for equipment repairs in excess of one-half hour per work day, travel to and from the site each day, and equipment movement to or from the project or between work sites shall not be measured for payment and is considered incidental to the work.

Measured labor quantities are to include only the actual hours, to the nearest half-hour, that the labor is conducted to perform the required scaling work. Actual hours of labor that are performed on the required work shall be recorded by the Contracting Officer or his Representative each day.

Equipment

Equipment on site and in use to complete the work defined in Section 214.01 shall not be measured and is incidental to the scaling crew.

Payment

214.10 Approved quantities will be paid at the contract unit price for each pay item designated in the

Schedule of Bid Items. The contract unit prices for each scaling crew shall include all costs associated with the labor, including but not limited to insurance, all applicable taxes, per diem, travel expenses, travel time and overtime payments, and equipment (including but not limited to operation, fuel, taxes, maintenance and repairs).

Payment will be made under:

Pay Item Pay Unit

21401 Rock Scaling Crew Hour

SECTION 261. — CEMENT-GROUTED UNTENSIONED ROCK DOWELS

Delete Section and replace with the following:

261.01 This work consists of furnishing, installing, and testing cement-grouted untensioned rock dowels. The terms rock bolt, spiling bolt, and rock dowel are used interchangeably in this specification.

This item consists of the furnishing of all labor, materials, and equipment required for installing fully cement-grouted, rock dowels of the CT-Bolt type (Saferoad), DCP Bolt type (DSI Underground), or similar, for ground support inside the tunnel. This type of rock dowel also includes a mechanical anchor for immediate support.

Rock dowels will be installed in the tunnel to improve tunnel stability and reduce rockfall hazard in the tunnel. The rock dowels will be installed as shown on the Drawings and described in the Specifications, or as directed and approved by the Contracting Officer.

The rock dowels shall be cement-grouted full-length in rock with attached steel plates, washers, and nuts as shown on the Drawings or as directed by the Contracting Officer.

Rock dowel holes may be abandoned at the direction of the Contracting Officer because of difficult ground conditions (for example, excessive voids or caving conditions), and no rock dowel will be installed.

The contractor’s means and methods for rock dowel installation shall be of such type to permit excavation to be accomplished in all areas in a safe and timely manner.

Definitions

Cement-Grouted Untensioned Rock Dowel: A steel bar with mechanical expansion shell for initial support installed into a previously drilled hole in the rock and that is later fully encapsulated in cement grout. The dowel includes a polyethylene sleeve for corrosion protection. Rock dowel installations shall include drilling of holes into rock, insertion of rock bolt, installation of the plate, washers and nut, and grouting.

Alignment Load (AL): A nominal load maintained on the rock dowel to keep the testing equipment in position, typically 5 to 10 percent of the Design Load.

Design Load (DL): The cement-grouted rock dowel axial design load for this project is 28,900 pounds.

Material

261.02 Materials Conform to the following Subsections:

(a) Manufacturers. Rock dowel assemblies shall be the DCP-Bolt or CT-Bolt or equal. Lead times for 15-foot bolts can be long (potentially 8 to 10 weeks) and the Contractor is encouraged to order the bolts early in the project to ensure that the schedule is not impacted by long lead times.

(b) Rock dowels. Rock dowel assemblies shall be the 7/8-inch-diameter #7 Grade 100 DCP-Bolt with a yield load of 46,200 pounds or CT-M22 CT-Bolt with a yield load of 51,600 pounds. The rock bolts shall be supplied in 15-foot lengths

(c) The rock dowels shall be installed with spin adapters to facilitate installation using standard construction tools and equipment or specialized bolt spinning equipment.

(d) Steel bearing plates shall conform to system requirements for the DCP-Bolt or CT-Bolt installation, as recommended by the manufacturer. Bearing plates shall include Nelson studs or rebar spiders to accommodate a structural connection between the installed rock bolt and shotcrete. A second bearing plate with Nelson studs or rebar spiders installed between the DCP-

Bolt or CT-Bolt bearing plate and the rock surface is an acceptable alternative.

(e) Hex nuts shall conform to system requirements for the DCP-Bolt installation, as recommended by the manufacturer. Nuts shall develop an ultimate strength of not less than 125 percent of the minimum yield strength of the rock dowel.

(f) Cement Grout. All cement grout shall conform to the following:

1. ASTM C 1107, Grade B: Dry-Package Hydraulic Non-shrink Cement-Grout.

2. A minimum unconfined compressive strength of 4,000 psi at 28 days.

3. Portland cement meeting ASTM C150, Type I or II.

4. Ready-mix grout meeting ASTM C94.

5. A pH between 10 and 13.

6. A total chloride content of all sources not to exceed 0.05 percent by weight of the Portland cement content.

(g) The grout shall enable the rock bolts to withstand the design load of the bar within 24 hours after grouting.

(h) Admixtures, which control bleed, reduce water content and retard set, may be used in the grout if recommended by the grout manufacturer, subject to the approval of the Contracting Officer.

Any admixtures used shall be compatible with the soil anchor steel and shall be dosed and mixed in accordance with the manufacturer's recommendations

(i) Water for mixing cement grout shall be potable.

Construction Requirements

261.03 Submittals. Not less than 14 days before the installation of rock dowels, the Contractor shall provide to the Contracting Officer or his Representative the following submittals. Allow 7 days for review. Do not begin work until submittals have been approved. Submittals shall include the following:

(a) Details of rock dowel type, plate, and nut type and method of installation.

(b) Qualifications and at least two references for foreman in charge of rock dowel installations.

(c) Manufacturers’ certificates for rock dowels and associated hardware.

(d) Proposed sequence and method of installation for rock dowels, including:

1. Drilling equipment, rod sizes, and bit diameters.

2. Work decks.

3. Cement grouting pump, mixing tank, pressure gages, volumetric measurement system and procedures.

4. Method for measuring placed grout volumes to an accuracy of 0.1 cubic-foot.

(e) Daily records of the number and locations of rock dowels installed, results of proof and performance tests completed, quantity of grout and pressure used to grout each rock dowel, and any difficulties encountered in drilling or installing rock dowels. Submit for approval a tabular form to provide this information.

(f) Methods and equipment to be used to measure grout volume.

(g) Submit, no less than 7 days prior to commencing rock dowel installation, details of procedures and facilities that will be used to maintain the rock dowels and rock dowel components at proper temperatures during extreme weather conditions.

(h) Submit calibration certificates for hydraulic rams, jack torque wrenches, pressure gages, and related equipment used for testing rock dowels. The calibrations shall be performed at the beginning of the project and updated at least every three months, after rough handling of the test equipment, after damage and repair of any test equipment component, or as directed by the

Contracting Officer.

261.04 Delivery, Storage, and Handling. Rock dowels and cement grout shall be stored and installed at temperatures ranging between 50 and 80 degrees F. The dowel bars and cement grout shall be at the same temperature at the time of installation. During cold weather heated storage facilities shall be provided at the primary storage area and at the excavation heading to meet this temperature range.

During wet weather, the bolts and grout shall be sheltered to keep them dry.

261.05 Qualifications. The following qualifications shall be met.

(a) Installer: Experienced in the work of this section with a minimum of 2 years of experience installing the cement-grouted rock dowels in underground conditions for the rock dowels specified herein.

(b) Foreman or Supervisor for each Rock Bolting Crew: An individual with a minimum of 5 years of experience supervising and installing cement-grouted rock dowels in underground conditions for the rock dowels specified herein, including installation of bolts at least 15 feet in length.

261.06 Quality Assurance. Installation of rock dowels shall be in accordance with the recommendations of the manufacturer. When such recommendations differ markedly from the requirements of this section, then the recommendations of this section shall govern. The manufacturer’s technical representative shall be available to answer questions and assist with solving problems relating to installation. A technical representative from the rock dowel manufacturer shall be on site during installation of the first 25 dowels.

261.07 Installation. Just prior to drilling holes for rock dowels, the area to be supported shall be inspected and scaled as required to assure safety and to provide adequate faces to seat the bearing plates.

Holes for installation of rock dowels shall be drilled into the rock at the locations and to depths as shown on the Drawings or as directed by the Contracting Officer.

Diameter of the holes shall be in accordance with the recommendations of the anchor system manufacturer for cement-grouted dowels.

Rotary percussion-type drilling equipment capable of reaching a rock surface at least 15 feet beyond the face of the existing tunnel shall be used to perform the drilling. Rock bolt holes shall be drilled to the depths and diameters necessary to give the optimum anchorage for the dowel and at approximate inclinations and spacing indicated on the Drawings, except where otherwise directed by the Contracting

Officer.

Drilled holes shall be blown clear with compressed air or water introduced at the back of the hole to remove all drill cuttings, sludge, and debris immediately before installation of the rock dowel and cement grout.

Rock dowels shall be installed in accordance with the recommendations of the manufacturer.

Rock dowels shall be installed immediately after the hole is drilled. The Contractor shall not drill a series of holes before attempting to install rock dowels.

Mechanical shell shall be expanded immediately after installation, using a calibrated torque wrench, to

150 foot-pounds.

Coupled connections shall not be allowed unless approved by the Contracting Officer.

Dowels which do not meet the testing requirements shall be not be paid, and shall be replaced at no additional cost to the USFS

The tail of the dowel shall be cut off, at no additional cost to the USFS, so that excessive shotcrete is not required to cover the tails.

Rock dowels shall be grouted full-length in rock with attached steel dished plates, and domed nut as shown on the drawings not more than 24 hours after dowel installation.

Cement grout shall have a water cement ratio of 0.3 by weight (equivalent to 0.3 lbs of water per 1 lb of cement) to provide a high viscosity consistency (mayonnaise consistency) thick enough to adhere to an overturned hand.

The minimum compressive strength of two-inch grout cubes, molded, cured, and tested in accordance with ASTM C 109 shall be 3,000 psi at 7 days, and 4,000 psi at 28 days. Four (4) cement-grout cube samples shall be obtained from each grout batch for testing: Two samples shall be tested at 7 days, and two samples at 28 days. The Contractor shall be responsible for sampling, curing, and breaking of grout test cubes for determining mix design, and all testing shall be done by an independent laboratory approved by the Contracting Officer. The compressive strength testing of grout cube samples is incidental to the rock dowel installation.

A colloidal type mixer shall be used to mix water, cement, and admixtures and to maintain the mix agitated. Avoid hard particles and lumps in the grout that can plug the injection path.

Water temperature prior to mixing shall be between 50 and 70 degrees Fahrenheit. During periods of cold or hot temperatures, water shall be heated or cooled before mixing grout.

A means shall be provided to measure the volume of water added to cement grout mix to determine the water/cement ratio.

A pump capable of pumping 0.3:1-water:cement-ratio grout in a ¾-inch hose for 40 feet and 15 feet of dowel shall be used.

Cement grout shall be pumped to the bottom (or back) of the hole through the bar center hole. Sufficient grout shall be used to completely encapsulate the rock dowel.

The volume of grout pumped into each rock dowel hole shall be measured to an accuracy of 0.1 cubic-foot and provided to the Contracting Officer. The Contractor shall describe per Section 261.03 the method and equipment to be used to meet this required accuracy.

261.08 Testing

Two sacrificial rock dowels shall be installed and performance-tested in the tunnel prior to commencing with the installation of production rock dowels, as directed by the Contracting Officer.

Provision shall be made by the Contractor for conducting proof tests on 20 percent of the production rock dowels. Dowels bolts to be tested will be determined and observed by the Contracting Officer.

Cement-grouted rock dowels and soil anchors shall be tested following a period of time not less than 48 hours after the installation has been completed. Minimum compressive strength of the cement grout at time of testing shall be 4,000 psi.

Rock dowel testing shall be performed as follows:

(a) For all testing, the maximum test load shall not exceed the lesser of 80 percent of the yield strength or 125 percent of the design load of the specific rock dowel type.

(b) A hydraulic jack and hand pump of the type typically used for testing rock dowels shall be used to apply the test load. The jack and pressure gauge shall be calibrated as a unit by an independent firm. The pressure gauge shall be graduated in 100 psi increments or less. The pressure gauge shall be used to measure the applied load. The ram travel of the jack shall not be less than ten times the theoretical elastic elongation of the total dowel length at the maximum load.

(c) Rock Dowel Performance Test.

i. The performance test shall be performed by cyclically and incrementally loading the rock dowel in accordance with the following schedule. The anchor movements shall be measured from the alignment load and recorded to the nearest 0.001 inches with respect to an independent fixed reference point at each increment of load. The alignment load is a nominal load maintained on the anchor to keep the testing equipment in position. The test load shall be monitored with the pressure gauge. At load increments other than the maximum test load, the load shall be held just long enough to obtain the movement reading. The alignment load shall be determined during testing, but shall be sufficient to seat the anchor plate prior to proceeding with the proof and performance tests.

ii. Performance Test Schedule:

AL

0.25 DL*

0.25 DL

0.50 DL*

0.50 DL

0.75 DL*

0.50 DL

0.75 DL

1.00 DL*

0.50 DL

0.75 DL

1.00 DL

1.20 DL*

0.50 DL

0.75 DL

1.00 DL

1.20 DL

1.33 DL*

Where: AL is the alignment load

DL is the design load

iii. The maximum test load (1.33 DL) shall be held for 10 minutes. The load-hold period shall start as soon as the maximum test load is applied. The rock dowel movement, with respect to a fixed independent reference, shall be measured at 1, 2, 3, 4, 5, 6, and 10 minutes. If the rock dowel movement between 1 minute and 10 minutes exceeds 0.04 inches, the maximum test load shall be held for an additional 50 minutes. If the load hold is extended, the rock dowel movement shall be recorded at 20, 30, 40, 50, and 60 minutes, and at intermediate intervals as may be requested by the Contracting Officer.

The total rock dowel movement within the period 10 to 60 minutes shall not exceed 0.08

in. The Contractor shall plot the rock dowel movement versus test load for each load increment marked with an asterisk(*) in the performance test schedule and plot the residual movement of the anchor at each alignment load versus the highest previously applied load.

iv. After the maximum test load has been held for 10 or 60 minutes, as appropriate, and a final reading of the anchor movement was recorded at the alignment load, the Contractor shall reduce the load on the anchor and remove the dial gage and fixed reference system.

v. The Contractor shall not proceed with the installation of production rock dowels until the performance test of the sacrificial rock dowels have been fully evaluated and accepted by the Contracting Officer.

(d) Rock Dowel Proof Test.

i. The requirements for proof testing of production rock dowels shall be the same as described above for Performance Testing, except for the following loading schedule.

ii. Proof Test Schedule:

AL

0.25 DL

0.50 DL

0.75 DL

1.00 DL

1.20 DL

1.33 DL*

Where: AL is the alignment load

DL is the design load

iii. Rock dowel movement, with respect to a fixed independent reference, shall be measured at 1, 2, 3, 4, 5, 6, and 10 minutes at the maximum test load. If the anchor movement between 1 minute and 10 minutes exceeds 0.04 inches, the maximum test load shall be held for an additional 50 minutes. If the total movement at the end of 10 minutes at the maximum test load exceeds 0.040 inches, the maximum test load shall be held an additional 50 minutes and the movement readings shall be taken at 20, 30, 40, 50, and 60 minutes, and at intermediate intervals as may be requested by the Contracting Officer.

Total creep movement within the period 10 to 60 minutes shall not exceed 0.08 in.

iv. Acceptance criteria shall be in accordance with PTI recommendations for untensioned anchors.

v. Production rock dowels that failed the proof test shall be replaced as directed by the

Contracting Officer and at no cost to the USFS.

Measurement

261.09 Measurement. The method of measurement is designated in the Schedule of Bid Items.

Cement Grouted Rock Dowels (Ea).

Payment

261.10 Payment. Cement-Grouted Rock Dowel. Full compensation for furnishing all labor, equipment, and materials, including steel bars with fastening and anchorage assemblies, (washers, nuts, and plates), cement-grout, drilled holes, installation of rock dowels, cutting bar tail to specified final length and removal if they protrude into the clearance envelope, supply of utilities such as air power and water necessary to install rock dowels, load testing (including labor, materials, and equipment) up to 20 percent of dowel installations, and compressive strength testing of cement-grout samples.

Rock dowels abandoned due to contractor negligence or which do not meet the testing requirements will not be paid.

Rock dowels placed for the convenience of the Contractor or for safety of the Contractor’s operations will not be paid.

26101 Cement Grouted Rock Dowels Each

261.11 References. The publications listed below form a part of this specification to the extent referenced. The publications are referred to in the text by basic designation only.

ASTM International (ASTM)

ASTM A36 Standard Specifications for Structural Steel

ASTM A615 Standard Specification for Deformed and Plain Carbon-Steel Bars

ASTM F432 Roof and Rock Bolts and Accessories

ASTM A325 Standard Specification for Structural Bolts, Steel, Heat-Treated

120/105 ksi Minimum Tensile Strength

ASTM A755 Standard Specification for Steel Sheet, Metallic Coated by the Hot-Dip Process and

Prepainted by the Coil-Coating Process for Exterior Exposed Building Products

ASTM C1107 Specification for Packaged Dry, Hydraulic-Cement Grout (nonshrink)

ASTM C150 Standard Specifications for Portland Cement

ASTM C94 Standard Specification for Ready-Mixed Concrete

Post Tensioning Institute (PTI)

PTI DC35.1-14 Recommendations for Prestressed Rock and Soil Anchors

PTI Manual, Sixth Edition

American Concrete Institute (ACI)

ACI 305R-10 Guide to Hot Weather Concreting

ACI 306R-10 Guide to Cold Weather Concreting

U.S. Army Corps of Engineers (USACE)

CRD-C 400-63 Requirements for Water for Use in Mixing or

Curing Concrete

EM 385-1-1 Safety and Health Requirements Manual

SECTION 566 — SHOTCRETE

566.01 The work consists of furnishing, installing, and testing wet-mix steel fiber reinforced shotcrete at locations shown on the plans and at locations to be determined by the Contracting Officer or his

Representative. This work also includes installation of drainage mat prior to the application of the shotcrete.

Definitions

Shotcrete. A sprayed concrete mix consisting of Portland cement, sand, aggregate, microsilica, steel fiber reinforcement, water, and admixtures to provide quick set, high strength, and strong adhesion forced through a nozzle by compressed air. Shotcrete shall be the wet-mix type.

Materials

566.02 Conform to the following Subsections and the requirements of ASTM International (ASTM)

C1436:

(a) Portland Cement. Portland cement shall Type II low alkali and meet the requirements of

ASTM C150 and ASTM C1116.

(b) Aggregate. Aggregates shall conform to ASTM C33 with the combined grading of coarse and fine aggregates conforming to the grading shown below.

PERCENT BY MASS PASSING INDIVIDUAL SIEVES

SIEVE SIZE GRADING *

12.5 mm (½ in.) 100

9.5 mm (⅜ in.) 90-100

4.75 mm (No. 4) 70-85

2.36 mm (No. 8) 50-70

1.18 mm (No. 16) 35-50

600 µm (No. 30) 20-35

300 µm (No. 50) 8-20

150 µm (No. 100) 2-10

* Fine and coarse aggregates shall be batched separately to avoid segregation.

Aggregates shall have a minimum specific gravity of 2.55

(c) Microsilica: Microsilica admixture shall contain a minimum of 90 percent SiO2, and shall be supplied by a company that has supplied the same product to shotcrete projects with documented success. Microsilica shall comply with ASTM C1240.

(d) Steel Fiber Reinforcement: Steel fiber reinforcement shall meet the requirements of ASTM

A820. Fibers shall have a tensile yield strength of at least 170,000 psi, shall have a cross-sectional area of approximately 0.0003 square inches, shall have a length between 1 and 1-1/2 inches, and shall have a length to diameter ratio of less than 80. Fibers shall be of the end-deformed type. Straight or continuously corrugated fibers shall not be used.

(e) Water: Mixing water used for this work shall be clear, free from loam, clay, oil, acid, alkali, sulfate, sewage, decayed vegetable matter, organic matter, or any other impurities, and shall be subject to the prior approval of the Contracting Officer or his Representative. Turbidity of the water shall not exceed 2,000 ppm. Total chloride content shall be within the limits specified in

American Concrete Institute (ACI) 201.2R. Unless water is obtained from a public drinking water supply, the Contractor shall perform the testing necessary, including a program of comparative strength tests, to verify that water meets the requirements of these Specifications.

All testing shall be performed by the Contractor at no additional cost to the Government.

(f) Admixtures: Admixtures, which reduce sulfate resistance of shotcrete such as aluminum, salts, chlorides, or nitrates or are corrosive to steel shall not be used. Admixtures to be used, when required or approved, shall comply with the appropriate sections of ASTM C494 and ASTM

C1141. The Contractor is responsible for selecting a brand of admixture that will produce a shotcrete meeting all requirements of these specifications. Unless otherwise approved, soluble admixtures shall be dissolved in water before introduction into the shotcrete mixture. Admixtures shall have a documented minimum five-year history of satisfactory performance in similar applications.

(g) Accelerators: When accelerating admixtures complying with ASTM C1141, Type II, Grade 1, are to be used, the Contractor shall establish the accelerator compatibility of the job cement and the proposed accelerators using ASTM C266, except as modified herein. Compatibility of accelerator, water reducing agents or plasticizers, and microsilica with cement, aggregate, and steel fiber reinforcement shall be demonstrated by the Contractor to the satisfaction of the

Contracting Officer or his Representative. The powdered accelerator shall be blended with 50 grams of cement until uniform and 15 milliliters of water shall then be added. The liquid accelerator shall first be mixed with 15 milliliters of water and then added to 50 grams of cement. Three percent of the proposed accelerator by mass of cement shall be used as a starting point. Mixing shall be accomplished within 15 seconds. The specimen shall be molded within 1 minute of adding the mixing water. If initial set is 2 minutes or less and a final set is 10 minutes or less, the accelerator is considered compatible. If these values are not achieved in the first test, additional tests shall be run using 2 percent and 4 percent of accelerator. Accelerator shall contain no water-soluble chlorides or materials corrosive to steel and shall not cause other detrimental effects such as cracking or spalling.

(h) Air Entraining Admixtures: Air entraining admixtures shall comply with ASTM C260. The

Contractor shall establish the compatibility of the air entraining admixtures with the cement, aggregate, microsilica, steel fiber reinforcement, and other admixtures.

(i) Packaged, Pre-Blended Shotcrete: Packaged, pre-blended shotcrete shall meet the shotcrete mix design requirements of this specification, including aggregate gradation, strength, and air content

(when mixed), and shall comply with ASTM C1480.

(j) Curing Materials: Curing materials shall meet the requirements for Membrane-Forming Curing

Compounds: ASTM C309, Type 1-D or Type 2.

566.03 Mix Design. The exact proportions of cement, fine aggregate, coarse aggregate, microsilica, admixtures, and water shall be determined by the Contractor, subject to approval by the Contracting

Officer or his Representative, prior to shotcreting and subject to adjustments in the field. Mixture proportions shall be selected during preconstruction testing on the basis of compressive strength tests of specimens continuously moist-cured until testing. Shotcrete and accelerator shall be adjusted as required to provide necessary immediate ground support and control of the ground while maintaining

28-day compressive strength development requirements. Shotcrete shall meet the following requirements:

(a) The shotcrete shall contain a minimum of seven and a half (7.5) sacks of cement, eighty (80) pounds of steel fibers, seventy-five (75) pounds of microsilica per cubic yard, and a coarse aggregate/total aggregate ratio of 0.4. Approved water reducing agents shall be used to maintain the water-cement and microsilica ratio below 0.4 while still obtaining a pumpable and sprayable mix.

(b) The required compressive strength development for shotcrete shall be 800 psi (8 hours), 2,500 psi (3 days), and 5,000 psi (28 days). Shotcrete testing shall conform to ASTM C39 and ASTM

C42.

(c) The shotcrete-rock adhesion and homogeneity of aggregate shall be in accordance with the requirements for a well bonded, dense, uniform tight shotcrete liner.

(d) The total air content of the shotcrete, as calculated in accordance with ASTM C185, shall be between 9 and 11 percent of the volume of the shotcrete based on measurement made on the shotcrete immediately before pumping.

566.04 Drainage Mat. Miradrain G100W or similar drainage composite with filter weave woven geotextile bonded to one side.

Construction Requirements

566.05 Qualifications. Shotcrete work shall be performed by personnel who have experience in shotcrete application for excavation support. Shotcrete shall be applied by nozzlemen having at least three years of documented previous satisfactory experience in the application of wet-mix shotcrete

(depending on the method to be used on this project) on at least two comparable projects. All nozzlemen shall be certified in accordance with ACI CP-60 for both vertical and overhead application of wet-mix shotcrete (depending on the method to be used on this project). These nozzlemen shall work under the immediate supervision of a foreman having at least 5 years of such experience, two of which shall be as a nozzleman. In no case shall inexperienced or unapproved workers be allowed to perform the nozzling of shotcrete.

566.06 Submittals. Not less than 14 days before beginning shotcrete placement, the Contractor shall provide to the Contracting Officer or his Representative the following submittals. Allow 7 days for review. Do not begin work until submittals have been approved. Submittals shall include the following:

(a) Work Plan: The Contractor shall submit to the Contracting Officer or his Representative for review and comment a detailed work plan for placing shotcrete. The work plan shall describe the sequence for shotcrete application, and methods and equipment to be used by the Contractor for thickness control, curing, and hot and cold weather protection.

(b) Contractor Certification and Qualifications: Submit satisfactory evidence of the Contractor’s experience and workmanship on similar projects, as required in ASCE 40068.

(c) Product Data: Submit the proposed mix design, materials, and equipment for approval. Use ingredients in design mixes that are representative samples of materials to be used in the work.

In the event that the source, brand, or…