Section_31_62_16_-_Steel_Piling_Marine_0006.pdf

COMPREHENSIVE FACILITY REHABILITATION ON MANITOU ISLANDS 31 62 16 - 1

SLBE 318729 STEEL PILING

SECTION 31 62 16

STEEL PILING MARINE

PART 1 - GENERAL

1.1 SUMMARY

A. Section includes:

1. Steel Pipe Piles.

1.2 REFERENCES

A. Society for Testing and Materials (ASTM International)

B. Contract, General, Supplementary and Other Conditions of the Governing Specification Sections and the Drawings apply to Work of this Section.

C. Michigan Department of Transportation (MDOT) Standard Specifications for Construction.

D. Soils information:

1. South Manitou Island soils information provided by Coleman Engineering Co. report #GD- 11093 dated July 8, 2011.

2. North Manitou Island soils information provided by McNamee, Porter & Seeley, Consulting Engineers dated October 1985.

3. Engineering Survey & Design Study For Manitou Islands provided by McNamee, Porter & Seeley, Consulting Engineers dated March 1984.

1.3 SUBMITTALS

A. Preconstruction Submittals:

1. Installer Qualifications

2. Installation Procedures

3. Contractor’s Geotechnical Consultant Documentation

4. Testing Agency Qualifications

5. Initial Wave Equation Analysis

6. Geotechnical Exploration Results

B. Product Data:

1. Driving

2. Pile Driving Equipment

a. Include type, make, and rated energy range; weight of striking part of hammer; weight of drive cap; and type, size, and properties of hammer cushion.

Morris Rectangle

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3. Pile Test

4. Pulling and Redriving

C. Shop Drawings:

1. Pipe Piles

a. Show fabrication and installation details as necessary to install piling and fabricate specialty connectors.

b. Include member sizes, lengths, and cuts.

c. Indicate welds by standard AWS symbols, distinguishing between shop and field welds, and show size, length, and type of each weld.

d. Pile Splicing

e. Pile Placement

f. As-Driven Survey

g. Final Certified Piles Survey: Submit within seven (7) days of pile-driving completion.

h. Geotechnical Instrumentation

2. Design Data

a. Quantities List

b. Procedure for Insufficient Pile Length

D. Test Reports

1. Materials Tests

2. Dynamic Pile Analysis

3. Refined Wave Equation Analysis

E. Certificates

1. Pile Splices

2. Welder Certification

3. Safety Data Sheets (SDS) and Content Information Sheets (CIS)

F. Closeout Submittals

1. Pile Driving Records

2. Readout Results

G. Field quality-control reports.

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1.4 QUALITY CONTROL

A. Material Tests: Provide one certified copy of mill test reports with heat numbers identified, including physical test reports and chemical analyses, and mill shipping papers to the Engineer before delivering the material to the project. Include the actual carbon, manganese, and phosphorus contents in the chemical analysis report. The CO may reject the material shipment if the mill certificates are not received.

B. No seconds, reject, or used piling will be considered unless approved by engineer of record.

C. Specifications for Steel Piling product for use on this Project must be submitted to the Engineer for review not less than seven (7) calendar days prior to the bid date. The request must include:

1. Product data and all necessary technical data to qualify the proposed product substitution.

2. Evidence showing manufacturer has at least five (5) years’ experience in the design and manufacture of Steel Piling.

D. Special Inspections: Contractor will perform special inspections as necessary to observe for proper installation of piling and is responsible for all testing and inspections.

E. All Steels Piles shall be driven utilizing the driving criteria established by the PDA testing.

F. Perform dynamic pile tests as indicated on drawings. PDA tests shall conform to ATM D4945 and Contractor may use production piles for the load test at their option. Piling must have a minimum of compression and tension capacity per pile as indicated on drawings. The Contractor may use the same pile firstly for a compression test and secondly for a tension test. Perform a drive test for the purpose of confirming pile lengths required and establishing driving criteria for all piles. Drive test piles shall be a minimum 15’ longer than as shown.

G. Steel Piles will be considered defective if they do not pass tests or inspections.

H. Corrosion protection shall consist of sacrificial steel in the form of extra thickness on each steel item. Thicknesses noted on drawings include sacrificial steel amounts. No other coatings or galvanizing are necessary.

1.5 QUALITY ASSURANCE

A. Contractor’s Geotechnical Consultant: The Contractor shall hire the services of an independent, Professional Geotechnical Engineer registered in the State of Michigan, experienced in soil mechanics and PDA, to observe the test pile installation and production pile installation as specified herein. The Contractor’s Geotechnical Consultant must be independent of the Contractor and must have no employee or employer relationship which could constitute a conflict of interest.

All services of the Contractor’s Geotechnical Consultant shall be paid for by the Contractor. The Contractor’s Geotechnical Consultant shall be available through the pile driving operation to consult with the Contracting Officer when required.

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B. Material Certificates: For each shipment, submit certificates identified with specific lots prior to installing piling. Include in the identification data piling type, dimensions, chemical composition, mechanical properties, section properties, heat number, and mill identification mark.

C. Installer Qualifications: Authorized representative who is trained and approved for installation of units required for this Project.

D. Welding Qualifications: Qualify procedures and personnel according to AWS D1.1, "Structural Welding Code - Steel."

E. Pre-installation Conference:

1. A preconstruction pre-installation meeting shall be held at the jobsite or virtually at least 5 business days prior to the start of test pile driving operations. The preconstruction pre-installation shall be arranged by the Contractor. The purpose of the meeting is to review the requirements of this specification and the associated drawings. The following individuals as a minimum will be in attendance at this meeting: Contractor’s Project Manager and Project Superintendent, Piling Foreman, Contractor’s Geotechnical Consultant, Supervisory Engineer, and Contracting Officer. The minutes of this meeting shall be recorded by the Contractor and published via email within 48 hours to all attendees. The minutes shall be re-published within 48 hours via email pending any subsequent comments from the attendees.

F. Installation Procedures

1. Submit information on the type of equipment proposed to be used, proposed methods of operation, pile driving plan including proposed sequence of driving, and details of all pile driving equipment and accessories.

2. Provide details of pile driving equipment and a Wave Equation Analysis of pile drivability for selection of the hammer along with a statement of driving procedures. Provide instructions and procedures on how the Contractor will perform Dynamic Pile Testing, Inspection and Monitoring of piles during installation and testing. The Wave Equation Analysis is to be completed by the Contractor’s Geotechnical Consultant for each test pile location where different subsurface conditions exist and is to include the following information pertaining to the proposed pile driving equipment:

a. Complete Pile and Driving Equipment Data Form, (which can be downloaded at https://www.wbdg.org/ffc/dod/unified-facilities-guide-specifications-ufgs/forms-graphics-tables) for each proposed pile hammer and pile type combination.

i. Copies of computer input and output sheets and graphs showing soil resistance versus blow count as well as maximum tension and compression stresses versus blow count.

Analysis must be run at the estimated tip elevation as well as other required elevations to define maximum stress levels in the pile during driving.

3. Provide detailed procedures for conducting the dynamic pile load test and equipment to be used for conducting the load test. The detailed description must explain how specific information of pile performance will be evaluated.

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1.6 SEQUENCING & SCHEDULING

A. Coordinate the schedule for Steel Pile Work necessary to maintain the Critical Path for subsequent work specified in related sections.

B. Obtain necessary permission from the Contracting Officer and/or regulatory authorities for Work that must be performed outside of normal work hours, on weekends, or over holidays, either as necessary to minimize the impact of temporary shutdown of utility services and traffic, or for the Contractor’s convenience.

C. Coordinate the schedule to provide for the Contracting Officer’s continuing operations on or adjacent to the site.

1.7 PROJECT CONDITIONS

A. Subsurface soil assumptions are based on the subsurface soil data logs appended to the contract requirements. The following assumptions were used for the purpose of determining pile lengths for bidding purposes.

1. North Manitou Island Soil Conditions:

a. Soil borings drilled in June 1985 indicate that the lake bottom soil is uniform through the area, consisting of firm medium sand in the upper 8 feet and compact medium sand below that depth.

b. Soil borings were terminated between 30 and 40 feet in depth (between elevation 542.1 feet to 549.1 feet). Soil was assumed to be uniform below these boring termination elevations for the design of the piles.

c. Contractor shall perform additional soil borings to verify in-place soil conditions utilizing the parameters stated in section 1.3 Submittals.

2. South Manitou Island Soil Conditions:

a. Soil borings drilled in July 2011 indicate native, fine to medium grained poorly graded sand to boring termination depths. The upper 15 to 18 ½ of the native sand was generally loose transition to medium dense at the termination depths.

b. Soil borings were terminated between 42 and 69 feet in depth (between elevations 509.9 feet and 536.4 feet). Soil was assumed to be uniform below these boring termination elevations for the design of the piles.

c. Contractor shall perform additional soil borings to verify in-place soil conditions utilizing the parameters stated in section 1.3 Submittals.

PART 2 - PRODUCTS

2.1 SYSTEM DESCRIPTION

A. The Contractor is responsible for determining the quantities of material necessary for completing the Work.

B. See plan for estimated pile lengths and pile tip elevations.

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C. Unless otherwise indicated, all required materials shall be furnished by the Contractor.

D. Materials required for this Work shall be new material conforming to the requirements of the referenced Specifications for the class, kind, type, size, grade, and other details indicated in these Specifications or on the Plans.

2.2 MATERIAL PROPERTIES

A. Steel Pipe: ASTM A252. Grade 3 with a minimum yield strength of 60 ksi. Provide test piles identical to those used elsewhere in the project. Provide steel pipe piles of the shape, size and sections shown in the drawings. Pipe piles must be either seamless pipe or full penetration welded with straight or spiral seams. Pipe must be welded in a manner that welding will not crack or fail when the pile is subjected to its intended use, including during installation. The weld seam of each length of pipe must be tested for acceptance by ultrasonic testing in accordance with the provisions for Nondestructive Electric Test of Weld Seam of ASTM A53.

B. Pile splices: Submit detail drawings of shop field pile splices prior to fabrication. Provide ASTM A148, Grade 90-60 proprietary pile splicer sleeves or provide ASTM A109 or ASTM A36 backing rings to prevent weld blow out during weld process. Submit procedure for insufficient pile length.

C. Fabrication must conform to the requirements shown. Submit steel plant certification.

D. Concrete infill must conform to the requirements as identified in Section 033000 Cast-in-Place Concrete.

2.3 PILE DRIVING EQUIPMENT

A. Submit complete descriptions of pile driving equipment, including hammers, power packs, driving helmets, hammer cushions, pile cushions, leads, jetting equipment, extractors, protection caps, preboring equipment, and other installation appurtenances, at least 30 days prior to commencement of work.

B. Select the proposed pile driving equipment, including hammers and other required items, and submit complete descriptions of the proposed equipment in accordance with paragraph SUBMITTALS. Final approval of the proposed equipment is subject to satisfactory completion and approval of pile tests. Submit pile test plan at least 30 calendar days prior to installing any test piles. Approval of the plan will not relieve the Contractor of the responsibility for structural and operational adequacies of the testing system. Changes in the selected pile driving equipment will not be allowed after the equipment has been approved except as directed. No additional contract time will be allowed for Contractor proposed changes in the equipment.

C. Driving Hammers

1. Hammers must be steam, air, or diesel drop, single-acting, double-acting, differential-acting, or vibratory type. The driving energy of the hammers must be as recommended by the manufacturer for the piling weights and subsurface materials to be encountered. Repair damage to piling caused by use of a pile hammer with excess delivered force or energy.

Provide impact or vibratory type pile driving hammers.

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a. Impact Hammers

i. Provide air, hydraulic or diesel-powered impact pile hammers of the single-acting, or differential-acting type. The size or capacity of hammers must be as recommended by the hammer manufacturer for the total pile weight and the character of the soil formation to be penetrated. Hammers must be capable of hard driving in excess of 20 blows per one inch. Provide boiler, compressor, or engine capacity sufficient to operate hammers continuously at the full rated speed. Hammers must have a gage to monitor hammer bounce chamber pressure for diesel hammers or pressure at the hammer for air hammers. This gage must be operational during the driving of piles and be mounted in an accessible location for monitoring by the Contractor and the Contracting Officer. Provide two spare operational bounce chamber read out units on site. Provide bounce chamber pressure gage correction tables and charts for the type and length of hose to be used with the pressure gage to the Contracting Officer.

Hydraulic hammers must be equipped with a system for measurement of ram energy.

The system must be in good working order and the results must be easily and immediately available to the Contracting Officer. Install an energy monitor on the hydraulic hammers and record headings every 10 inches of pile installation. Use wave equation analysis to verify that the hammer will develop stresses within acceptable limits in the pile. Position a pile cap or drive cap between the pile and hammer. Place hammer cushion or cap block must have consistent elastic properties, minimize energy absorption, and transmit hammer energy uniformly and consistently during the entire driving period. In accordance with paragraph SUBMITTALS, submit the following information for each impact hammer proposed:

1. Make and Model

2. Ram weight (pounds)

3. Anvil weight (pounds)

4. Rated stroke inches

5. Rated energy range foot-pounds

6. Rate speed (blows per minute)

7. Air pressure, hammer, and boiler or compressor psi

8. Rated bounce chamber pressure curves or charts, including pressure correction chart for type and length of hose used with pounds per square inch

9. Pile driving cap, make, and weight (pounds)

10. Cushion block dimensions and material type

11. Power pack description

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b. Vibratory Hammers

i. The use of vibratory hammers to install steel pipe piles is dependent upon satisfactory driving and load testing of piles. Final approval of the proposed hammer and other driving equipment is subject to satisfactory completion and approval of the pile tests.

The size or capacity of hammers must be as recommended by the hammer manufacturer for the total pile weight and the character of the soil formation to be penetrated. The hammer must provide for maintaining a rigid connection between the hammer and the pile. In accordance with paragraph SUBMITTALS, submit the following information for each vibratory hammer proposed:

1. Make and model

2. Eccentric moment (inch-pounds)

3. Dynamic force (tons)

4. Steady state frequency or frequency range (cycles per minute)

5. Vibrating weight (pounds)

6. Amplitude (inches)

7. Maximum pull capacity (tons)

8. Non-vibrating mass weight (pounds)

9. Power pack description

D. Pile Driving Leads

1. Support and guide hammers with fixed extended leads or fixed underhung leads. Provide two intermediate supports for the pile in the leads to reduce the unbraced length of the pile during driving and pulling.

E. Pile Extractors

1. Pile extractors may be vibratory or impact pile driving hammers. Impact hammers are required for pulling piles not extractable with vibratory hammers.

F. Jetting Equipment

1. Jetting will not be permitted.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Contractor shall engage an independent testing and inspecting agency to perform special inspections as necessary to observe for proper installation of piling.

1. Independent testing agency shall be qualified according to ASTM E329 for testing indicated, as documented according to ASTM E548, and approved by Contracting Officer.

3.2 PREPARATION

A. Pile-Length Markings: Mark each pile with horizontal lines at 12-inch intervals; label the distance from pile tip at 60-inch intervals. Maintain markings on piles until driven.

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B. Fabricate full-length piles to eliminate splicing during driving, with ends square.

C. Fit and weld driving points to tip of pile (if required) according to manufacturer's written instructions and AWS D1.1 for procedures, appearance and quality of welds, and methods used in correcting welding work.

D. Wave Equation Analysis of Pile Drivability

1. Prior to driving any pile, submit a pile Wave Equation Analysis, performed by Contractor’s Geotechnical Consultant, for each size pile and distinct subsurface profile condition. These analyses must take into account the proposed hammer assembly, pile cap block and cushion characteristics, the pile properties and estimated lengths and the soil properties anticipated to be encountered throughout the installed pile length based on static capacity analysis with consideration of driving gain/loss factors. Only one specific model of pile hammer may be used for each pile type and capacity.

2. Demonstrate using the Wave Equation Analysis that the piles will not be damaged during driving, indicate that the driving stresses will be maintained within the limits below and indicate the blow count necessary to achieve the required ultimate static pile capacities.

Steel Piles Allowable Driving Stresses

Compression 0.9fy

Tension 0.9fy

Where fy is yield strength of steel

3. Perform a refined Wave Equation Analysis upon completion of the dynamic and static testing programs outlined in this specification section, taking into consideration the evaluated capacities, gain/loss factors and recommended production pile lengths. Develop production pile driving criteria based on the results of the refined Wave Equation Evaluations.

4. All pile driving equipment provided by the Contractor will be subjected to the approval of the Contractor’s Geotechnical Consultant. Complete the attached pile and driving equipment data form, including hammer information, in full as part of the submittal of the results of the Wave Equation Analyses.

5. Pay for the cost of performing the Wave Equation Analyses and include in the base bid.

3.3 GEOTECHNICAL EXPLORATION

A. Contractor shall hire the services of an independent, Registered Professional Geotechnical Engineer licensed in the State of Michigan, experienced in soil mechanics to obtain and review soil borings at site prior to construction.

B. The soil borings shall be completed in the water from a barge or other support vessel down to a minimum depth of 90 feet below the mudline. Selected geotechnical firm shall perform the following services:

1. Public and private utility locate prior to geotechnical exploration.

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2. Two standard penetration test (SPT) borings to minimum depth specified above. Geotechnical firm shall determine the exact length based on the attached bathymetric survey. Standard penetration tests shall be performed at 2.5-foot vertical intervals until refusal.

3. Collect field samples and perform the necessary laboratory testing to provide the following design information:

a. Boring log

b. Blow Counts

c. Soil Classification

d. Water content

e. In-situ unit weight, saturated weight, and effective unit weight of soils

f. Internal Friction Angle or Cohesion for all soil layers

4. In addition to the required parameters listed above, the geotechnical firm shall provide the required design parameters for the software, Group by Ensoft. The required parameters are shown below for reference.

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5. If bedrock is encountered prior to the planned termination elevation, the selected firm shall collect a minimum of a 10-foot-long rock core to determine the design parameters required by Group software.

6. Geotechnical report to be prepared including design parameters and a description of the field and laboratory testing procedures.

3.4 INSTALLATION

A. General: Continuously drive piles to elevations indicated. Establish and maintain axial alignment of leads and piles before and during driving. Inspect piles when delivered and when in the leads immediately before driving. Cut piles at cutoff grade by an approved method.

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B. Lengths of Production Pile

1. The estimated quantities of piles are given for bidding purposes only. Drive piles to “calculated” or indicated tip elevation to reach a driving resistance established by the wave equation analyses (WEAP) in accordance with the schedule which the Contractor’s Geotechnical Consultant will prepare from the test-pile driving data.

C. Pile Driving Records

1. Keep a complete and accurate record of each pile driven. Indicate the pile location, deviations from pile location, cross section shape and dimensions, original length, ground elevation, tip elevation, cut-off elevations, number of blows required for each foot of penetration and number of blows for the last 6 inches penetration or fraction thereof as required for the “calculated” driving resistance. Include in the record the beginning and ending times of each operation during driving of pile, type and size of hammer used, rate of operation, stroke or equivalent stroke for diesel hammer, type of driving helmet, and type and dimension of hammer cushion (cap block) and pile cushion used. Record retap data and unusual occurrences during pile driving such as redriving, heaving, weaving, splicing, obstructions, and any driving interruptions.

2. Additional data required to be recorded for impact hammers includes the rate of hammer operation. Additional data required to be recorded for vibratory hammers includes hammer power pack description, make size, horsepower applied to pile, and hammer operating frequency.

D. Placing and Driving

1. Placing

a. Submit a written description of the site-specific pile installation procedures for Contracting Officer review and approval. Pile placement installation drawings and details must also be provided.

b. Excavate minimum 5 feet below the mudline to clear any debris in the drive line which may impede the installation of the piles. Any excavation required within the area where pilings are to be installed must be completed prior to placing pilings. The production pile may not be used to clear the drive line. Probe driveline minimum 5 feet below mudline and clear any debris which may impede the installation of the piles. Any excavation required within the area where pilings are to be installed must be completed prior to placing pilings. The production pile may not be used to clear the drive line.

c. Piling must be carefully located as indicated. Pilings must be placed plumb with out-of-plumbness not exceeding 1/8 inch per foot of length and true to line. Place the pile so the face will not be more than 6 inches from vertical alignment at any point. Top of pile at elevation cut-off must be within 1/2 inch horizontally and 2 inches vertically of the location indicated. Manipulation of piles to force them into position will not be permitted. Check all piles for heave. Re-drive all heaved piles to the required tip elevation.

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2. Driving

a. Submit records of the completed pile driving operations, including a system of identification which shows the disposition of approved piling in the work, driving equipment performance data, piling penetration rate data, piling dimensions and top and bottom elevations of installed piling. Prior to driving piles in water, paint a horizontal line on both sides of each piling at a fixed distance from the bottom so it will be visible above the water line after installation. This line must indicate the profile of the bottom elevation of installed pilings and potential problem areas can be identified by abrupt changes in elevation. Drive pilings with the proper size hammer and by approved methods so as not to subject the pilings to damage.

i. Maintain driving hammers in proper alignment during driving operations by use of leads or guides attached to the hammer. Caution must be taken in the sustained use of vibratory hammers when a hard driving condition is encountered to avoid damage.

Discontinue the use of vibratory hammers and impact hammers employed when the penetration rate due to vibratory loading is one foot or less per minute.

ii. Employ a protective cap in driving when using impact hammers to prevent damage to the tops of pilings. Remove and replace pilings damaged during driving at the Contractor’s expense.

iii. Drive pilings without the aid of a water jet.

iv. Take adequate precautions to ensure that pilings are driven plumb.

E. Driving Tolerances: Drive piles without exceeding the following tolerances, measured at pile heads:

1. Within 2 inches from baseline indicated on plans after driving completed.

2. Maintain maximum 1/8 inch per foot out of plumb within either plane.

F. Inspection of Driven Piling

1. Perform continuous inspection during pile driving. Inspect all piles for compliance with tolerance requirements. Bring any unusual problems which may occur to the attention of the Contracting Officer.

2. Allow testing and inspecting agency to visually inspect and verify that each pile pipe is clean, watertight, plumb, and free of distortion or other defects.

3. Any pile damaged by reason of internal defects or by improper driving must be corrected by one of the following methods approved by the Contracting Officer for the pile in question:

a. The pile is withdrawn, if practicable, and replaced by a new and, if necessary, longer pile.

b. A PDA and/or low integrity testing must be performed by the Contractor’s Geotechnical Consultant to assess the structural integrity of the driven pile(s).

c. Contractor is responsible for replacement of damaged piling due to improper driving and or handling of piling during the driving process. Contractor will be allowed to re-drive piles not damaged during extraction after inspection by engineer if approved by Engineer.

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G. Pulling and Redriving

1. Submit the proposed method for pulling piling, prior to pulling any piling. Pull, as directed, selected pilings after driving to determine the condition of the underground portions of pilings.

Any piling so pulled and found to be damaged, to the extent that its usefulness in the structure is impaired, must be removed and replaced at the Contractor’s expense.

H. Cutting-Off:

1. Pilings driven to refusal or to the point where additional penetration cannot be attained and are extending above the required top elevation in excess of the specified tolerance must be cut off to the required elevation. Pilings driven below the required top elevation and pilings damaged by driving and cut off to permit further driving must be extended as required to reach the top elevation by splicing when directed at no additional cost to the Contracting Officer. Submit procedure for insufficient pile length. Provide pile splicing information and details for Contracting Officer review and approval prior to installation in the field. If directed, pilings must be spliced as required to drive them to depths greater than shown and extend them up to the required top elevation.

a. Pilings adjoining spliced pilings must be full length unless otherwise approved. If splices are allowed in adjoining pilings, the splices must be spaced at least 10 feet apart in elevation. Splicing of pilings must be as indicated. Ends of pilings to be spliced must be squared before splicing to eliminate dips or camber. Shop and field welding, qualification of welding procedures, welders, and welding operators must be in accordance with AWS D1.1. Submit welding certifications for all welders and welding operators for Contracting Officer review and approval.

b. The tops of pilings excessively battered during driving must be trimmed when directed, at no cost to the Contracting Officer. Piling cut-offs will become the property of the Contractor Contracting Officer and must be removed from the site.

2. Cut off tops of driven piles square with pile axis and at elevations indicated.

I. Do not place concrete until other piles within a radius of 20 feet have been driven and approved.

J. Remove withdrawn piles that are not re-useable and cutoff sections of piles from site and legally dispose of them off the Contracting Officer’s property at no additional cost to Contracting Officer.

K. After the driving of each pile group is complete, provide the Contracting Officer with an as-driven survey showing actual location and top elevation of each pile. Submit an as-driven survey showing actual location and top elevation of each production pile within 7 calendar days of completing the pile installation. Present survey in such form that it gives deviation from plan location in two perpendicular directions and elevations of each pile to nearest half inch. Survey must be prepared and certified by a land surveyor licensed in the State of Michigan.

3.5 OBSTRUCTIONS

A. Contractor shall anticipate encountering obstructions below the mudline during driving of the steel pipe piles. Anticipate shallow obstructions at 40% of the piles and deep obstructions at 10% of the piles for bidding purposes.

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B. Practical Refusal: The presence of obstructions shall be determined by practical refusal of the pile, defined as: pile penetration resistance (blow count) of 10 blows per inch for a maximum of 3 consecutive inches of pile penetration using an approved hammer system operating properly at its maximum fuel or stroke setting.

C. Shallow Obstructions: Defined as obstructions greater than 5 feet and less than 20 feet below the mudline. Shallow obstructions should be anticipated during driving.

D. Deep Obstructions: Defined as obstructions greater than or equal to 20 feet below the mudline.

Deep obstructions should be anticipated during driving.

E. Obstruction Mitigation Procedures:

1. Mitigation of obstructions encountered will follow the below general procedure:

a. Contractor encounters an obstruction as defined by practical refusal.

b. Contractor notifies Contracting Officer immediately that an obstruction has been encountered and provides information regarding the depth and apparent size of the obstruction.

c. Contractor obtains approval from Contracting Officer that obstruction has been encountered and which depth category the obstruction is categorized as (Deep or Shallow).

d. Once categorized and approved by Contracting Officer, Contractor implements mitigation efforts in accordance with the suggested procedures indicated below. Suggested procedures for mitigating obstructions encountered during driving are provided in this Section. Note that Contractor may also submit alternate methods for mitigating obstructions for approval by the Contracting Officer. Personnel and equipment required to perform any and all obstruction mitigation measures include at a minimum a spudding device and a down-the-hole (DTH) hammer.

F. Shallow Obstructions: If the driven pile encounters an obstruction shallower than 20 feet below the mudline at the time of driving, possible Contractor options to mitigate the obstruction include, but are not limited to:

1. If the obstruction is determined to be relatively close to the approximate mudline elevation at the time of driving, extract the pile, attempt to extract the obstruction by means and methods determined by the Contractor, and re-drive the pile to the pile tip elevations shown on the drawings.

2. Use a steel H-pile, thick-walled steel pipe section, or other spudding device and attempt to break up the obstruction and re-drive the pile through the obstruction to the pile tip elevations shown on the drawings.

3. Use a DTH hammer to drill through the obstruction and attempt to re-drive the pile through the obstruction to the pile tip elevations shown on the drawings.

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G. Deep Obstructions: If the driven steel pipe pile encounters an obstruction greater than or equal to 20 feet below the mudline at the time of driving, the Contractor shall perform additional PDA testing according to the project specifications to determine if the pile was damaged during installation. The PDA report shall be provided to the Contracting Officer within 72 hours of encountering the obstruction. If it is determined that the pile was damaged during installation, the Contractor shall remove and replace the pile at no additional cost to the Contracting Officer. If the pile has not been damaged, the Contractor shall notify the Contracting Officer and provide final tip elevations of the pile encountering an obstruction and the two (2) adjacent piles. The Contracting Officer will utilize this information to determine if the pile can structurally accommodate the shorter pile length at the obstruction location. Acceptance of the pile will be determined by the Contracting Officer within 96 hours of receipt of the pile tip elevations.

H. If the driven steel pipe pile encounters an obstruction greater than or equal to 20 feet below the mudline at the time of driving, but the Contracting Officer determines that the pile cannot be accepted, possible Contractor options to mitigate the obstruction include, but are not limited to:

1. Use a steel H-pile, thick-walled steel pipe section, or other spudding device and attempt to break up the obstruction and re-drive the pile through the obstruction to the pile tip elevations shown on the drawings.

2. Use a DTH hammer to drill through the obstruction and attempt to re-drive the pile through the obstruction to the pile tip elevations shown on the drawings.

3.6 INSTALLATION RECORDS

A. Maintain a pile driving record for each pile driven. Indicate on the installation record: installation dates and times, type and size of hammer, rate of operation, total driving time, dimensions of driving helmet and cap used, blows required per foot for each foot of penetration, final driving resistance in blows for final 6 inches, pile locations, tip elevations, ground elevations, cut-off elevations, and any reheading or cutting of piles. Record any unusual pile driving problems while driving. Submit complete records to the Contracting Officer.

3.7 FIELD QUALITY CONTROL

A. Test Piles

1. Drive test piles at the locations indicated and as determined by the Contractor’s Geotechnical Consultant. Drive test piles to indicated tip elevation and required driving criteria. Use test piles, if located properly and offering adequate driving resistance in finished work. Provide and operate a pile driving analyzer as specified in paragraph DYNAMIC PILE ANALYSIS during the driving of each test pile.

B. Dynamic Pile Analysis

1. Submit a performance report summarizing dynamic test results for test piles within 7 calendar days of completing field work. Dynamic testing provides supplemental information for evaluating pile integrity, hammer and drive system performance, assess pile installation driving stresses, and pile capacities. Provide equipment to obtain dynamic measurements, record, reduce and display its data that meet the requirements of ASTM D4945. The equipment must have been calibrated within 6 months prior to the start of the testing operations and thereafter throughout the contract duration. Drive test piles at the locations indicated. Perform dynamic pile analysis as follows:

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2. Pile Analyzing

a. 15 working days prior to driving the test piles, submit PDA testing plan including the pile and complete driving equipment data. The Contractor must use the submitted information to perform wave equation analyses and must prepare a summary report of the wave equation results. The wave equation analysis using GRLWEAP software by Pile Dynamics, Inc. or equivalent must be used to assess the ability of the proposed driving system to install the pile to the required capacity and desired penetration depth within the allowable driving stresses. Approval of the proposed driving system must be based upon the wave equation analyses indicating that the proposed driving system can develop a pile capacity within allowable driving stress limits. The hammer must also be sized or adjustable such that the penetration per blow at the required ultimate capacity does not exceed 0.5 inches.

3. Pile Drivability

a. Perform each dynamic pile analysis in two steps. The first step is to check the hammer, pile and soil performance, and to determine the suitability of the proposed hammer for the size, length and type of pile being installed for the soil types encountered as the piles are driven. This initial monitoring must determine whether efficiency of the hammer relative to the specified efficiency, effectiveness or cushion, level of compressive and tensile stress in pile and extent/location of any pile damage caused by the initial driving. With each blow of the pile, record the information listed below electronically and analyze the information using the Pile Driving Analyzer:

i. Blow Number

ii. Blow rate per minute and stroke

iii. Input and reflected values of force and velocity

iv. Value of upward and downward traveling force wave with time

v. Maximum and final transferred energy to pile, hammer system efficiency

vi. Maximum compressive stress, velocity, acceleration and displacement

vii. Maximum tensile stress in pile

viii. Pile structural integrity, damage detection, extent and location

ix. Bearing capacity of pile by Case method

b. If the pile, hammer and soil performance evaluation recommends changes to the hammer stroke, pile cushioning, augering or any other aspect for the pile driving operation, incorporate these changes into production pile driving in an effort to control excessive stresses and pile damage. Replace test piles damaged or broken during installation, incorporating driving modifications as determined. Repeat this procedure until allowable tensile and compressive stresses are achieved in the pile and pile damage is minimized.

Subject selected initial driving records to rigorous computer analysis by the Case Pile Wave Analysis Program (CAPWAP) for determination of resistance distribution, soil resistance and properties, and estimation of anticipated gain/loss factors.

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4. CAPWAP

a. Signal matching analysis by CAPWAP software of the dynamic pile testing data must be performed on data obtained from the end of initial driving and the beginning of restrike of all control piles. CAPWAP analyses must be performed by an engineer who has achieved Advanced Level or better on the PDI / PDCA Dynamic Measurement and Analysis Proficiency Test for Providers of PDA Testing Services.

b. Upon completion of test pile driving, allow the piles to set-up for at least 5 days. After analysis may proceed. This portion of the evaluation requires striking the set-up piles a minimum of 20-50 times, or as directed using the same hammer which was used for the test pile driving and which will be used for production pile driving. “Warm up” the hammer and make it optimally ready prior to restriking, in order to avoid capacity losses during evaluation of restrike data. Apply maximum hammer energy during restrike in order to fully mobilize the soil resistance. However, exercise care so as to not overstress the pile. In addition to those items listed above, selected restrike driving records (as directed) are to be subjected to rigorous computer analysis by the Case Pile Wave Analysis Program (CAPWAP) for determination of resistance distribution, soil resistance and properties, and plot of applied load vs. average pile displacement based on the calculated soil properties.

5. Dynamic Load Test Reporting

a. Upon satisfactory completion of each dynamic load test, submit a Pile Performance Report. The submittal must be prepared and sealed by a Professional Engineer. The report for the Dynamic Pile Analysis must contain the following information:

i. Capacity of pile from Case Pile Wave Analysis Program (CAPWAP). Information resulting from analysis of a selected restrike blow.

ii. Maximum and final transferred energy, hammer system efficiency during pile installation.

iii. Maximum compressive stress, velocity, acceleration and displacement.

iv. Maximum tensile stress in pile.

v. Pile structural integrity, damage detection, extend and location.

vi. Blows per minute and blow number.

vii. Input and reflection values of force and velocity, upward and downward traveling force wave with time.

viii. Pile skin friction and toe resistance distribution.

ix. Maximum energy transferred to pile.

b. The maximum allowable pile design load must be based upon the results of a satisfactory pile load test conducted on a pile driven as specified herein and must include the effects of load transfer to the soil above the foundation stratum.

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c. Use either a Model 8G or PAX Pile Driving Analyzer as manufactured by Pile Dynamics, Inc., of Cleveland Ohio or approved equivalent, for dynamic testing of the pile hammer and for dynamic load testing of the test pile. All equipment necessary for dynamic monitoring such as sensors, cables or wireless transmitters, must be furnished by the Contractor’s Geotechnical Consultant. The equipment must conform to the requirements

ASTM D4945.

C. Welding Inspection

1. Employ a testing agency to perform the welding inspections as specified in the statement of special inspection.

D. Weld Testing

1. In addition to visual inspection, welds must be tested and inspected according to AWS D1.1 and inspection procedures listed below, at testing agency’s option. Correct deficiencies in work that test reports and inspections indicate do not comply with the Contract Documents.

Test 10 percent of pile splices.

a. Liquid Penetrant Inspection: ASTM E165

b. Magnetic Particle Inspection: ASTM E709 performed on root pass and on finished weld.

Cracks or zones of incomplete fusion or penetration are not acceptable.

c. Radiographic Inspection: ASTM E94, minimum quality level “2-2T”.

d. Ultrasonic Inspection: ASTM E164

3.8 REMOVAL

A. The removal of pilings must consist of pulling, sorting, cleaning, inventorying, and storing previously installed pilings as shown and directed.

B. Pulling

1. The method of pulling piling must be approved. Provide pulling holes in pilings, as required.

Extractors must be of suitable type and size. Exercise care during pulling of pilings to avoid damaging adjacent construction. If the Contracting Officer determines that adjacent construction has been damaged during pulling, the Contractor will be required to repair this construction at no cost to the Contracting Officer. The Contractor will not be paid for the removal of pilings damaged beyond structural use due to proper care not being exercised during pulling.

C. Sorting, Cleaning, Inventorying, and Storing

1. Pulled pilings must be sorted, cleaned, inventoried, and sorted by type into groups as:

a. Piling usable without reconditioning.

b. Piling requiring reconditioning.

c. Piling damaged beyond structural use.

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