Thompson Park SPS.doc

SPECIAL PROJECT SPECIFICATIONS

THOMPSON PARK

SECTION 101 – ABBREVIATIONS, ACRONYMS, & TERMS

101.01 Terms, Organizations, & Standards.

(a) Acronyms. Add the following:

BMP

Best Management Practice

EPA

Environmental Protection Association

FPL

Forest Products Laboratory

ICRI

International Concrete Repair Institute

SSPC

Steel Structures Painting Council

WCLIB

West Coast Lumber Inspection Bureau

WWPA

Western Wood Products Association

USN

United States Navy”

101.02 – Abbreviations

Delete in its entirety and substitute the following:

And

AC

Acre

AGG …………………………Aggregate

AL.

Aluminum

ASP

Asphalt

AQ……………………………Actual Quantities

AVAIL

Available

BARR

Barrier

BKN

Broken

BST

Bituminous Surface Treatment

CATTLEGD

Cattle guard

CLEAR (CLG)

Clearing

CLEAR/GRUB

Clearing & Grubbing

CMP

Corrugated Metal Pipe

CMPA………………………..Corrugated Metal Pipe Arch

COMP

Compaction

CO……………………………Contracting Officer

CONC

Concrete

CONST

Construction (Construct)

CTD

Coated (Coating)

CUSH

Cushion

CY (CU YD)

Cubic Yard

CY MI (CYM)

Cubic Yard Mile

DIA

Diameter

DL

Double Lane

DQ……………………………Design Quantities D/S…………………………...Downstream

DWGS

Drawings

EA

Each

EMB

Embankment

EXC

Excavation F&I Furnish & Install

FDN

Foundation

FT

Foot (Feet)

FUNC

Function

GAL

Gallon

GR.

Grade

GRUB

Grubbing

HDPE

High Density Polyethylene

Ha… .…………………… Hectare

HOR………………………….Horizontal

HR

Hour

HT

Height I Install

IN

Inches

INCL

Including (Includes)

IND

Individual

JCT

Junction

Kg ……………………………Kilogram

Kl..……………………………Kiloliter

Kl km...…………………….…Kiloliter Kilometer L Logs l ……………………………...Liter

L……………………………...Length

LBS

Pounds

LDG

Loading

LF (LIN FT)

Linear (lineal) Foot LS…………………………….Lump Sum

LSL…………………

Lower Specification Limit LSQ…………………………..Lump Sum Quantities

MAT'L

Material M Metal m……………… Meter mm……… Millimeter

MAX

Maximum

MBF

One Thousand Feet Board Measure

MGALS

One Thousand Gallons

MHD

Method

MI

Mile

MIN

Minimum

MISC

Miscellaneous

MP

Mile Post

MSF

One Thousand Square Feet

OTBC

Open Top Box Culvert

PI……………………………..Plasticity Index P M Placement Method

PVC

Polyvinyl chloride

RD

Road

RECOND

Reconditioning

RECONST

Reconstruction (Reconstruct)

REFL

Reflectorized

RT

Right

STMP (STP)

Stump(s)

SB

Self Balance

SEC

Section

SF

Square Foot (Feet)

SL

Single Lane

SLD

Solid

SQ……………………………Staked Quantities

ST

Slash Treatment

STA

Station (100 Feet)

STA YD

Station Yard

STL

Steel

STR (STRUC)

Structural

SY (SQ YD)

Square Yard

SZ

Size

T………………………… Ton (1,000 kg)

T km.…….

Ton Kilometer T&L Tops & Limbs

TBR

Timber

TH

Thickness

TM

Ton Mile

TV……………………………Target Value

TO

Turnout

TOL

Turnout Left

TOR

Turnout right

TRS

Trees

UOT

Utilization of Timber

U/S……………………………Upstream

USL…………………………..Upper Specification Limit

VERT

Vertical W Width W/ With W/O Without

X-SEC

Cross Section

YD

Yard”

SECTION 102 - DEFINITIONS

Add the following:

"Noxious Weeds or Weeds. Any exotic plant species established or that may be introduced in the State which may render land unfit for agriculture, forestry, livestock, wildlife, or other beneficial uses and which is designated by the State's Department of Agriculture, or by the County's weed management district, or by other appropriate agencies having jurisdiction, or as listed on the current ‘All States Noxious Weed List.’

Shop Drawings. Incidental design sheets and/or drawings which the Contractor is required to submit to the Forest Service. Shop drawings shall conform to the contract requirements, but they are not part of the contract drawings. They may be drawings, diagrams, schedules, performance charts, brochures, and similar data prepared by the Contractor, subcontractor, manufacturer, suppliers, or distributors that illustrate how specific portions of the work are to be fabricated or installed.

Weed Management District. A weed management district is any area of land identified for the purpose of weed management or control. Such an identified land area may be, but is not limited to one of the following: a project or job site, a County, two or more Counties, or a National Forest.

Engineer. The Contracting Officer’s Representative (COR) responsible for onsite administration of the contract. “

SECTION 103 – INTENT OF CONTRACT

Add the following:

This project is for the rehabilitation of two tunnels and one railroad trestle on an abandoned segment of the old Milwaukee Railroad near Butte, Montana. This project is located in Section 33, Township 2 North, Range 7 West, and Section 3, Township 1 North, Range 7 West, in Silver Bow County, Montana.

The work includes but is not limited to rock scaling, disposal of rock debris, furnishing and installing resin-grouted untensioned rock bolts, shotcreteing, removal of bridge ballast, removal and disposal of timber curb, furnishing and installing bridge rail posts, installing Government-furnished cable bridge rail, furnishing and installing timber curbs, concrete repair, installing a cable lifeline, furnishing and installing timber ties, and all other incidental items necessary to complete the project in accordance with the plans and specifications.

SECTION 104 – MAINTENANCE FOR TRAFFIC

104.01 Roads to be Constructed.

Delete the last two paragraphs of this subsection and add the following:

“The Contractor will be allowed to close the trail to public taffic during construction work under this contract. Provide at least 14 days advance written notice to the CO prior to any closure period, to allow public notice of the closure period by the Forest Service. The Contractor will not be allowed to close any public roadways during construction.

Develop a construction sign plan identifying the type and location of all advanced warning signs necessary to safely restrict or pass public traffic. Install construction signs conforming to the Manual on Uniform Traffic Control Devices (MUTCD) prior to proceeding with any construction work. Furnish, maintain and remove all barricades and signs required for construction signing and trail closures. Provide traffic control, including flagers, as required to protect the traveling public during construction of the trestle.

PAYMENT

Measurement

104.03 Method.

“No payment will be made for this item. Include all costs associated with erecting, maintaining and removing traffic control construction signing and commensurate road maintenace in the unit price bid for Mobilization.”

SECTION 105 – CONTROL OF MATERIALS

105.06 Material Sources

(a) Designated Sources. Add the following:

Waste Area – Government Provided. Dispose of debris from rock scaling operations per subsection 222.05 of the Special Project Specifications. Dispose of ballast removed from the trestle by spreading on the approach fill slopes at either end of the bridge as directed by the CO.

SECTION 106 – MEASUREMENT & PAYMENT

106.03 Units of Measurement

Delete this subsection and add the following:

“Forest Service Specifications for Construction of Roads and Bridges (Revised August 1996) are based on Modern Metric units of measurement. The dimensions and units of measure SHOWN ON THE DRAWINGS and used to develop SPECIAL PROJECT SPECIFICATIONS for this contract, utilize U.S. Standard English units of measure. All measurements referenced in the August 1996 Forest Service Standard Specifications (EM-7720-100) shall be converted to U.S. Standard English units of measure. Appendix A – Engineering Conversion Factors and Appendix B – SI (Modern Metric) Conversion Factors, are included on pages 611 – 614 of the Standard Specification Appendices to assist with any required conversions.

Work required by the contract will be paid based on the PAY UNIT (U.S. Standard English measure) as DESIGNATED IN THE SCHEDULE OF ITEMS.

Under each Specification Section with PAY ITEMS of work DESIGNATED IN THE SCHDULE OF ITEMS for measurement and payment under this contract, the last subsection “Payment - Basis”, shall have the following format:

Pay Item - Numbering system and work description to remain the same.

Pay Unit - Pay unit(s) DESIGNATED IN THE SCHEDULE OF ITEMS have been changed from metric to the corresponding unit of U.S.

Standard English measure.

Payment will be by units defined and determined according to U.S. Standard English measure and by the following:

(a) Cubic Yard in Place. Measure solid volumes by the average end area method as follows:

(1) Measure cross sections of the original ground and use with design or staked templates, or take other comparable measurements to determine the end area. Do not measure work outside of the established lines or slopes.

(2) If any portion of the work is acceptable, but is not completed to the established lines and slopes, remeasure cross sections or comparable measurements of that portion of the work. Deduct any quantity outside the designated or staked limits. Use these measurements to calculate new end areas.

(3) Compute the quantity using the average end areas multiplied by the horizontal distance along a centerline or reference line between the end areas. Deduct any quantity outside the designed or staked limits.

Where it is impractical to measure material by the average end area method, other approved methods involving three-dimensional measurements may be used.

Measure liquid volumes in accordance with SPS Subsection 106.03(h).

(b) Cubic Yard in the Hauling Vehicle. Measure the cubic yard volume in the hauling vehicle using three-dimensional measurements at the point of delivery. Use vehicles bearing a legible identification mark with the body shaped so the actual contents may be readily and accurately determined. Before use, mutually agree in writing upon the volume of material to be hauled by each vehicle. Vehicles carrying less than the agreed volume may be rejected or accepted at the reduced volume.

Level selected loads. If leveling reveals that the vehicle was hauling less than the approved volume, reduce the quantity of all material received since the last leveled load by the same ratio as the ratio of the current leveled load volume to the agreed volume. Payment will not be made for material in excess of the agreed volume.

Material measured in the hauling vehicle may be weighed and converted to cubic yards for payment purpose if the conversion factors are mutually agreed to in writing.

Compute measurement using measurements of material in the hauling vehicles at the point of delivery. Load vehicles to at least their water-level capacity. Leveling of the loads may be required when vehicles arrive at the delivery point.

(c) Cubic Yard Mile. A combination of linear and volumetric measurement meaning the movement of a cubic yard of material one(1) mile.

(d) Hour. Measurement will be for the actual number of hours ordered and performed by the Contractor.

(e) Each. One complete unit, which may consist of one or more parts.

(f) Lump Sum. Do not measure directly. The bid amount is complete payment for all work described in the contract and necessary to complete the work for that item.

(g) MFBM. One thousand feet board measure based on nominal widths, thickness, and extreme usable length of each piece of lumber or timber actually incorporated in the job. For glued laminate timber, 1,000 board feet based on actual width, thickness, and length of each piece actually incorporated in the job.

(h) Gallon. The quantity may be measured by any of the following methods:

a. Measured volume container.

b. Metered volume. Use an approved metering system.

c. Commercially packaged volumes.

(i) Station. One hundred linear feet measured horizontally.

(j) Station Yard. A combination of linear and volumetric measurement meaning the movement of a cubic yard of material one station.

(k) Square Yard. Measure on a plane parallel to the surface being measure or horizontal.

(l) Thousand Gallons Mile. A combination of linear and volumetric measurement meaning the movement of 1,000 gallons of material one(1) mile.

(m) Ton Mile. A combination of linear and weight measurement meaning the movement of one(1) ton of material one(1) mile.”

(n) Ton. Short ton consisting of 2,000 pounds. Use net certified scale weights based on certified volumes.

(o) Lineal foot. As applicable, measure the work along its length from end-to-end; parallel to the base or foundation; along the top; along the front face; or along the invert. Do not measure overlaps.

SECTION 202 – REMOVAL OF STRUCTURES AND OBSTRUCTIONS

Construction

202.02 Salvaging Material. Add the following:

The jersey barriers at both ends of the trestle are to be salvaged and hauled to the yard at the Butte Ranger District. The Contractor is responsible for loading, hauling, unloading and stockpiling the jersey barriers. Jersey barriers damaged by the Contractor will be replaced at the Contractor’s expense.

202.04 Disposing of Material or Structures Not Designated for Salvage.

Delete the first sentence of this subsection and replace it with the following:

“Dispose of timber members by Removal from the Project. “

(a) Removal From Project. Replace this paragraph with the following:

“Dispose of all materials designated for removal off of National Forest System Lands in an environmentally safe manner in accordance with all State and Federal requirements.”

(b) Burning. Delete this subsection

(c) Burying. Delete this subsection.

Add the following to this subsection:

(d) Wasting. Ballast removed from the trestle will be wasted on the fill slopes within 500 feet of either ends of the trestle as directed by the CO.

Payment

Add the following:

Removal of the timber poles and remnant timber rail posts is considered incidental to Item 202(05).

Add the following pay items:

Pay Item

Pay Unit 202(06) Remove, ________________ ………………………………………. Cubic Yard

SECTION 204 – SOIL EROSION & WATER POLLUTION CONTROL

Materials

204.02 Requirements. Add the following:

“Provide straw for erosion and water pollution control from a certified noxious weed free source.”

Construction

204.03 Performance. Delete the first sentence and replace it with the following:

“Prior to the start of construction, submit a written plan for review that provides permanent and temporary erosion control measures to minimize erosion and sedimentation during and after construction. Include methods to minimize disturbance to the stream, prevent runoff from the construction site entering directly into the stream, prevent the release of fuel and oil into the water and soil and to contain and control any spills that may occur.”

Add the following to this subsection:

“Emergency Spill Kit. Keep sufficient quantities of absorbent materials on the project site to absorb accidental fuel, hydraulic oil, or other petroleum product spills. Use absorbent materials that are biodegradable, non-water absorbing and designed specifically for the types of spills associated with the Contractor’s operation.”

Measurement

204.14 Method. Make no separate measurements for ths item.

Payment

204.15 Basis. Payment will be considered incidental to other pay items in this contract.

SECTION 222 – TUNNEL SCALING

Description

222.01 Furnish a scaling crew(s) and associated equipment to scale loose rock blocks from the perimeter of the unlined tunnel segments as shown on the drawings and as directed by the Contracting Officer or his Representative. Unlined sections of the tunnels are a modified horseshoe shape with near vertical sidewalls and an irregular radius arch. The work will also include the removal of the scaled rock material from the tunnel and disposal of it in designated locations within 500 feet of each tunnel portal.

Definitions

Scaling – Scaling is the process by which loose rock is removed from the crown, arches and sidewalls of the tunnel. Scaling will be limited to hand-scaling methods, which typically includes the use of scaling bars.

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 equipment shall be selected by the Contractor. At a minimum, scaling equipment shall consist of one telescoping or scissor work platform, one rubber-tire loader, two light towers, and all miscellaneous tools and equipment necessary for the Contractor to complete the work.

Materials

Not Used.

Construction Requirements

222.02 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 222.01.

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 scaling crews, and with emergency personnel, contacts for nearest emergency facilities (police, fire, medical, Life Flight), personal protective equipment, and spill containment plans.

222.03 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 222.02, SUBMITTALS and after the Preparatory Meeting.

222.04 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 tunnels 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 tunnels or at the portals.

222.05 Construction Requirements. The work shall consist of removing loose rock blocks from the tunnel perimeter in the unlined segments of each tunnel. 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 500 feet outside of each tunnel. 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 each 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. Therefore, to the extent practical, the Contractor shall hand pick and place rock scaling debris into the loader bucket rather than using the loader bucket to pickup the debris.

222.06 Measurement.

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

Labor

Labor to complete the work defined in Section 222.01 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 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 222.01 shall not be measured and is incidental to the scaling crew.

222.07 Payment.

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:

222 (01) Rock Scaling Crew Hour

SECTION 260. — RESIN-GROUTED UNTENSIONED ROCK DOWELS

Description

260.01 The work consists of furnishing, installing, and testing resin-grouted untensioned rock dowels.

Definitions

Resin-Grouted Untensioned Rock Dowel – Rock dowels shall be Grade 75, resin-grouted, untensioned, #8, continuously-threaded bar. Rock dowel installations shall include drilling of holes into rock, insertion of polyester-resin grout, threadbar, and installation of the plate, washers and nut.

Material

260.02 Conform to the following Subsections:

(a) Polyester Resin Grout. Polyester resin grout shall consist of high strength, unsaturated polyester resin with high viscosity and of fast and slow setting times. The cartridges shall be supplied in 12-inch or 24-inch lengths. Gel and cure time of cartridges shall be as specified by the manufacturer and approved by the Contracting Officer or his Representative. The material shall be thixotropic and of such viscosity that the threaded bar can adequately mix the material. At least 3 feet of quick setting cartridges (2 to 4 minute gel time) shall be required at the back of all holes to hold the dowel in place while the slower setting cartridges set up. The polyester resin grout shall have the following minimum properties:

Compressive Strength 12,000 pounds per square inch (psi)

Tensile Strength 4,000 psi

Shear Strength 3,000 psi

Cartridge boxes shall indicate date of manufacture. Cartridges shall have a maximum shelf life of six (6) months. Cartridges older than the stated shelf life shall not be used. Cartridges shall be stored according to the manufacturer’s recommendations to ensure maximum protection until their use. All cartridges shall be inspected prior to insertion to assure that the polyester resin compounds have not hardened, and meet the above requirements.

(b) Rock Dowels. Each rock dowel shall consist of a single deformed (threaded) bar, one steel bearing plate, one nut, flat washer, and beveled washers as required. The deformed rock dowel Grade 75 ksi shall have a continuous hot rolled pattern of threadlike deformations along their entire length. The Grade 75 ksi threaded bar shall conform to ASTM International (ASTM) A615.

(c) Bearing Plates. Steel bearing plates shall conform to ASTM A36 and shall meet load and deflection criteria of ASTM F432. The bearing plates shall be 3/8-inch-thick, flat steel or equal, providing a 36-square-inch area (6 inch by 6 inch square) for each dowel. If dome nuts are used, the bearing plates shall be dished and at least ½-inch thick. A hole drilled and sized to allow at least a 15 degree skew of the dowel in all directions from normal to the plate shall be at the center of each bearing plate.

(d) Hex Nuts. Hex or dome nuts used on threaded portions of rock dowels shall be heavy-duty type. Nuts shall develop an ultimate strength not less than 125 percent of the minimum rock dowel yield strength.

(e) Washers. Washers used with threaded dowels shall ensure continuous load transfer between the tightened hex nut and the bearing plate. Beveled washers shall be steel or malleable iron. Flat steel washers shall conform to the requirements of ASTM A325. One beveled washer and one flat washer shall be provided with each hex nut. Washers are not required when domed anchor nuts are used.

Construction Requirements

260.03 Submittal. 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.

(a) Qualifications of the Contractor’s personnel. The Contractor shall provide written evidence that the foreman has a minimum 5 years and the drill operators have a minimum 2 years of satisfactory work experience in similar installation of resin-grouted untensioned rock dowels. The foreman shall be on-site with the rock doweling crew a minimum of 40 percent of the time during each working day. Experience records shall identify all individuals responsible for the rock dowel installations and shall include a listing of similar scope projects performed including points of contact. The Contractor shall submit the qualifications and receive approval from the Contracting Officer or his Representative prior to installing any rock dowels.

(b) Health and Safety Plan. See Section 222 for Health and Safety Plan requirements.

(c) Construction sequence and schedule. The Contractor shall submit to the Contracting Officer or his Representative for approval the rock dowel installation plan. The plan shall describe the equipment and methods to be used for drilling, handling, and installing the rock dowels; including the proposed hole diameter and resin cartridge information. Rock dowel installation procedures shall be determined by the Contractor.

(d) Material. Proposed rock dowel, bearing plate, anchor nut, flat washer, and beveled washer specifications including manufacturer’s data sheets and specifications for any additional hardware items. Certified test reports for each heat or lot of Grade 75 steel shall be submitted with the materials delivered to the site. The Contractor shall furnish five copies of mill reports and five copies of a certificate from the manufacturer stating chemical properties, ultimate strengths, yield strengths, modulus of elasticity, and any other physical properties needed for the required computations, for the type of steel furnished. Written certification for coating material and coated bars shall be submitted with the delivery of the bars.

(e) The contractor shall furnish manufacturer’s data sheets and placement procedures for the polyester resin cartridges.

(f) Calibration data for each torque wrench and stressing jack to be used. Calibration test results shall be submitted prior to use.

(g) Rock Dowel Proof Testing results. Test results shall be submitted to the Contracting Officer or his Representative for review. The proof test results shall include measured lengths of drill holes and rock dowels, loads and elongations recorded during testing, and graphs of test results. Descriptions of stressing jacks, gages, load cells, or other devices for measuring stressing load, certified calibration records for each set of jacking equipment, and current testing curves for stress measurement gages shall be submitted for review 14 days prior to the start of the testing operations. Gages shall be calibrated for the jacks with which they are used.

(h) Closeout. Upon completion of rock dowel installation in each tunnel, the Contractor shall furnish a developed section drawing for each tunnel showing the location of each rock dowel, rock dowel length, and rock dowel inclination. This drawing shall also identify rock dowels that were proof tested. Contractor shall also provide drilling records for each hole indicating drilling equipment used, dates and times of drilling and rock dowel installation, depths and descriptions of voids encountered in the rock mass, proof test results, and groundwater conditions.

260.04 Prepatory Meeting.

Prior to commencing any work on the rock dowels, the Contractor, including all field personnel to be involved in drilling and rock dowel installation, shall meet with the Contracting Officer or his Representative to review the Health and Safety Plan, plans and specifications, work plans, and submittals. Rock dowel installation may commence upon approval of the rock dowel installation plan and procedures described in Section 260.03 SUBMITTALS and after the Preparatory Meeting.

260.05 Handling and Storage Rock dowels shall be transported and stored in a manner to prevent contamination or damage to any components. Protect dowels from dirt, mud, water, and other harmful substances to avoid damage and corrosion. Do not use rock dowels that are heavily corroded, pitted, damaged due to welding, or show signs of abrasions, cuts, or nicks. Materials shall be suitably wrapped, packaged or covered at the factory or shop to prevent damage from dirt, water, oil, grease, and rust. Materials shall be protected against abrasion or damage during shipment and handling. Materials stored at the site shall be placed on a well supported platform and covered with plastic or other approved material. Materials shall be protected from adjacent construction operations. Grounding welding leads to rock dowels shall not be permitted. If required, dowels are to be cut to length with a saw only. Use of cutting torches will not be allowed. Rock dowel components damaged by abrasion, cuts, nicks, heavy corrosion, pitting, welds or weld spatter shall be rejected and removed from the site.

260.06 Installation. The area to be supported shall be inspected and scaled by the Contractor as required to assure safety and to provide an adequate face to seat the bearing plate. Holes shall be drilled at the locations, depths and inclinations determined by the Contracting Officer or his Representative. Hole diameters shall be in accordance with the manufacturer’s recommendations to ensure complete encapsulation of the rock dowel and satisfactory in-hole mixing. Hole locations may be changed only where approved by the Contracting Officer or his Representative. Unless otherwise specified, the Contractor shall determine the drilling method used. Care shall be taken while drilling to avoid damage of any kind to the existing structures. Damages of any nature will be evaluated by the Contracting Officer or his Representative and repairs or replacements shall be made at his discretion.

Drilling equipment shall be suitable for advancing the drill tools to the depths and at the alignment specified. Holes in rock may be drilled by rotary drilling, percussion drilling, rotary/percussion drilling, down-the-hole hammer or other suitable methods. Contractor shall select the equipment, means and methods to drill and install the dowels through the steel-rebar reinforced concrete liner, timber and backfill behind the liner, and rock.

Clean holes of all drill cuttings, sludge, and debris before inserting resin cartridges. Holes in rock shall be cleaned by pressurized air and/or water to remove drill cuttings and mud. At least 3 feet of quick setting cartridges (2 to 4 minute gel time) shall be required at the back of all holes to hold the rock dowel in place while the slower setting polyester resin sets up. The Contractor shall be responsible for each drilled hole until the rock dowel has been installed and accepted.

Drilling equipment shall be capable of installing the rock dowels through the resin grout per the resin grout manufacturer’s recommendations. Break and mix resin cartridges by spinning the dowel according to the manufacturer’s instructions as the dowel is inserted into the drill hole. Attach the bearing plate, washers, and nut to the dowel with the threaded outer end of the dowel projecting a maximum of 2 inches beyond the nut. Nuts shall be tightened on the thread bar using a calibrated torque wrench to 100 foot-pounds plus or minus 10 foot-pounds. The torque wrench shall have been calibrated as a unit a maximum of 30 calendar days prior to commencing work under this contract.

All equipment used in handling and placing the rock dowels shall be such that it does not damage or deteriorate the Grade 75 steel, or the rock dowel head. Each rock dowel shall be inspected prior to insertion into the hole. Damaged rock dowels shall be repaired prior to insertion or, if determined by the Contracting Officer or his Representative to be not repairable, shall be replaced. The bearing plate and nut shall be installed perpendicular to the rock dowel, within 3 degrees, and centered on the rock dowel without bending the rock dowel.

The Contractor shall submit driller logs and records as specified in Section 260.03. The presence of the Contracting Officer or his Representative shall not relieve the Contractor of the records submission responsibility specified in Section 260.03. Payment will not be made for any work for which the required records have not been furnished by the Contractor.

Operation of equipment inside and outside of the tunnels 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 tunnels or at the portals. Site safety is the sole responsibility of the Contractor.

A minimum of one light tower shall be provided by the Contractor for each rock doweling 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 these inspections, the equipment shall be operated by the Contractor. For estimating purposes, the Contractor shall assume that the equipment shall be utilized by the Contracting Officer or his Representative for a maximum of 30 minutes in an eight (8) hour day.

The Contractor shall cleanup the work area at the end of each days shift.

260.07 Testing.

Five (5) installed rock dowels in each tunnel shall be proof tested. The proof testing stressing schedule shall be in accordance with the guidelines in Post-Tensioning Institute Manual, 6th Edition, paragraph 15.5.1. During proof testing a record shall be kept of gage pressure and rock dowel elongation at each stressing stage. The maximum Test Load shall not exceed 1.33DL, where DL = 35,000 lbs for #8 Grade 75 rock dowels. Final rock dowel acceptance will be made by the Contracting Officer or his Representative. All tests shall be conducted in the presence of the Contracting Officer or his Representative.

Testing equipment, furnished and provided by the contractor, shall consist of a hydraulic jack with calibrated pressure gage for applying the load and a dial gage or vernier scale to measure rock dowel movement. The ram travel of the stressing equipment shall be a minimum 6 inches. The pressure gage shall be graduated in 100 psi increments. The stressing equipment and pressure gage shall have been calibrated as a unit a maximum of 30 calendar days prior to commencing work under this contract. The movement measuring device shall have a minimum travel equal to the theoretical elastic elongation of the total rock dowel length at the maximum Test Load without resetting the device.

Total movement with respect to a fixed reference point shall not exceed 0.040 inch at maximum Test Load during the first 10 minutes of the proof test. If the total movement exceeds this limit, it shall not exceed 0.080 inch at the maximum Test Load at the end of 60 minutes. If the movement exceeds 0.080 inch at the maximum Test Load at the end of 60 minutes, the rock dowel shall be rejected.

Any rock dowel that fails the proof test or is rejected by the Contracting Officer or his Representative shall be replaced. A replacement rock dowel, including a new rock dowel hole, shall be provided by the Contractor at no expense to the Government. The location of the replacement rock dowel shall be selected by the Contracting Officer or his Representative. The Contractor shall provide all materials, supplies, equipment, and labor necessary to provide a new rock dowel assembly to the satisfaction of the Contracting Officer or his Representative. Additional proof tests, equal to the number of failed tests, shall be provided by the Contractor at no additional cost to the Government.

260.08 Measurement.

The method of measurement is designated in the Schedule of Bid Items. Accepted rock dowel installations shall be measured by the number of 10-foot-long, #8 threadbar dowels installed.

260.9 Payment.

Payment shall be made for each 10-foot-long rock dowel installed by the Contractor and accepted by the Contracting Officer or his Representative. This price shall be full compensation for all furnished materials including resin grout, threadbar, plates, hex nuts, washers, drilled holes into rock, area cleanup, tunnel lighting, localized slope scaling for safety, equipment (including but not limited to operation, fuel, taxes, maintenance and repairs), tools, and all other items of expense required to install and test the rock dowels. The contract unit prices for rock dowels shall also 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. Use of equipment by the Contracting Officer or his Representative for inspections is incidental to the work.

260 (01) Rock Dowels Each

260.10 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

Carbon Structural Steel

ASTM A325

Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength

ASTM A615

Deformed and Plain Billet-Steel Bars for Concrete Reinforcement

ASTM A722

Uncoated High-Strength Steel Bar for Prestressing Concrete

ASTM F432

Roof and Rock Bolts and Accessories

POST-TENSIONING INSTITUTE (PTI)

PTI (2004) Recommendations for Prestressed Rock and Soil Anchors

PTI (2006, Sixth Edition) Post Tensioning Manual

SECTION 270 — SHOTCRETE

Description

270.01 The work consists of furnishing, installing, and testing dry or wet-mix steel fiber reinforced shotcrete (method to be decided by the Contractor) at locations shown on the plans and at locations to be determined by the Contracting Officer or his Representative.

Definitions

(f) Shotcrete is 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.

(g) Shotcrete may be either dry-mix or wet-mix type.

Materials

270.02 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.)

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.

i. 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.

ii. 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.

(g) Packaged, Pre-Blended, Dry Mix Shotcrete: Packaged, pre-blended dry-mix 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.

(h) Curing Materials: Curing materials shall meet the following requirements.

iii. Impervious Sheet Materials: ASTM C171, type optional except polyethylene film, if used, shall be white opaque.

iv. Membrane-Forming Curing Compounds: ASTM C309, Type 1-D or Type 2.

270.03 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.

(a) The shotcrete shall contain a minimum of seven and a half (7.5) sacks of cement, one hundred (100) 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.

Construction Requirements

270.04 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- or dry-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- and/or dry-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.

270.05 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.

(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.

i. In the event that the source, brand, or characteristic properties of ingredients would need to be varied during the work, submit revised laboratory mix reports in accordance with procedures defined for original mix designs.

ii. Submit a plan…