B.08.02 Attachment E - Bridge Painting-Concrete Repairs - FJS-IRD-CUR-Exhibits-v2.pdf

EXHIBIT 1

Indian Rock Dam: Location maps, drawings, and photos depicting existing conditions of spillway bridge.

Photo 1: East elevation, looking west

Photo 2: West elevation, looking east

Page 10 of 22Reports

6/12/2020https://cebis.usace.army.mil/brgtest/cebis_2.rpts_dtl_utl.rpt_open?p_url=entire_rpt

Photo 3: Looking south across bridge

Photo 4: Looking north across bridge

Page 11 of 22Reports

Photo 5: South approach road looking south

Photo 6: North approach road looking north

Page 12 of 22Reports

Photo 7: Typical shallow deck spalls with minor exposed rebar- photo for reference only.

Photo 8: Soffit spall between U2E and U3E

Page 13 of 22Reports

Photo 9: East pin at south abutment with minor pack rust forming between retainer plates.

Photo 10: West mid-span pin retainer plates with minor pack rust forming between plates

Page 14 of 22Reports

Photo 11: Typical external stringer rust on top and bottom flanges

Photo 12: Minor pitting of truss members at L2E gusset plate

Page 15 of 22Reports

Photo 13: Floorbeam 0 at south abutment rusted with pitting and possible section loss

Photo 14: South abutment backwall cracking with efflorescence - photo for reference only.

Page 16 of 22Reports

Photo 15: Corroded anchor bolt nut with section loss at south east bearing - clean & repaint only.

Photo 16: Cross bracing members and truss top chord member with paint failure

Page 17 of 22Reports

Photo 17: Upstream spillway channel looking west

Photo 18: Deteriorated concrete approach wall at the south abutment

Page 18 of 22Reports

EXHIBIT 2

Foster J. Sayers Dam, drawings and photos depicting existing conditions of Service Bridge and Concrete Tower Repair location.

Exhibits

Foster Joseph Sayers Dam – Service Bridge Page 4 of 6

Foster Joseph Sayers Dam – Service Bridge Page 5 of 6

Foster Joseph Sayers Dam – Service Bridge Page 6 of 6 e1opxjhl Cross-Out

Foster Joseph Sayers Dam – Service Bridge

Photograph No. 1 – Typical Spot Rust on Beams

Photograph No. 2 – Expansion Gauge at Northeast Bearing

Photograph No. 3 – Southeast Bearing at Gate Structure

Bridge No. CENNABPA-000016 – Exhibits

Photograph No. 4 – Underside of Bridge

General Concrete Repairs, Sayers Tower

Panel A

Panel B Estimated Repair Limits

EXHIBIT 3

Curwensville Dam, drawings and photos depicting existing conditions of Service Bridge and Concrete Tower Repair location.

Photograph 1: East Elevation of bridge.

Photograph 2: West Elevation of bridge.

Page 9 of 26Reports

1/18/2021https://cebis.usace.army.mil/brgtest/cebis_2.rpts_dtl_utl.rpt_open?p_url=entire_rpt

Photograph 3: General overview of bridge looking south across deck.

Photograph 4: General overview of bridge looking north across deck.

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Photograph 5: Typical light scaling to deck surface - reference only no repair work

Photograph 6: Typical condition of deck soffit. Note minor water staining.

Page 11 of 26Reports

Photograph 7: Delamination to deck adjacent to tower door - reference only, no repair work.

Photograph 8: General view of west fascia of girder, looking north.

Page 12 of 26Reports

Photograph 9: Typical condition of Girder cover plate end.

Photograph 10: Isolated areas of paint failure and minor surface corrosion to south end of west girder.

Page 13 of 26Reports

Photograph 11: Isolated areas of paint failure and minor surface corrosion to south end of east girder.

Photograph 12: General overview of Pier 2 - reference only.

Page 14 of 26Reports

Photograph 13: General view of north abutment backwall - reference only, no work.

Photograph 14: General view of tower corbel. Note water staining - reference only, no work.

Page 15 of 26Reports

Photograph 15: Bearings at Pier 2. Note minor corrosion to expansion bearing nuts

Photograph 16: General view of East bearings. Note minor corrosion to masonry plate of expansion bearings and bent anchor bolts.

Page 16 of 26Reports

Photograph 17: Delaminated and spalling concrete to East parapet (Span 2) - reference only.

Photograph 18: Cracked and delaminated concrete to West parapet (Span 3) - reference only, no work.

Page 17 of 26Reports

Photograph 19: Delaminated and spalling concrete to East parapet (Span 3) - reference only, no work

Photograph 20: Longitudinal crack is the east parapet of Span 3 - reference only, no work.

Page 18 of 26Reports

Photograph 21: Typical transverse cracking with efllorenscence to the parapets, adjacent to railing post -reference only, no work.

Photograph 22: Deteriorated concrete at east end post at the North abutment - reference only, no work.

Page 19 of 26Reports

Photograph 23: Typical condition of expansion joints (Pier 2).

Photograph 24: New paint system label.

Page 20 of 26Reports

Photograph 25: Lip in asphalt approach pavement reference only, no work.

Photograph 26: Approach roadway sloughing along east edge - reference only, no work.

Page 21 of 26Reports

Photograph 27: Birds nest along conduit below deck

Photograph 28: Typical condition of diaphrams with minor freckled corrosion.

Page 22 of 26Reports

EXHIBIT 4

Foster J. Sayers Dam, drawings and photos depicting existing conditions Concrete Tower Repair location.

Exhibit 4: Concrete Repairs, Foster J. Sayers Tower

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I. SURFACE PREPERATION:

1. Repair the large spall area in the concrete, north face of gate structure (Tower), below corbel. See Exhibit 4 Photographs 1 & 2.

2. The Contractor shall provide all labor, materials, equipment to restore deteriorated concrete on the north face of gate structure (Tower), below corbel.

3. Sound with a hammer to identify delaminated and unsound concrete areas.

4. Repairs shall be conducted by square cutting (Saw cut) the perimeter of repair area a minimum of ½ inch laterally beyond the distressed area into adjacent sound concrete and to a minimum depth of 1.0 inch below the finished vertical concrete surface or ½ inch into sound concrete, whichever is deeper, in a rectangular pattern to minimize over-break, featheredging, and spalling at edges and to assure removal of all unsound concrete and a minimum repair thickness of 1.0-inch. Saw cutting and concrete removal shall be conducted such that the shape of the repair area results in a rectangular shape within each vertical concrete panel (vertical concrete panel is defined as the area containing the spall bound on all four sides by control joints).

Therefore, based upon the shape of the spall and repair limits within the concrete panels as illustrated on Photo No. 4, the Contractor shall anticipate the removal of sound competent concrete with unconfined compressive strengths exceeding 6000 psi to produce rectangular repair areas with minimum depths of 1.0 inches.

5. Edges that are chipped shall taper at 45 degrees toward the center of the repair area.

Remove all material inside sawn area to ½ inch below surface of sound concrete utilizing lightweight pneumatic chipping hammers not exceeding 15 pounds. Abrupt changes in the repair thickness shall be avoided.

6. Where more than 50 percent of steel bar (circumference) is exposed, remove additional concrete to provide a minimum ¾” clearance beneath steel bar.

Undercutting will provide clearance for under bar cleaning, full bar circumference bonding to surrounding concrete and will secure the new concrete repair material structurally. Concrete removal shall extend along the bars to locations along the bar free of bond exhibiting corrosion and where bar is well bonded to surrounding concrete. To reduce the potential for damage to steel reinforcing bars and competent concrete beneath the bars, the removal of both sound and unsound concrete shall be completed utilizing hand-held pneumatic 15 lb. class chipping hammers.

7. When unoxidized reinforcing steel is exposed during the undercutting process, special precautions shall be taken not to damage reinforcing steel and the reinforcing steel’s bond to surrounding concrete. If bond between the reinforcing steel and concrete is broken, undercutting of concrete to a depth of ¾” beneath the reinforcing steel and replacement with material will be required. Any steel damaged during undercutting shall be replaced. Any reinforcement that is loose shall be secured by approved methods.

8. Mechanically clean substrate to remove any surface contaminants such as grease, paint, oil, corrosion deposits, rust, dust laitance or other contaminants.

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9. Mechanically clean all existing reinforcement with wire brush to remove any corrosion, rust or other impurities from the exposed reinforcing. Coat all exposed steel with Sika Armatec 110 EpoCem, Emaco P24, or approved equivalent as per manufacturer’s recommendations.

II. REPAIR MATERIAL: Patching material shall be a two component, polymer-modified, cementitious non sag, shrinkage compensated trowel grade mortar with corrosion inhibitor that has a coefficient of thermal expansion compatible with concrete and a minimum 28 day compressive strength of 5000 psi. Repair material shall be mixed, extended, applied, and cured per manufacturer’s recommendations.

The material shall be SikaTop 123 PLUS (Manufactured by Sika) or an approved equivalent that meets the above specified requirements.

III. MEASUREMENT AND PAYMENT: All work pertaining to the repair of the concrete spall will be paid for by lump sum and will not be measured.

Therefore, the Contractor shall base their bids on the removal and replacement of concrete to result in rectangular repairs with the limits within vertical concrete panels A and B as illustrated Exhibit 4, Photos 1 & 2. The actual depth of the delaminated concrete is unknown; however, the Contractor will be required to remove sound concrete with compressive strengths exceeding 6000 psi to produce rectangular repair areas resulting in a minimum depth of 1 inch.

Where the limits of concrete removal and replacement exceeds the limits illustrated on Photo 4, payment will be made in conformance with the CHANGES clause of the CONTRACT CLAUSES. The Contracting Officer shall be notified of any changes in repair limits immediately once the change is encountered and prior to removing any additional concrete beyond limits illustrated in Photo 1 & 2.

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Panel A

Panel B Estimated Repair Limits

Photograph No. 1 – Control Tower with estimate Spalling Area indicated.

Photograph No. 2 – Hollow Sounding and Large Spal (North Face of Gate Structure, Below Corbel)