Book_2Solicitation IFB_Davey'sBridge.pdf

INVITATION FOR BIDS

Solicitation No. DTFH70-11-B-00017

ID PFH 24(10)

DAVEY’S BRIDGE BOOK 2

Solicitation, Offer & Award, Bid Schedule, Contract Clauses, Minimum Wage Schedule, Special Contract Requirements, and Plans

This solicitation cites

Standard Specifications for Construction of Roads and Bridges on Federal Highway Projects, FP-03 U.S. Customary Units

ISSUING OFFICE:

U.S. DEPARTMENT OF TRANSPORTATION

FEDERAL HIGHWAY ADMINISTRATION

610 EAST FIFTH STREET

VANCOUVER, WA 98661-3801

Phone: (360) 619-7520 – FAX: (360) 619-7932 Web site: http://www.wfl.fhwa.dot.gov/contracting/ e-mail : wfl.contracts@dot.gov

Bid Opening Date:

See Page A-3, Block 13A

QUICK INDEX

Page Item

F-1 Special Contract Requirements

(Cont) H-1 Permits I-1 Storm Water Pollution

Prevention Plan

BID REMINDERS

Electronic bids will not be accepted. Submit printed copy of bid to the address listed on the enclosed SF 1442. Before submitting your bid, please review the following:

• Have you rechecked your bid figures?

• Have you completed the bid schedule?

• Have you completed and signed the SF 1442, Solicitation, Offer & Award?

• Have you acknowledged all amendments?

• Have you completed the Representations &

Certifications (Page B-1)?

• Is your bid guarantee enclosed in proper form and amount (see FAR Clause 52.228-1), including Power of Attorney affidavit?

• Does the lower left corner of the proposal envelope state “Bid Enclosed”?

• Does the lower left corner include the Solicitation Number and the project number/name?

A-1 Notice to Bidders http://www.wfl.fhwa.dot.gov/contracting/ mailto:wfl.contracts@fhwa.dot.gov

PROJECT NAME ID PFH 24(10)

DAVEY’S BRIDGE

BEGINNING AT 10+00

ENDING AT 24+00

NATIONAL FOREST BOISE

COUNTY BOISE

STATE IDAHO

LENGTH 0.327 MILES

FIXED COMPLETION DATE See FAR Clause 52.211-10 (FAR Clauses begin on page C-1)

F-1

Special Contract Requirements Project: ID PFH 24(10), Davey’s Bridge

03USC01/01/04

Section 201. — CLEARING AND GRUBBING

Construction Requirements

201.03 General. Add the following:

Perform felling, bucking, and decking of merchantable timber according to accepted logging practices with a minimum of breakage, damage, and waste. Saw the merchantable timber into standard log lengths with proper trim allowance.

201.06 Disposal. Delete the first sentence of this Subsection and substitute the following:

All merchantable timber within the areas to be cleared on either private or Government land will remain the property of the landowners. Deck on each owner’s property adjacent to the road in locations suitable for loading by others with self-loaders. Contact David Bruce, Pine Patch Tree Farm Enterprises, 208-793-2237, for location of decked timber and removed fencing on east side of bridge.

F-2

03USC06/04/07

Section 203. — REMOVAL OF STRUCTURES AND

OBSTRUCTIONS

203.04 Removing Material. Delete the text of this Subsection and substitute the following:

(a) General. Saw cut sidewalks, curbs, pavements, and structures when partial removal is required.

Construct structurally adequate debris shields to contain debris within the construction limits.

Do not permit debris to enter waterways, travel lanes open to public traffic, or areas designated not to be disturbed.

Raze and remove all buildings, foundations, pavements, sidewalks, curbs, fences, structures, and other obstructions interfering with the work and not designated to remain.

Where part of an existing culvert is removed, remove also all of the culvert that is upstream from the removed portion. The remaining downstream portion of the culvert may be left in place if no portion of the culvert is within 4 feet of the subgrade, embankment slope, or new culvert or structure; and the culvert ends are sealed with concrete.

Remove structures and obstructions in the roadbed to 3 feet below subgrade elevation.

Remove structures and obstructions outside the roadbed to 2 feet below finished ground or to the natural stream bottom.

Abandon existing manholes, inlets, catch basins, and spring boxes according to Subsection 604.07.

Except in excavation areas, backfill and compact cavities left by structure removal with backfill material to the level of the finished ground. Backfill excavated areas according to Subsection 209.10. Compact backfill according to Subsection 209.11.

(b) Concrete removal by mechanical impact methods. Saw cut 3/4 inch deep along all boundaries of repair areas.

Use power-driven hand tools to remove existing concrete with the following restrictions:

(1) Do not use jack hammers heavier than 15 pounds;

(2) Do not operate jack hammers and mechanical chipping tools at an angle in excess of 45 degree from the surface of the slab; and

(3) Do not use chipping hammers heavier than nominal 15 pound class to remove concrete from beneath reinforcing bar.

F-3

Where the bond between existing concrete and reinforcing steel is destroyed, remove all concrete adjacent to the steel to provide at least 3/4 inch clearance for the new concrete to bond to the steel.

Use hand tools (hammers and chisels) to remove final particles of concrete or to achieve the required depth.

After removal of deteriorated and unsound concrete, sandblast all exposed structural steel, reinforcing steel, and concrete surfaces that will be in contact with repair material. Remove all rust and foreign material. Clean the sound concrete surface by flushing with a high-pressure water jet or oil-free compressed air.

(c) Reinforcing steel. Do not cut or damage reinforcing steel designated to remain in place.

Repair or replace all damaged or severely deteriorated bars.

Clean all exposed reinforcing steel that is to remain in place. Remove all rust and corrosive products, including oil, dirt, concrete fragments, laitance, loose scale, and other coatings that may destroy or inhibit the bond with new concrete.

If cleaned reinforcing steel will be exposed for more than 7 days, protect the steel from corrosion and contamination. If the steel becomes corroded or contaminated, clean the steel immediately before the concrete pour.

(d) Bridge removal. Comply with Subsection 203.04(a). Do not position any equipment in the water. Operate equipment from the stream banks at each end of the existing bridge.

Clean the work zone of any debris upon completion of the bridge removal. Comply with the conditions in Subsection 107.10(c)(7).

Submit a bridge removal plan to the CO for review and approval. The bridge removal plan shall include but not be limited to removal narrative, removal methods, equipment list, barrier or dewatering system, drawings of equipment positions, pickup points, and removal sequences, and any debris shield or temporary work/support system.

(1) Saw cut and lift the bridge deck out in pieces.

(2) Place a barrier system between the work area and the river in order to prevent any spoils from reaching the river prior to removing the existing abutments.

(3) Prior to any in-water work, comply with Subsections 107.01 and 107.10(b) and (c).

Pull the timber piles directly out. If piers break during the extraction process, cut them off at or below existing riverbed elevation. Do not position any equipment in the water but parts of the equipment, such as the backhoe bucket, may enter the water to facilitate the pile removal. Prior to any in-water work, comply with Subsections 107.01 and 107.10(b).

F-4

03USC08/12/09

Section 204. — EXCAVATION AND EMBANKMENT

Construction Requirements

204.05 Conserved Topsoil. Add the following text after the first paragraph:

(a) Locate stockpile 150 feet away from storm water flow paths, live streams, wetlands, and roads.

(b) Place on a level area as a low, flat, elongated mound.

(c) Construct temporary topsoil stockpiles no more than 7 feet in height.

(d) Construct an earth bank on the upslope side to divert run off around the stockpile and a sediment fence downslope of the stockpile or use other BMPs for sediment and erosion control to comply with Subsection 157.04(g).

204.06 Roadway Excavation. Delete the text of paragraph (a) and substitute the following:

(a) General. Excavate material suitable for backfill or other purposes in a sequence that permits the placement of the excavation directly into its final position or in stockpiles for subsequent placing.

F-5

Measurement

Delete Table 204-1 and substitute the following:

T ab le

-1

Sa m pl in g an d

T es tin g

R eq ui re m en ts

R ep or tin g T im e

B ef or e us in g in w or k

B ef or e us in g in w or k

B ef or e pl ac in g ne xt la ye r

(1

M in im um o f 5 p oi nt s p er p ro ct or

Sp lit pl e

Y es

, w he n re qu es te d

Y es

, w he n re qu es te d

Po in t o f S am pl in g

Pr oc es se d m at er ia l b ef or e in co rp or at in g in w or k

In -p ce

Pr oc es se d m at er ia l b ef or e in co rp or at in g in w or k

In -p pl in g Fr eq ue nc y pe r s oi l t yp e pe r s oi l t yp e bu t no t l es s t ha n pe r

,0 y d3 pe r 6 yd bu t n ot le ss th an pe r l ay er r s oi l t yp e bu t no t l es s t ha n fo r ea ch d ay o f pr od uc tio n pe r s oi l t yp e bu t no t l es s t ha n pe r

,0 y d3 pe r 6 yd bu t n ot le ss r l t M et ho ds ec ifi ca tio ns

A

SH

TO

M

SH

TO

T m et ho d

D (1

) o r

T

, m et ho d

C (1

A A

SH

TO

T o th er a pp ro ve d pr oc ed ur

SH

TO

M

SH

TO

T

T

A A

SH

TO

T

9, M et ho

SH

TO

T m et ho d

D (1

) o r

T

, m et ho d

C (1

A A

SH

TO

T th er a pp ro ve d pr oc ed

C at eg or y ha ra ct er is tic ss ifi ca tio n

M oi st ur e-de ity om pa ct io n

C la ss ifi ca tio n

G ra da tio n

Li qu id li m it

M oi st ur e-de pa ct io n

T yp e of

A cc ep ta nc e

(S ub se ct io n) ea su re d an d te st ed fo r co nf or m

(S ub se ct io n

6.

M ea su re d an d te st ed fo r co nf or m se ct io n

6.

M at er ia l o r

Pr od uc t

To pp in g

(S ub se ct io n

4.

Se le ct to pp in g (S ub se ct io n

4.

F-6

T ab le

-1

(c on tin ue d) pl in g an d T es tin g R eq ui re m or tin g T im e

B ef or e us in g in w or k

B ef or e pl ac in g r h ou rs ef or e pl ac in g r

(1

M in im um o f 5 p oi nt s p er p ro ct or pl e

Y es

, w he n re qu es te

, w he n re qu es te d

Po in t o f S am pl in g

Pr oc es se d m at er ia l b ef or e in co rp or at in g in w or k

In -p es se d m at er ia l b ef or e in co rp or at in g in w or k

In -p pl in g Fr eq ue nc y pe r s oi l t yp e pe r s oi l t yp e bu t n ot le ss th an p

,0 y d3 pe r 3 yd bu t n ot le ss r l r s oi l t yp e bu th an fo r e ac h da y of p ro du ct io n pe r s oi l t yp e bu th an p

,0 y d3 pe r 3 yd bu t n ot le ss r l t M et ifi ca

SH

TO

M

SH

TO

T m et ho d

D (1

) or T ho d C

(1

A A

SH

TO

T he r a pp ro ve d pr oc ed

SH

TO

M

SH

TO

T

T

A A

SH

TO

T ho

SH

TO

T m et ho d

D (1

, m et ho d C(1

A A

SH

TO

T r a pp ro ve d pr oc ed eg or ra ct er ss ifi ca tio n

M oi st e-de pa ct io n

C la ss ifi ca n

G ra da tio n

Li qu id li m it

M oi st pa ct yp e of

A cc ep ta nc e

(S ub se ct su re d an d te st ed fo r c on fo rm se ct io n

6.

M ea su re d an d te on fo rm se ct io n

6.

M at er ia l o r

Pr od uc t

U nc la ss ifi ed b or ro w se ct io n

4.

Se le ct b or se ct io n

4.

F-7

03USC10/06/11

Section 208. — STRUCTURE EXCAVATION AND

BACKFILL FOR SELECTED MAJOR STRUCTURES

Delete Table 208-1 and substitute the following:

T ab le pl in g an d

T es tin g

R eq ui re m or tin g T im e

B ef or e us in g in w or or e pl ac in g r

B ef or e us in g in w or or e pl ac in g r

(1

M in im um o f 5 p oi nt s p er p ro ct or pl e

Y es

, w he n re qu es te

, w he n re qu es te

Po in t o f

Sa m pl in g

So ur ce o f m at er ia l

In -p

So ce o f m at er ia

In -p pl in g Fr eq ue nc y pe r s oi l t yp e r 3 y d3 pe r s oi l t yp r l ift t M et ifi ca

SH

TO

M

SH

TO

T

T

A A

SH

TO

T ho d

C(1

A A

SH

TO

T r a pp ro ve d pr oc ed

SH

TO

T

T

A A

SH

TO

T

9, M et ho

A A

SH

TO

T ho d

C(1

A A

SH

TO

T o r ot he r a pp ro ve d pr oc ed eg or ra ct er ss ifi ca tio n

G ra da tio n

M oi st pa ct io n

G ra da tio n

Li qu id li m it

M oi st pa ct io n

T yp e of

A cc ep ta nc e

(S ub se ct su re d an d te on fo rm se ct io n

6.

M ea su re d an d te on fo rm se ct io n

6.

M at er ia l o r

Pr od uc t

Fo un da tio n fil l (S ub se ct io n

4.

St ru ct ur al b ac kf ill se ct io n

4.

F-8

03USC10/06/11

Section 209. — STRUCTURE EXCAVATION AND BACKFILL

Delete Table 209-1 and substitute the following:

T ab le pl in g an d T es tin g R eq ui re m or tin g T im e

B ef or e us in g in w or k

B ef or e pl ac in g ne xt la ye r

B ef or e us in g in w or k

B ef or e pl ac in g ne xt la ye r

B ef or e us in g in w or k

(1

M in im um o f 5 p oi nt s p er p ro ct or pl e

, w he n re qu es te d

Po in t o f

Sa m pl in g

So ur ce o f m at er ia l

In -p ce o f m at er ia l

In -p es se d m at er ia l b ef or e in co rp or at in g in to w or k

Sa m pl in g Fr eq ue nc y pe r s oi l t yp e pe r s oi l t yp e pe r s oi l t yp e

T es t M et ifi ca

SH

TO

T

T

A A

SH

TO

T ho d

C(1

A A

SH

TO

T o r ot he r a pp ro ve d pr oc ed

SH

TO

T ho d

C (1

A A

SH

TO

T o r ot he r a pp ro ve d pr oc ed

SH

TO

M eg or ra ct er da tio n

M oi st pa ct io n

M oi st pa ct io n

C la ss ifi ca tio n

T yp e of

A cc ep ta nc e

(S ub se ct su re d an d te on fo rm se ct io n

6.

M ea su re d an d te on fo rm se ct io n

6.

M at er ia l o r

Pr od uc t

B ac kf ill m at er ia l (S ub se ct io n

4.

B ed di ng m at er ia l (S ub se ct io n

4.

F-9

T ab le

-1

(c on tin pl in g an d T es tin g R eq ui re m or tin g T im e

B ef or e us in g in w or k

B ef or e pl ac in g ne xt la ye r

B ef or e us in g in w or k

B ef or e pl ac in g ne xt la ye r

(1

M in im um o f 5 p oi nt s p er p ro ct or pl e t o f

Sa m pl in g

So ur ce o f m at er ia l

In -p ce o f m at er ia l

In -p pl in g Fr eq ue nc y pe r s oi l t yp e pe r s oi l t yp e pe t M et ifi ca

SH

TO

T ho d

C(1

A A

SH

TO

T o r ot he r a pp ro ve d pr oc ed

SH

TO

T ho d

C (1

A A

SH

TO

M

SH

TO

T o r ot he r a pp ro ve d pr oc ed eg or ra ct er oi st pa ct io n

(S ub se ct io n

4.

M oi st ss ifi ca tio n

C om pa ct io n

T yp e of

A cc ep ta nc e

(S ub se ct su re d an d te on fo rm se ct io n

6.

M ea su re d an d te on fo rm se ct io n

6.

M at er ia l o r

Pr od uc t

Fo un da tio n fil l (S ub se ct io n

4.

U nc la ss ifi bo rro se ct io n

4.

F-10

03USC10/04/07

Section 251. — RIPRAP

Material

251.02 Add the following:

Structural Excavation and Backfill 209

Construction Requirements

251.03 General. Add the following:

Do not compromise the integrity of new piles, pile caps, or the mechanically stabilized earth (MSE) wall during excavation and placement of riprap trenches. Restore any material excavated below the bottom of pile cap elevation and the bottom of MSE wall elevation with compacted structural backfill or approved material. Dewater and compact or replace material below the water table in accordance with methods approved in the riprap placement plan.

Submit the following riprap placement information to the CO at least 30 days before excavation near proposed abutment locations:

(a) Construction narrative. Provide a narrative describing the proposed construction of the riprap trenches. Include a description of how the riprap trenches will be installed in relation to the pile driving and pile cap construction. Include a description of the excavation, including backslopes and any temporary excavation support that will be used.

Describe the timeline for riprap trench and driven pile construction. Describe the methods, materials, and equipment that will be used to backfill below the bottom of pile cap elevation and around piles.

(b) Drawings. Provide drawings to fully describe the proposed riprap trench construction. The drawings shall illustrate the relative location of the riprap trench, the piles, the pile cap, the MSE wall, and the riprap trench excavation limits. Include both plan views and typical cross-sections.

(c) Dewatering. Provide a detailed dewatering plan that illustrates the locations of any sumps, well points, and pumps and illustrates the proposed location and methods for sedimentation and release of removed water.

F-11

Delete Table 251-1 and substitute the following:

T ab le pl in g an d

T es tin g

R eq ui re m or tin g T im e

B ef or e us in g in w or k

B ef or e us in g in w pl e es

, w he n re qu es te d

Po in t o f

Sa m pl in g

So ur ce o f m at er ia pl in g Fr eq ue nc y pe r m at er ia l t yp e pe r m ix d es ig n

T es t M et ifi ca

SH

TO

T

A A

SH

TO

T

SH

TO

T

T

C at eg or ra ct er pp ar en t sp ec ifi c gr av a bs or pt io n

C oa rs e du ra bi lit y in de x

M ak in g te sp im en s

C om pr es si ve re ng e of

A cc ep ta nc e

(S ub se ct su re d an d te on fo rm se ct io n

6.

M ea su re d an d te on fo rm se ct io n

6.

M at er ia l o r

Pr od uc t

R ip ra p

(S ub se ct io n

5.

M or ta r

F-12

Section 255. — MECHANICALLY STABILIZED EARTH WALLS

Description

255.01 Add the following:

This work also includes furnishing and installing drainage systems using pipe, granular backfill, and geotextile.

Material

255.02 Add the following to the material list:

Granular Backfill 703.03 Select Granular Backfill 704.10 Corrugated Polyethylene Drainage Tubing 706.08(d) (Corrugated perforated collector pipe) (Corrugated solid outlet pipe) Geotextile Type I-A 714.01 Welded wire form 720.01(k) Support strut 720.01(l) Geogrid (Uniaxial) 720.04

Construction Requirements

255.03 General. Delete the text of this Subsection and substitute the following:

Survey according to Section 152 and verify the limits of the wall installation. Prepare and submit installation drawings according to Subsection 104.03 if they differ from the MSE wall plan sheet details. Perform the work under Section 209.

Install collector pipe and outlet pipe according to Section 605.

Grade the foundation for a width equal to the length of reinforcing elements plus 12 inches.

Provide a smooth, uniform foundation surface free from protruding objects. Place and compact a 6 inch leveling pad of select granular backfill under the bottom course of welded wire frames and geogrid reinforcement.

255.04 Wall Erection. Add the following:

(d) Geogrid reinforced MSE walls. Place and align welded wire forms to the wall face.

Lay geogrid against welded wire form with the machine direction perpendicular to the face of the wall, allowing adequate length for the wrapping at the top of the select granular backfill course. Do not reduce the reinforcement lengths shown on the plans without the permission of the CO. Do not splice geogrid. Secure support struts as shown in the plans.

F-13

Align the wall face to within 1 inch along the batter of the face and 1 inch horizontally when measured with a 5-foot straightedge.

Lay geogrid at the proper elevation and orientation as shown on the plans. Butt adjacent sheets of geogrid together without overlap. Hand-tension the geogrid to remove all wrinkles and use pins, stakes, soil piles, or the manufacturer’s approved method to anchor the geogrid ahead of the backfill placement to ensure intimate contact between the geogrid and underlying material. Avoid damaging the geogrid during installation. Replace excessively damaged material, as determined by the CO.

255.05 Backfilling. Delete the text of this Subsection and substitute the following:

Backfill and compact the MSE wall reinforced volume with select granular backfill according to Subsection 209.10. Start backfill placement at the wall face and work toward the back. Do not wrinkle, tear, or displace the geogrid reinforcement while placing backfill material. Place backfill in 6 inch uniform lifts. Compact each layer according to Subsection 204.11, except use only an acceptable lightweight mechanical or vibratory compactor within 3 feet of the wall face.

Rollers with studs (Sheep’s Foot type) are not allowed for compaction.

A minimum of 6 inch fill thickness is required prior to operating equipment over geogrid. Avoid sudden braking and sharp turns when operating equipment on the backfill to prevent displacing the fill and damaging the geogrid.

Replace all wall materials damaged by the backfill placement operation as determined by the CO. Correct all misaligned or distorted wall elements caused by the placement of backfill.

255.06 Acceptance. Add the following:

Survey work will be evaluated under Section 152.

Geogrid, welded wire framing, and related hardware will be evaluated under Subsections 106.02 and 106.03.

MSE wall construction will be evaluated under Subsections 106.02 and 106.04.

See Table 255-1 for minimum sampling, testing, and acceptance requirements.

Measurement

255.07 Amend as follows:

Delete the second paragraph.

Add the following:

Measure MSE walls by the square foot of vertical projection of the wall face.

F-14

Do not measure wall backfill materials for payment.

Do not measure geogrid, welded wire framing, and related hardware for payment.

Do not measure wall underdrain system bedding, granular backfill, collector pipe, outlet pipes, rodent guards, or geotextile for payment.

Do not measure structural excavation for payment.

Delete Table 255-1 and substitute the following:

Table 255-1

Sampling and Testing Requirements

Section 255 - Mechanically Stabilized Earth Walls

Type of Acceptance (Subsection)

Material or

Product

Characteristic

Category

Test Methods / Specifications

Tolerance

Sampling

Frequency

Point of

Sampling

Split

Sample

Reporting

Time

Remarks

Measured and tested for conformance (Subsection 106.04)

Excavation

Select granular backfill

Geogrid wall construction

Reinforcement material

Elevation and dimension specified

Compaction

Line and grade

Installation

Field measured

Subsection 204.11

Field measured

106.02

12 in. Horz.

and 4 in.

Vert. from reference stakes

2 in.Horz.

and 2 in.along batter from reference stakes

+/- 2 inches

Each foundation

1 for each 325 yd3 or fraction thereof but not less than 1 for each installation

As determined by the CO

1 for each layer

Prior to being covered

F-15

Table 255-1

Sampling and Testing Requirements

Section 255 - Mechanically Stabilized Earth Walls

Certificate of Compliance (Subsection 106.03)

Geogrid reinforcement

Support strut

Welded wire form

Select granular backfill

Quality

Gradation

Electrochemical Requirements

720.04

Subsection 720.01

720.01

704.10

Each shipment

1 for each 500 yd^3 but not less than 1 for each installation

1 for each 500 yd^3 but not less than 1 for each installation

1 for each 500 yd^3 but not less than 1 for each installation source

Yes

Prior to use in work

F-16

03USC09/13/05

Section 403. — HOT ASPHALT CONCRETE PAVEMENT

Construction Requirements

403.03 Composition of Mix (Job-Mix Formula). Amend as follows:

(b) Submission. Delete the text of the last sentence of the first paragraph and substitute the following:

At the direction of the CO, submit the following for each job-mix formula:

(e) Acceptance. Add the following:

Prepare four hot mix asphalt correction specimens and one aggregate only specimen in accordance with AASHTO T308 and the Federal Lands Highway addendum to AASHTO T308. Submit specimens to the CO five days before production.

F-17

Delete Table 403-1 and substitute the following:

T ab le pl in g, T es tin g an d

A cc ep ta nc e

R eq ui re m or tin g T im e d ay s be ap pr ov al o f jo b-ix rm ul a h ou rs

Te ed b y G ov er nm en t pl

, w he n re qu es te

- 1

-q ua rt sa m pl t o f

Sa m pl in g

Fl ow in g ag gr eg at e st re am

(b in o r be lt di sc ha rg e) ff o f B eh in d pa ve r be co pa ct in g

C om pl ad w ay a fte r ro lli

Li b et w ee n st or ag e ta nk as ph al t p nt pl g

Fr eq ue nc y pe r a gg re ga kp ile r 7 to r 1 to of li qu id t M et ifi ca

Su bs ec tio n

3.

SH

TO

T

A A

SH

TO

T

ST

M

D r a pp ro ve d pr oc ed ec tio n

3.

ec tio n

2.

eg or ra ct er

Jo b-ix rm ul a ve rif ic at io n

G ra da tio n

A sp lt en t C om pa ct io n

Sm oo th

Q ua lit y

T yp e of

A cc ep ta nc e

(S ub se ct su re d an d te on fo rm se ct io n

6.

M at er ia l o r

Pr od uc t

H ot a sp lt nc re te p av em en t

A sp ha lt bi nd

F-18

03USC01/01/04

Section 412. — ASPHALT TACK COAT

Construction Requirements

412.07 Acceptance. Delete the text of the first paragraph and substitute the following:

Emulsified asphalt will be evaluated under Subsections 106.02, 106.03, and 702.09.

F-19

Section 551. — DRIVEN PILES

Delete Section 551 and substitute the following:

Description

551.01 This work consists of furnishing and driving piles. This work includes one 18 inch test pile at each abutment with dynamic load tests. This work also includes furnishing and placing reinforcing steel and concrete in concrete-filled steel shell and concrete-filled pipe piles.

Piles are designated as concrete-filled steel shell piles or concrete-filled pipe piles.

Material

551.02 Conform to the following Sections and Subsections:

Structural excavation and backfill 209 Concrete piles 715.03 Grout 725.22(b) Paint 708 Pile shoes 715.08 Reinforcing steel 709.01 Sheet piles 715.07 Splices 715.09 Steel H-piles 715.06 Steel pipes 715.05 Steel shells 715.04 Structural concrete 552 Treated timber piles 715.02 Untreated timber piles 715.01

Construction Requirements

551.03 General. If excavations are required, restore any material excavated below the bottom of pile cap elevations and the bottom of MSE wall elevation between Station 17+76.80 and 18+12.80, and Station 19+39.14 and 19+75.14 with compacted structural backfill or approved material.

Comply with Subsection 251.03 for excavation and backfill requirements.

Drive 18 inch diameter piles to the tip elevations and minimum compressive nominal bearing resistance (ultimate capacity) shown on the plans and listed in Subsection 551.05. Drive 12 inch diameter piles to the tip elevations shown on the plans. Do not perform dynamic load tests on 12 inch diameter piles.

551.04 Pile Driving Equipment. Furnish equipment meeting the following requirements.

(a) Pile hammers.

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(1) Gravity hammers. Gravity hammers may only be used to drive timber piles. Furnish a hammer with a ram weighing between 2,000 and 3,500 pounds and limit the drop height to 15 feet. The ram mass shall be greater than the combined mass of the drive head and pile. Provide hammer guides to ensure concentric impact on the drive head.

(2) Open-end diesel hammers. Equip open-end (single acting) diesel hammers with a device, such as rings on the ram or a scale (jump stick) extending above the ram cylinder, to permit visual determination of hammer stroke. Submit a chart from the hammer manufacturer equating stroke and blows per minute for the hammer to be used. A speed versus stroke calibration may be used if approved.

(3) Closed-end diesel hammers. Submit a chart, calibrated to actual hammer performance within 90 days of use, equating bounce chamber pressure to either equivalent energy or stroke for the hammer to be used. Equip hammers with a dial gauge for measuring pressure in the bounce chamber. Make the gauge readable from ground level. Calibrate the dial gauge to allow for losses in the gauge hose. Verify the accuracy of the calibrated dial gauge during driving operations by ensuring that cylinder lift occurs when bounce chamber pressure is consistent with the maximum energy given in the hammer specifications. Do not use closed-end diesel hammers that do not attain cylinder lift at the maximum energy-bounce chamber pressure relationship given in the hammer specification.

(4) Air or steam hammers. Furnish plant and equipment for steam and air hammers with sufficient capacity to maintain the volume and pressure specified by the hammer manufacturer. Equip the hammer with accurate pressure gauges that are easily accessible. Use a hammer with the mass of the striking parts equal to or greater than one third the combined mass of the driving head and pile. The combined mass shall be at least 2,750 pounds.

Measure inlet pressures for double-acting and differential-acting air or stream hammers with a needle gauge at the head of the hammer when driving test piles. If required, also measure inlet pressures when driving production piles. A pressure versus speed calibration may be developed for specific driving conditions at the project as an alternative to periodic measurements with a needle gauge.

(5) Nonimpact hammers. Use nonimpact hammers, such as vibratory hammers, only when permitted in writing or when specified in the contract. If permitted, use such equipment for installing production piles only after the pile tip elevation or embedment length for safe support of the pile load is established by static or dynamic load testing.

Control the installation of production piles when using vibratory hammers by power consumption, rate of penetration, specified tip elevation, or other acceptable methods that ensure the required pile load capacity is obtained. Strike all piles with an impact hammer of suitable energy to verify the required pile capacity is obtained.

(6) Hydraulic hammers. Provide a power plant for hydraulic hammers with sufficient capacity to maintain the volume and pressure, specified by the manufacturer, at the hammer under working conditions. Equip the power plant and equipment with accurate pressure gauges that are easily accessible to the CO.

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(b) Approval of pile-driving equipment. Furnish pile-driving equipment of such size that the permanent piles can be driven with reasonable effort to the required lengths without damage.

Approval of pile-driving equipment will be based on a wave equation analysis. The CO will evaluate the proposed equipment and accept or reject the driving system within 14 days of receipt of the pile and driving equipment information.

Use only the approved equipment during pile-driving operations. Approval of the pile-driving system is specific to the equipment submitted. If the proposed equipment is modified or replaced, re-evaluate and resubmit the analysis and revised data for approval before using. The CO will accept or reject the revised driving system within 14 days of receipt of the revised submittal. Approval of a pile hammer does not relieve the Contractor of responsibility for piles damaged due to driving stress.

(1) Equipment submittal. Submit the following pile-driving equipment information to the CO at least 30 days before driving piles. Include in the report a wave equation analysis for the proposed pile driving system. Use a professional engineer with at least 3 years’ experience in wave equation analyses to perform the wave equation analysis.

Submit a resume of the engineer to conduct the wave equation analysis for approval.

(a) General. Project and structure identification, pile-driving contractor or subcontractor, and auxiliary methods of installation such as jetting or preboring and the type and use of the equipment.

(b) Hammer. Manufacturer, model, type, serial number, rated energy ( _____ at _____ length of stroke), ram weight, and modifications.

(c) Capblock (hammer cushion). Material, thickness, area, modulus of elasticity (E), and coefficient of restitution (e).

(d) Pile cap. Helmet weight, bonnet weight, anvil block weight, and drivehead weight.

(e) Pile cushion. Material, thickness, area, modulus of elasticity (E), and coefficient of restitution (e).

(f) Pile. Pile type, length (in leads), weight per foot, wall thickness, taper, cross-sectional area, design pile capacity, description of splice, and tip treatment description.

(g)Test pile details. Location, type, estimated tip elevation, minimum allowable embedment, length, capacity, allowable compressive and tensile stresses.

(h) Subsurface conditions. Soil description, soil damping and quake parameters used in analysis, anticipated driving difficulties (if any).

(i) Bearing graph analysis results. Calculated maximum compressive and tensile stresses, penetration resistance (blow counts), hammer stroke and energy transferred to the pile for a range of nominal (ultimate) soil resistance values.

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(2) Wave equation. The required number of hammer blows indicated by the wave equation at the nominal (ultimate) pile capacity shall be between 3 and 10 per inch.

In addition, the pile stresses resulting from the wave equation analysis shall not exceed the values at which pile damage is impending. The point of impending damage is defined for steel piles as follows.

(a) Steel piles. Limit the compressive driving stress to 90 percent of the yield strength of the pile material.

(c) Driving appurtenances.

(1) Hammer cushion. Equip all impact pile-driving equipment, except gravity hammers, with a suitable thickness of hammer cushion material to prevent damage to the hammer or pile and to ensure uniform driving behavior. Fabricate hammer cushions from durable, manufactured material according to the hammer manufacturer’s recommendations. Do not use wood, wire rope, or asbestos hammer cushions. Place a striker plate, as recommended by the hammer manufacturer, on the hammer cushion to ensure uniform compression of the cushion material. Inspect the hammer cushion in the presence of the CO when beginning pile driving at each structure or after each 100 hours of pile driving, whichever is less. Replace the cushion when its thickness is reduced by more than 25 percent of its original thickness.

(2) Pile drive head. Provide adequate drive heads for impact hammers and provide appropriate drive heads, mandrels, or other devices for special piles according to the manufacturer’s recommendations. Align the drive head axially with the hammer and pile. Fit the drive head around the pile head so that transfer of torsional forces is prevented during driving and proper alignment of hammer and pile is maintained.

(3) Leads. Support piles in line and position with leads while driving. Construct pile driver leads to allow freedom of movement of the hammer while maintaining axial alignment of the hammer and the pile. Do not use swinging leads unless permitted in writing or specified in the contract. When swinging leads are permitted, fit swinging leads with a pile gate at the bottom of the leads and, in the case of battered piles, fit with a horizontal brace between the crane and the leads. Adequately embed leads in the ground or constrain the pile in a structural frame (template) to maintain proper alignment.

Provide leads of sufficient length that do not require a follower but will permit proper alignment of battered piles.

(4) Followers. Followers are not permitted unless approved in writing. When followers are permitted, drive the first pile in each bent or substructure unit and every tenth pile thereafter, full length without a follower, to verify that adequate pile embedment is being attained to develop the required nominal (ultimate) capacity. Provide a follower of such material and dimensions that will permit the piles to be driven to the required penetration.

Hold and maintain follower and pile in proper alignment during driving.

(5) Jetting. Do not use jetting unless approved in writing. Provide jetting equipment with sufficient capacity to deliver a consistent pressure equivalent to at least 100 pounds

F-23 per square inch at two 3/4 inch jet nozzles. Jet so as not to affect the lateral stability of the final inplace pile. Remove jet pipes when the pile tip is at least 5 feet above the prescribed tip elevation, and drive the pile to the required nominal (ultimate) capacity with an impact hammer. Control, treat if necessary, and dispose of all jet water in an approved manner.

(6) Pile cushion. For concrete piles, use a new pile cushion to protect the head of each pile. Cut the pile cushion at least 4 inches thick and to match the cross-section of the pile top. Replace the pile cushion if it is compressed more than one-half its original thickness or it begins to burn. For steel and timber piles, protect each pile with an approved driving cap. Enclose timber piles with approved collars or bands to prevent splitting or brooming. Replace caps when damaged. Do not reuse cushions or caps.

(7) Pile shoes. Provide pile shoes to protect the pile-tip from damage during driving.

Fabricate all shoes to snugly fit the pile tip. For steel piles, design and fit the shoe to the steel shape and weld the shoe to the pile so as not to stress the web or the flange. Do not install pile shoes on production piles until the dynamic load testing is complete on the first pile driven at each abutment.

551.05 Pile Lengths. Furnish piles with sufficient length to obtain the required penetration and the required compressive nominal bearing resistance (ultimate capacity) and to extend into the pile cap or footing as indicated on the plans. In addition, increase the length to provide fresh heading and to provide for the Contractor’s method of operation. When test piles are required, furnish piles in the lengths determined by the test piles.

551.06 Test Piles. The first 18 inch pile driven at each abutment location will be driven as a test pile. Determine the compressive nominal bearing resistance (ultimate capacity) of each test pile using a dynamic load test. Use the results of the test pile to establish the driving criteria for the remaining 18 inch production piles in the same abutment.

Excavate the ground at the site of each test pile or production pile to the elevation of the bottom of the footing before the pile is driven. Furnish test piles longer than the estimated length of production piles. Drive test piles with the same equipment as the production piles.

Drive test piles to the required compressive nominal bearing resistance (ultimate capacity) at the estimated tip elevation. The required compressive nominal bearing resistance (ultimate capacity) is equal to the total skin plus tip resistance determined from the dynamic pile load test minus the skin resistance above the design scour elevation 2983 feet. The required compressive nominal bearing resistance (ultimate capacity) is 414 kips/pile for the 18 inch diameter piles. Allow test piles that do not attain the required nominal bearing resistance (ultimate capacity) within 5 feet of the estimated tip elevation to “set up” for 24 hours before re-driving. Warm the hammer before re-driving begins by applying at least 20 blows to another pile. If the required nominal bearing resistance (ultimate capacity) is not attained on re-driving, drive a portion or all of the remaining test pile length, and repeat the “set up” and re-drive procedure as directed. Splice and continue driving until the required nominal bearing resistance (ultimate capacity) is obtained.

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Test piles to be used in the completed structure shall conform to the requirements for production piles. Remove test piles not incorporated in the completed structure to at least 2 feet below finished grade.

551.06 Driven Pile Capacity. Drive piles to the specified penetration and to the depth necessary to obtain the required compressive nominal bearing resistance (ultimate capacity). Splice piles not obtaining the required compressive nominal bearing resistance (ultimate capacity) at the ordered length, and drive with an impact hammer until the required compressive nominal bearing resistance (ultimate capacity) is achieved.

Use the dynamic load tests to determine compressive nominal bearing resistance (ultimate capacity) of the test piles. Use the results of the test pile to establish the driving criteria for the remaining production piles in the same abutment.

551.07 Preboring. Use auguring, wet rotary drilling, or other approved methods of preboring.

In compacted embankments more than 5 feet deep, prebore the pile hole to natural ground.

Prebore holes 6 inches greater than the diameter of the pile. For square, rectangular, or H piles, make the diameter of the hole equal to the diagonal of the pile cross-section plus 6 inches.

For piles end-bearing on rock or hardpan, preboring may extend to the surface of the rock or hardpan. Seat the pile into the end-bearing strata.

For piles not end-bearing on rock or hardpan, stop preboring at least 5 feet above the estimated pile tip elevation, and drive the pile with an impact hammer to a penetration which achieves the required nominal (ultimate) pile capacity. Prebore holes smaller than the diameter or diagonal of the pile cross-section while allowing penetration of the pile to the specified depth.

If the subsurface obstructions such as boulders or rock layers are encountered, the hole diameter may be increased to the least dimension adequate for pile installation. After driving is complete, fill all remaining void space around the pile with sand or other approved material. Do not use a punch or a spud in lieu of preboring.

Do not impair the capacity of existing piles or the safety or condition of adjacent structures. If preboring disturbs the capacity of previously installed piles or structures, restore the required nominal (ultimate) capacity of piles and structures by approved methods.

551.09 Preparation and Driving. Perform the work under Section 208. Make the heads of all piles plane and perpendicular to the longitudinal axis of the pile. Coordinate pile driving to prevent damage to other parts of the completed work.

Drive piles to within 3 inches of plan location at cutoff elevation. Drive piles no closer than 6 inches from any cap face. Drive piles so that the axial alignment is within 1/4 inch per foot, along the longitudinal axis, of the required alignment. The CO may stop driving to check the pile alignment. For piles that cannot be internally inspected after installation, check alignment before the last 5 feet are driven. Do not pull laterally on piles or splice to correct misalignment. Do not splice a properly aligned section on a misaligned pile.

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Place individual piles in pile groups either starting from the center of the group and proceeding outward in both directions or starting at the outside row and proceeding progressively across the group.

Correct all piles driven improperly, driven out of proper location, misaligned, or driven below the designated cutoff elevation in an approved manner. Replace piles damaged during handling or driving. Obtain approval for the proposed method(s) of correcting or repairing deficiencies.

Furnish full-length, unspliced piles for lengths up to 60 feet. If splices are required in the first pile driven and it is anticipated that subsequent piles will also require splices, place the splices in lower third of the pile. Splice lengths less than 10 feet are not permitted and only 2 splices per pile are allowed.

Load, transport, unload, store, and handle steel piles so the metal is kept clean and free from damage. Do not use piles that exceed the camber and sweep permitted by allowable mill tolerance.

Steel piles damaged during installation are considered unsatisfactory unless the bearing capacity is proven to be 100 percent of the required nominal (ultimate) capacity by load tests. Perform tests at no cost to the Government.

Use cast steel 60 degree conical driving points that do not project beyond the pile perimeter on all piles. Do not install driving points on production piles until the test piles have been driven to the design compressive nominal bearing resistance (ultimate capacity) and the driving criteria for the production piles has been established. Weld driving point to steel piles in accordance with AWS D1.1, or D1.5 as applicable.

When practicable, drive all pile shells or pipes for a substructure unit before placing concrete in any of the shells or pipes. Do not drive pile shells or pipes within 15 feet of any concrete-filled pile shell or pipe until the concrete has cured for at least 7 days or 3 days if using high-early-strength concrete. Do not drive any pile shell or pipe after it is filled with concrete.

Remove and replace shells that are determined to be unacceptable for use due to breaks, bends, or kinks.

551.10 Splices. Submit details for pile field splices for approval. Align and connect pile sections so the axis of the spliced pile is straight.

Submit a welder certification for each welder. Use welders certified for structural welding.

Make surfaces to be welded smooth, uniform, and free from loose scale, slag, grease, or other material that prevents proper welding. Steel may be oxygen cut. Carbon-arc gouging, chipping, or grinding may be used for joint preparation.

Weld according to AASHTO/AWS D 1.5 Bridge Welding Code. Weld the entire pile cross-section using prequalified AWS groove weld butt joints. Weld so there is no visual evidence of cracks, lack of fusion, undercutting, excessive piping, porosity, or inadequate size. Do not use manufactured splices unless approved in writing or specified in the contract. Manufactured splices may be used in place of full penetration groove butt welds if they can develop the full strength of the pile in compression, tension, and bending.

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551.11 Heaved Piles. Check for pile heave during the driving operation. Take level readings immediately after each pile is driven and again after piles within a radius of 15 feet are driven. Re-drive all piles that heave more than 1/4 inch. Re-drive to the specified resistance or penetration.

551.12 Dynamic Load Test. Use a qualified pile specialty consultant with at least 3 years’ experience in dynamic load testing and analysis to perform the dynamic load test, the signal matching analysis, and the wave equation analysis including the initial wave equation analysis specified in Subsection 551.03(b). Submit a resume of the specialty consultant for approval.

Furnish equipment and perform dynamic load tests according to ASTM D 4945 under the supervision of the CO.

Place the piles designated as dynamic load test piles in a horizontal position and not in contact with other piles. Drill holes for mounting instruments near the head of the pile. Mount the instruments and take wave speed measurements. Place the designated pile in the leads. Provide at least a 4-foot by 4-foot rigid platform with a 3½-foot safety rail that can be raised to the top of the pile.

Drive the pile to the depth at which the dynamic test equipment indicates that the required compressive nominal bearing resistance (ultimate capacity) is achieved. If necessary to maintain stresses in the pile below the values in Subsection 551.03(b)(2), reduce the driving energy transmitted to the pile by using additional cushions or reducing the energy output of the hammer.

If nonaxial driving is indicated, immediately realign the driving system.

When the required compressive nominal bearing resistance (ultimate capacity) is not obtained within 5 feet of the estimated tip elevation, wait at least 24 hours after initial driving to re-drive each dynamic load test pile with instrumentation attached. The 24-hour waiting period may be waived at the direction of the CO. Warm the hammer before re-driving by applying at least 20 blows to another pile. Re-drive the dynamic load test pile to the depth at which the dynamic test equipment indicates that the required nominal bearing resistance (ultimate capacity) is achieved.

Verify the assumptions used in the initial wave equation analysis submitted according to Subsection 551.03(b) using signal matching analysis. Analyze at least one blow from the original driving for each pile tested. Determine the side resistance of the pile above the design scour elevation of 2983 feet, and subtract this resistance from the total compressive nominal bearing resistance (ultimate capacity). Report the side resistance measured above elevation 2983 feet.

Perform additional wave equation analyses with adjustments based on the signal matching analysis results. Provide a graph showing blow count versus compressive nominal bearing resistance (ultimate capacity). For open-ended diesel hammers, provide a blow count versus stroke graph for the compressive nominal bearing resistance (ultimate capacity) listed on the plans plus the skin resistance determined above the design scour elevation 2983 feet to be used on the remaining production piles in the same abutment. Provide the driving stresses, transferred energy, and pile capacity as a function of depth for each dynamic load test.

Based on the results of the dynamic load testing, signal matching analyses, and wave equation analyses, the order list and production driving criteria may be approved and the required cut-off

F-27 elevations provided, or additional test piles and load testing may be specified. This information will be provided within 7 days after receipt of the order list and all required test data for the test piles driven.

551.13 Pile Cutoffs. Cut off the tops of all permanent piles and pile casings at the required elevation. Cut off the piles clean and straight perpendicular to the longitudinal axis of the pile.

Dispose of cutoff lengths according to Subsection 203.05(a).

Do not paint steel to be embedded in concrete. Before painting the exposed steel pile, thoroughly clean the metal surface of any substance that may inhibit paint adhesion. Use aluminum colored paint system 2 according to Section 563. Paint piles before driving. Use one prime coat and two finish coats on trestles or other exposed piling to at least 4 feet below the finished groundline or waterline. Paint exposed piling above finished groundline or waterline with one field finish coat.

551.14 Unsatisfactory Piles. Correct unsatisfactory piles by an approved method. Methods of correcting unsatisfactory piles may include one or more of the following:

(a) Use of the pile at a reduced capacity;

(b) Install additional piles;

(c) Repair damaged piles; and

(d) Replace damaged piles.

551.15 Placing Concrete in Steel Shell or Pipe Piles. After driving, clean the inside of shells and pipes by removing all loose material. Keep the shell or pipe substantially water tight. Remove water before placing concrete or place the concrete using a tremie when water is present in the pile.

Provide suitable equipment for inspecting the entire inside surface of the driven shell or pipe just before placing concrete.

(a) Reinforcing steel. When reinforcing steel is required, make the spacing between adjacent cage elements at least 5 times the maximum size of aggregate in the concrete.

Securely tie concrete spacers or other approved spacers at fifth points around the perimeter of the reinforcing steel cage. Install spacers at intervals not to exceed 10 feet measured along the length of the cage.

Place the reinforcement cage into the driven shell or pipe when the concrete reaches the planned bottom elevation of the reinforcement. Support the reinforcement so it remains within 2 inches of the required vertical location. Support the cage from the top until the concrete reaches the top of the pile.

(b) Concrete. Construct concrete according to Section 552. Place concrete in one continuous operation from the bottom to the top of the pile. Before the initial concrete set, consolidate the top 10 feet of the concrete pile using approved vibratory equipment.

551.16 Acceptance. Pile material will be evaluated under Subsections 106.02…