Div60.pdf

Lower Rio Grande Flood Control Project Rehabilitation of Hidalgo Protective Levee (Modified Phases I and II) and Banker Floodway South Levee Hidalgo County, Texas

DIVISION 60-

USIBWC Contract No.: IBM09B0003 STRUCTURES

US INTERNATIONAL BOUNDARY & WATER COMMISSION

GOVERNING TECHNICAL SPECIFICATIONS AND PROVISIONS

DIVISION 60 – STRUCTURES

Rehabilitation of Hidalgo Protective Levee (Modified Phases I and II) and Banker Floodway South Levee

DIVISION 60-

USIBWC Contract No.: IBM09B0003 STRUCTURES

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Rehabilitation of Hidalgo Protective Levee (Modified Phases I and II) and Banker Floodway South Levee

TRENCH EXCAVATION PROTECTION

USIBWC Contract No.: IBM09B0003 Page 60.02.00 - 1

SPECIFICATION 60 02 00

This specification includes requirements for providing trench excavation protection within the Work area, and includes the following:

1.0 General

2.0 Materials & Equipment

3.0 Construction Methods

4.0 Measurement and Payment

PART 1 - GENERAL

1.1 RELATED DOCUMENTS, CONTRACT CLAUSES, & SPECIFICATIONS

The following may not include all related documents, contract clauses, & technical specifications, and does not relieve the Contractor of the responsibility of performing work associated with this specification in accordance with all terms of the Contract herein.

A. Related documents: As described in paragraph 1.2 of SPECIFICATION 01 01 00.

B. Contract: Section I, 52.236-21“Specifications and Drawings for Construction”

C. Technical Specifications:

• SPECIFICATION 01 33 00, “Submittals”

• SPECIFICATION 01 39 00, “Safety”

• Divisions 31, 33, 50 and 60

D. References.

• Occupational Safety and Health Act (OSHA), 29 CFR, Part 1926, as amended

• Texas Health and Safety Code, Chapter 756

• US Army Corps of Engineers (USACE) Engineering Manual (EM) 385-1-1, 2008

1.2 GENERAL

In general, the Contractor shall furnish and place excavation protection for trenches deeper than 5 ft.

PART 2 – MATERIALS & EQUIPMENT

2.1 MATERIALS (No Requirements Defined for this Specification)

2.2 EQUIPMENT (No Requirements Defined for this Specification)

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PART 3 – CONSTRUCTION METHODS

In general, the Contractor shall furnish and place excavation protection for trenches deeper than 5 feet.

Trench excavation protection shall include but not be limited to vertical or sloped cuts, benching, shields, support systems, sheeting, trench boxes or trench shields, sheet piling, cribbing, bracing, shoring, dewatering or diversion of water to provide adequate drainage.

A. Regulatory Requirements

(1) The Contractor shall design, install and maintain trench excavation protection systems in accordance with the detail specifications set out in the provision of Excavations, Trenching, and Shoring, Federal OSHA Standards, 29CFR, Part 1926, as amended and USACE EM 385-1-1, 2008. The sections that are incorporated into these specifications by reference include 1926-650 throughout 1926.653 and Section 25 of the USACE EM 385-1-1, 2008.

(2) The Contractor is responsible for obtaining a copy of the OSHA standards.

(3) Legislation that has been enacted by the Texas Legislature with regard to Trench Safety Systems, is hereby incorporated, by reference, into these specifications. Refer to Texas Health and Safety Code Chapter 756.

B. Submittals. Submittals shall conform to requirements of SPECIFICATION 01 33 00 – Submittals as well as the following:

(1) The Contractor shall submit a Trench Excavation Protection System and Plan specifically for the construction of trench excavation; design the Trench Excavation Protection System and Plan to be in accordance with OSHA 29CFR 1926 Subpart P and USACE EM 385-1-1, 2008, Section 25 standards governing the presence and activities of individuals working in and around trench excavations.

(2) The Trench Excavation Protection System and Plan construction and shop drawings containing shall be signed, sealed, and dated by a Texas Professional Engineer.

(3) Review of the Contractor’s Trench Excavation Protection System and Plan by the COR will only be in regard to compliance with this specification and will not constitute approval by the COR nor relieve Contractor of obligations under State and Federal trench safety regulations.

PART 4 – MEASUREMENT AND PAYMENT

4.1 MEASUREMENT

The Work performed under this Specification will be measured by the linear foot along the long axis of the trench where the depth of trench exceeds 5 feet. This measurement includes all required trench protection, including trench ends.

4.2 PAYMENT

The work performed and materials furnished in accordance with this Specification and measured as provided under “Measurement” will be paid for at the unit price bid for “Trench Excavation Protection.”

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This price is full compensation for excavation and backfill required for excavation protection; furnishing, placing, and removing shoring, sheeting, or bracing; dewatering or diversion of water; jacking and jack removal; and equipment, labor, materials, tools, and incidentals.

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Rehabilitation of Hidalgo Protective Levee (Modified Phases I and II) and Banker Floodway South Levee

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Rehabilitation of Hidalgo Protective Levee (Modified Phases I and II) and Banker Floodway South Levee

DRIVING PILING

USIBWC Contract No.: IBM09B0003 Page 60.04.00 - 1

SPECIFICATION 60 04 00

This specification includes requirements for the construction of piling within the Work area, and includes the following:

1.0 General

2.0 Materials & Equipment

The following may not include all related documents, contract clauses, & technical specifications, and does not relieve the Contractor of the responsibility of performing work associated with this specification

• SPECIFICATION 60 05 00, “Foundation Test Load”

D. References: <No Requirements Defined for this Specification.>

In general, the Contractor shall drive pile.

2.1 MATERIALS <No Requirements Defined for this Specification.>

2.2 EQUIPMENT

A. Driving Equipment. The Contractor shall use power hammers for driving piling with specified bearing resistance. Use power hammers that comply with Table 1. Gravity hammers may be used for driving sheet piling and timber piling if no required design load is shown on the plans. For initial rating of diesel hammers to determine compliance with the requirements of Table 1, the height of fall of the ram of the single-acting (open-end) hammer must be 7 feet.

For a double-acting (enclosed ram) hammer, the energy rating must be eighty-five percent (85%) of the rated output by the manufacturer. A hammer that produces less energy than required by Table 1 may be compliance-confirmed if a wave equation analysis indicates that the hammer can drive the specified pile against a bearing resistance of 3 times the required design

Rehabilitation of Hidalgo Protective Levee (Modified Phases I and II) and Banker Floodway South Levee

USIBWC Contract No.: IBM09B0003 Page 60.04.00 - 2 load before reaching 0.l-inch of penetration per blow. The bearing resistance of the piling driven with this particular equipment will be determined in accordance with the Wave Equation Method. Use an air compressor that supplies the volume and pressure specified by the manufacturer of the hammer. Provide an accurate pressure gauge. Maintain the valve mechanism and other parts of power hammers so that the hammer will operate at the speed and stroke length specified by the manufacturer. Equip enclosed ram diesel hammers with a gauge and provide charts to evaluate the equivalent energy being produced. Calibrate the gauge before work begins, whenever gauge accuracy is in question, and at least once each 6 months.

Table 1 Size of Driving Equipment

Piling Type

Hammer Type

Ram Weight

(lb.)

Maximum Ram

Stroke (ft.)

Minimu m

Hammer Energy (ft.-lb.)1

Air, Hydraulic 2,000 min. 5 330R Timber

Diesel 2,000 min. 10 330R

Air, Hydraulic 3,000 min. 5

Larger of 250R or 2-1/2 Wp Steel

Diesel 2,000 min. 10 Larger of 250R or 2-1/2 Wp

Air, Hydraulic

3,000 min., but not less than 1/4 Wp

250R, but not less than 1 ft.-lb.

per lb. of pile weight Concrete

Diesel

2,700 min., but not less than 1/4 Wp

250R, but not less than 1 ft.-lb.

per lb. of pile weight

1 R = Design load in tons. Wp = Weight of pile in pounds based on plan length.

2 Diesel hammers with less ram weight or greater ram stroke are permitted if a wave equation analysis indicates that the combination of ram weight, stroke, and cushioning will not overstress the piling.

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Cap block cushioning material, when used between the ram and anvil or follow block, must consist of layers of micarta plastic and aluminum or other material specifically produced and compliance-confirmed for this application.

When using gravity hammers, regulate the height of fall to avoid damage to the piling.

Drive all test piling in a structure or in any compliance-confirmed segment of it with the same hammer, and use the same type and size hammer to drive the remainder of the piling in the structure or segment.

Equip pile drivers with leads constructed to allow freedom of movement of the hammer and to provide adequate support to the pile during driving. The longitudinal axis of the leads, hammer, and pile should coincide.

Except where piling is driven through water, ensure that leads are long enough that a follower will not be necessary. Where a follower is required when driving piling underwater, use 1 pile in each 10 that is long enough to permit driving without a follower. Drive it as a test pile for proper correlation of the follower-driven piling. Payment will be made as regular piling.

Hammers designed to operate underwater may be used for underwater driving without a follower and without the correlation required for other hammers

B. Protection of Pile Heads. Use a steel driving head (helmet) suitable for the type and size of piling. Drive steel H-piling and sheet piling with a helmet compatible with the specific pile shape driven.

For concrete piling, provide a cushion block between the driving head and the top of the pile. Use a cushion block that is a minimum of 4-inch thick for short piling (50 feet or less) and at least 6 inches thick for longer piling. Use multiple layers of one of the following:

• 3/4-inch or 1-inch structural grade southern pine or fir plywood;

• green oak or gum, with the grain of the wood horizontal; or

• other compliance-confirmed material specifically produced for this application.

Pay special attention to the condition of the cushioning material. Do not drive more than 3 piles with one cushion block. Change cushioning more frequently if necessary to prevent damage.

Immediately replace any cushion block that has ignited. Do not use a tight-fitting driving helmet for concrete piling. Allow room for slight movement, but ensure that the driving helmet is not large enough for the pile head to rotate freely. Center concrete piling and cushion within the helmet throughout the driving operation

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This Specification uses the following terms:

• Foundation piling – Piling placed under interior bent footings or retaining wall abutment footings.

• Trestle piling – Piling embedded directly into the abutment cap or interior bent cap.

• Sheet piling – Retaining piling not considered either foundation or trestle piling.

• Test piling – Specific piling driven to investigate site conditions and determine regular piling lengths.

• Test-loaded piling – Specific piling driven and test-loaded to investigate site conditions and determine regular piling lengths. Do not fabricate regular piling until test loading and analysis is completed.

• Regular piling – All piling other than test piling and test-loaded piling.

Do not fabricate regular piling until test pile driving and analysis or test loading and analysis is completed.

Do not drive foundation piling until the footing excavation is approximately complete. Do not drive concrete piling until the piling concrete, including build-ups, has aged at least 14 days. Do not drive piling in a saltwater environment until the piling concrete, including build-ups, has aged at least 21 days after concrete placement.

Re-drive any piling that is raised when driving adjacent piling. Withdraw and replace any broken, split, or displaced piling, or correct it after a design analysis.

To control excessive stresses resulting in damage to the piling during driving, the following, alone or in combination, may be required:

• increase in cushion thickness,

• reduction of ram stroke,

• heavier ram with a shorter stroke,

• use of pilot holes or jetting when driving through hard or alternating hard and soft strata.

A. Tolerance for Driving. Drive piling to the required vertical or batter alignment, within the tolerances of this Section. Drive piling in pilot holes or with templates when necessary to comply with tolerances. Cut off piling reasonably square at the elevation shown on the plans, with a tolerance of not more than 2 inches above or below established cutoff grade. When tolerances are exceeded and the COR requires corrective action, submit for compliance-confirmation structural analysis and proposed corrective action, signed and sealed by a Texas-licensed professional engineer.

(1) Trestle Piling.

• Transverse to the centerline of the bent, the top of the piling may be at most 2 inches from the position shown on the plans.

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• Parallel to the centerline of the bent, the top of the piling may be at most 4 inches from the position shown on the plans.

(2) Foundation Piling.

• The top of each pile may be at most 4 inches in any direction from the position shown on the plans.

• The center of gravity of the piling group may be at most 3 inches from the center of gravity determined from plan location.

• The minimum edge distance for piling in a footing is 5 inches. Additional concrete required to obtain this edge distance and specified reinforcing steel cover will be at the Contractor’s expense.

B. Penetration. Piling lengths shown on the plans are the lengths estimated to give required bearing and are for estimating purposes only. Drive piling to within 5 feet of plan length and to greater depths as necessary to obtain the required bearing resistance shown on the plans, unless other penetration requirements or bearing evaluation methods govern. When test piling or test loaded piling is used, the COR will establish regular pile lengths on the basis of the test data. In these cases, drive regular piling to this approximate elevation and to greater depths as required to obtain the required bearing resistance. For unusually hard driving conditions, typically less than 0.1-inch of penetration per blow, provide either pilot holes or jetting or a combination of both if plan penetration is not obtained. Penetration may be reduced upon compliance-confirmation if stability requirements are met.

C. Pilot Holes. Except as specified, do not extend pilot holes more than 5 feet below the bottom of footings for foundation piling or 10 feet below finished ground line for trestle piling, unless the specified penetration cannot be obtained by using the depth of holes indicated. When deeper pilot holes are required, determine their size and depth from the results of trial operations on the first piling driven or from available test pile data. Obtain compliance-confirmation for any excess depth or size of pilot holes. The maximum hole diameter permitted will be approximately 4 inches less than the diagonal of square piling or steel H-piling and 1 inch less than the diameter of round piling. The COR may vary hole size and depth to obtain penetration and bearing resistance.

Extend pilot holes through all embankments to natural ground when driving concrete piling.

Where a pilot hole is required in granular material that cannot be sealed off by ordinary drilling methods, a casing may be required around the boring device deep enough to prevent loose material from falling into the pilot hole.

Drive the piling below the depth of the pilot hole a minimum of 1 foot or 100 blows but not less than the required bearing resistance shown on the plans. Do not drive piling beyond the point where the penetration per blow is less than 0.1-inch as determined by an average of 10 blows. If damage to the pile is apparent, stop driving.

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D. Jetting. Jetting is permitted when the specified penetration cannot be obtained by driving and pilot holes or other methods are not feasible. Before jetting, submit details of the proposed methods for compliance-confirmation. The COR may compliance-confirm varying depths of jetting to achieve the desired results.

Jet as required in conjunction with driving but only to the compliance-confirmed depth. For jetting operations, use enough power to simultaneously operate at least two 2-1/2-inch diameter pipes equipped with 3/4-inch nozzles at a pressure of 150 psi. Perform the jetting with 1 or 2 jets as determined and compliance-confirmed from results of trial operations.

Drive the piling below the depth of the jetting a minimum of 1 foot or 100 blows but not less than the required bearing resistance shown on the plans. Do not drive piling beyond the point where the penetration per blow is less than 0.1-inch as determined by an average of 10 blows. If damage to the pile is apparent, stop driving.

E. Hammer Formula Method of Bearing Evaluation. Unless otherwise shown on the plans, determine the dynamic bearing resistance of piling by one of the hammer formulas in this Section.

If the COR has determined a K factor based on test piling, test-loaded piling, or other methods, the computed resistance will be the driving resistance determined based on the appropriate formula multiplied by the K factor.

(1) Single-Acting Power Hammers. Use the following formula:

=P 1.0

+S

WH

where:

P = dynamic resistance in pounds.

W = weight of ram in pounds.

H = height of fall of ram in feet.

S = average penetration in inches per blow for the last 20 blows.

Determine H by visual observation of the ram against a calibrated rod mounted on the hammer, by an compliance-confirmed stroke indicator and blow count logging device, or by the following formula:

3.0301.16

B H where B = blows per minute.

(2) Double-Acting Power Hammers. Use the following formula:

=P 1.0

+S E

Rehabilitation of Hidalgo Protective Levee (Modified Phases I and II) and Banker Floodway South Levee

USIBWC Contract No.: IBM09B0003 Page 60.04.00 - 7 where:

P = dynamic resistance in pounds E = manufacturer’s rated energy in foot-pounds (for double-acting power hammers), or the equivalent energy in foot-pounds determined by a calibrated gauge attached to the hammer and taken when the average penetration in inches per blow is determined (for enclosed ram diesel hammer) S = average penetration in inches per blow for the last 20 blows.

F. Wave Equation Method of Bearing Evaluation. When the plans specify that the bearing capacity of the piling be determined by the wave equation method, submit the following data:

• manufacturer’s specification data for the hammer proposed for use, including all modifications and

• complete description and dimensions of all cushioning material used between the pile and helmet and in the cap block, including total thickness of each, and the direction of grain if wood is used.

These data are used by the COR to determine the required number of blows per unit of penetration the hammer must deliver to obtain the required bearing resistance.

After evaluation by the wave equation method, any change in the driving equipment may require reevaluation. Such changes must be compliance-confirmed before further driving.

G. Test Piling. Drive test piling at locations shown on the plans or as directed. In general, make test piling part of the completed work, cut off or built up to grade as necessary. Use the required bearing evaluation method to determine bearing resistance.

Initially drive test piling to 3 feet above plan tip elevation of the regular piling for the structure with the blow count recorded for each foot of driving (for example, drive test piling to 13 feet above its plan tip elevation if the test piling is 10 feet longer than regular piling). Retain the cushion if used.

At least 7 days after the original driving, re-drive the test piling the additional length required by the plans with the same hammer and cushion originally used. Record the blow count for each inch of driving for the first foot, for every 3 inches for the next 2 feet, and for each foot thereafter.

Provide the data to the COR for use in determining regular piling lengths and K factors. The K factor will be determined based on the following formula:

PPK R=

K = a static correction factor applied to the evaluation method PR = re-drive bearing (tons) of the test pile determined by the evaluation method

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P = original bearing (tons) of test pile determined by the evaluation method.

H. Test-Loaded Piling. The Contractor shall conduct test load in accordance with Item 405, “Foundation Test Load.” Provide the data to the CORfor use in determining regular piling lengths and K factors. The K factor will be determined based on the following formula:

PLK =

K = a static correction factor applied to the evaluation method L = maximum safe static load proven by test load P = bearing resistance of the test loaded pile determined by the evaluation method.

The work performed, materials furnished, equipment, labor, tools, and incidentals will not be paid for directly, but will be considered subsidiary to pertinent Items

Rehabilitation of Hidalgo Protective Levee (Modified Phases I and II) and Banker Floodway South Levee

FOUNDATION TEST LOAD

USIBWC Contract No.: IBM09B0003 Page 60.05.00 - 1

SPECIFICATION 60 05 00

This specification includes requirements for the construction of Test-load piling within the Work area,

1.0 General

2.0 Materials & Equipment

The following may not include all related documents, contract clauses, & technical specifications, and does not relieve the Contractor of the responsibility of performing work associated with this specification

• SPECIFICATION 60 04 00, “Driving Pile”

• SPECIFICATION 60 07 00, “Steel Piling”

D. References:

• Texas Department of Transportation (TxDOT) Construction Bulletin C8, Pile Driving Manual

In general, the Contractor shall provide piling for test loading as shown on the plans.

2.1 MATERIALS <No Requirements Defined for this Specification.>

The Contractor shall furnish the jacking equipment, jacking beams, and displacement indicators.

The Contractor shall furnish and drive the piling to be test-loaded, and furnish necessary anchors; drive anchor and test piling in accordance with SPECIFICATION 60 04 00, “Driving Pile.”

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Keep a complete record of pile-driving data for all foundations used in the test load. Apply the test load no earlier than the seventh day after driving the test piling.

Construct a shelter to protect the test load equipment from weather and direct sunlight, and furnish incidentals necessary for the handling, transportation, and installation of the complete test load setup.

Apply incremental static loads to the pile and measure the resulting settlement. Apply loads by a hydraulic jack acting against suitable anchorage, transmitting the load directly to the pile. Carry all test loads to failure of the test pile.

Load and record data in accordance with TxDOT Construction Bulletin C 8, Pile Driving Manual, “Test Loading Piling.” Provide the data to the COR for evaluation.

After completing the test, dismantle the test setup.

Upon completion of the test load, remove piling that are not part of the structure, or cut off at least 1 foot below the bottom of the footing or the finished grade. If permanent piling is raised during the test load, re-drive it to its original grade and bearing.

The Work performed by the Contractor under this Specification shall not be paid for directly, but shall be considered subsidiary to SPECIFICATION 60 07 00 “Steel Piling” under this Contract

Rehabilitation of Hidalgo Protective Levee (Modified Phases I and II) and Banker Floodway South Levee

STEEL PILING

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SPECIFICATION 60 07 00

This specification includes requirements for the construction of steel piling within the Work area, and includes the following:

1.0 General

2.0 Materials & Equipment

The following may not include all related documents, contract clauses, & technical specifications, and does not relieve the Contractor of the responsibility of performing work associated with this specification

• SPECIFICATION 60 04 00, “Driving Pile”

• SPECIFICATION 60 05 00, “Foundation Test Load”

• SPECIFICATION 60 41 00, “Steel Structures”

• SPECIFICATION 60 46 00, “Cleaning and Painting Steel”

• SPECIFICATION 60 48 00, “Structural Field Welding”

• ASTM A27 / A27M - 08 Standard Specification for Steel Castings, Carbon, for General Application

• ASTM A148 / A148M - 08 Standard Specification for Steel Castings, High Strength, for Structural Purposes

• ASTM A328 / A328M - 07 Standard Specification for Steel Sheet Piling

• ASTM A572 / A572M - 07 Standard Specification for High-Strength Low-Alloy Columbium-Vanadium Structural Steel

• ASTM A588 / A588M - 05 Standard Specification for High-Strength Low-Alloy Structural Steel, up to 50 ksi [345 MPa] Minimum Yield Point, with Atmospheric Corrosion Resistance

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In general, the Contractor shall place steel H piling and/or sheet piling, as indicated in the plans.

2.1 MATERIALS

The Contractor shall furnish steel H piling and steel sheet piling in accordance with SPECIFICATION 60 41 00, “Steel Structures,” and details shown on the plans. For H piling, furnish steel that meets ASTM A 572 Grade 50 or ASTM A 588. For hot-rolled sheet piling, furnish steel that meets ASTM A 328 or ASTM A 572 Grade 50. For cold-rolled sheet piling, furnish steel that meets ASTM A 572 Grade 50.

Steel sheet piling may be substituted with a section modulus and minimum thickness of material equal to or greater than that of the section specified. If a hot-rolled section is specified, the substitute section must also be hot-rolled. Furnish piling in the lengths indicated on the plans. Where test piling is required, the COR will compliance-confirm lengths based on test driving data or test load data. Do not fabricate piling until the COR has determined the compliance-confirmed lengths. The piling may need to be fabricated by cutting and welding together up to 3 sections of piling with a minimum section length of 5 feet.

Unless otherwise shown on the plans, shop-paint piling as needed with 3.0 mils minimum dry film thickness (DFT) inorganic zinc primer in accordance with the System III or IV paint protection system specified in SPECIFICATION 60 46 00, “Cleaning and Painting Steel.” Do not apply appearance or intermediate coatings unless specified on the plans. Paint the portion of the pile to be above ground, in water, and a minimum distance of 10 feet below ground based on the ground line shown in the plans.

Reinforce steel H pile tips when the piling is to be driven into rock, shale, or other material of similar hardness. Use the pile tip reinforcement detail shown in Figure 1 or attach prefabricated pile points manufactured from ASTM A 27 Grade 65 35 or ASTM A 148 Grade 80 50 material. Furnish certification that materials conform to this requirement. Store piling above ground on adequate blocking.

Keep piling clean and fully drained at all times during storage.

Figure 1 Pile tip reinforcement.

2.2 EQUIPMENT <No Requirements Defined for this Specification.>

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Drive piling in accordance with SPECIFICATION 60 04 00, “Driving Piling.” Test-load, when required, in accordance with SPECIFICATION 60 05 00, “Foundation Test Load.”

A. Splices and Cutoffs. Make all splices for steel H piling in accordance with Figure 2. If the required penetration or bearing resistance has not been obtained, drive spliced piling the additional depth required as soon as the splice is completed. After driving the piling to the approximate penetration and bearing resistance required, cut it off square at plan grade or to the established grade. If the head of the pile is appreciably distorted or otherwise damaged below cutoff level, cut off the damaged portion and splice an undamaged section in its place, at no additional expense to the Government. Prepare sheet pile splices similar to the details shown for H piling. Do not interfere with the interlocks. Weld in accordance with SPECIFICATION 60 48 00, “Structural Field Welding.”

Figure 2 Steel piling splice detail.

B. Painting. Apply paint in accordance with SPECIFICATION 60 46 00, “Cleaning and Painting Steel.” After driving piling, clean and paint damaged areas, field splices, or areas missing the shop coat with enough epoxy zinc primer to bring the total zinc primer to the minimum 3.0 mils DFT. When a polyurethane appearance coating is specified on the plans, apply at least 2.0 mils DFT each of the System III epoxy intermediate coating and appearance coating. When an acrylic latex appearance coating is specified on the plans, apply at least 2.0 mils DFT of the System IV appearance coating. Use a concrete gray appearance coating unless shown otherwise on the plans. Extend the paint 1 foot. below finished ground line unless the piling is standing in water, in which case extend the paint to the low water line. Replace any earth removed for this painting after the paint has dried.

C. Test Piling. Test piling must meet requirements for steel piling. The COR may adjust the number of test piling to secure desired information

A. Steel H Piling – Not required as a Bid Item for this Project.

B. Steel Sheet Piling. Steel sheet piling will be measured by the square foot of acceptable piling in

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USIBWC Contract No.: IBM09B0003 Page 60.07.00 - 4 place. Sheet piling driven below the elevation required by the plans or the elevation shown in the plans will not be measured for payment.

4.2 PAYMENT

No direct payment will be made for painting or excavation and backfill required for the painting of portions of piling below ground line. Payment for all work and materials required by these items will be included in the unit price bid for “Steel Pile”. The price bid is full compensation for jetting, pilot holes, test piling, alignment holes, driving piling, painting, materials, tools, equipment, labor, and incidentals.

A. Steel H Piling. – Not required as a Bid Item for this Project.

B. Steel Sheet Piling. Steel sheet piling will be paid for at the unit price bid per square foot for “Sheet Pile (Temp)” and “Sheet Pile (type specified)” as shown on the plans. No payment will be made for cutoffs or splices of sheet piling, except otherwise noted.

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EXCAVATION AND BACKFILL FOR STRUCTURES

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SPECIFICATION 60 10 00

This specification includes requirements for the excavation and backfill of structures within the Work area, and includes the following:

1.0 General

2.0 Materials & Equipment

The following may not include all related documents, contract clauses, & technical specifications, and does not relieve the Contractor of the responsibility of performing work associated with this specification

• SPECIFICATION 60 20 00, “Concrete Structures”

• SPECIFICATION 60 21 00, “Hydraulic Cement Concrete”

• American Association of State Highway and Transportation Officials (AASHTO) Standard Specifications for Highway Bridges, 17th Edition

• Texas Department of Transportation Department Material Specification (DMS)-4600 Hydraulic Cement, March 2009

• Texas Department of Transportation Testing Standard (Tex)-120-E Soil-Cement Testing, August 1999

• 2003 Texas Manual on Uniform Traffic Control Devices

1.2 GENERAL

In general, the Contractor shall excavate for placement and construction of structures and backfill structures; and cut and restore pavement.

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The Contractor shall use materials that meet the requirements of the following:

• DMS-4600, “Hydraulic Cement.”

2.2 EQUIPMENT (No Requirements Defined for this Specification)

3.1 EXCAVATION

A. General. The Contractor shall excavate to the lines and grades shown on the plans; provide slopes, benching, sheeting, bracing, pumping, and bailing as necessary to maintain the stability and safety of excavations up to five (5) feet. Excavation protection for excavations deeper than five (5) feet will require trench protection and / or safety shoring. The Contractor shall use satisfactory excavated material as backfill or as embankment as required by the plans; dispose of material not incorporated into the final project off the right of way in accordance with federal, state, and local regulations. When excavating for installation of structures across private property or beyond the limits of the embankment, keep any topsoil removed separate, and replace it, as nearly as feasible, in its original position. Restore the area to an acceptable condition.

(1) Obstructions. The Contractor shall remove obstructions to the proposed construction, including trees and other vegetation, debris, and structures, over the width of the excavation to a depth of one (1)-foot below the bottom of excavation. If abandoned storm drains, sewers, or other drainage systems are encountered, remove as required to clear the new structure, and plug in a compliance-confirmed manner. After removing obstructions, restore the bottom of the excavation to grade by backfilling in accordance with this Item.

Dispose of surplus materials in accordance with federal, state, and local regulations.

(2) Excavation in Streets. When structures are installed in streets, highways, or other paved areas, cut pavement and base to neat lines. Restore pavement structure after completion of excavation and backfilling.

(3) Maintain and control traffic in accordance with the compliance-confirmed traffic control plan and the Texas Manual on Traffic Control Devices.

(4) Utilities. The Contractor shall conduct work with minimum disturbance of existing utilities, and coordinate work in or near utilities with the utility owners. Inform utility owners sufficiently before work begins to allow them time to identify, locate, reroute, or make other adjustments to utility lines.

(5) Avoid cutting or damaging underground utility lines that are to remain in place. If damage occurs, promptly notify the utility company. If an active sanitary sewer line is damaged during excavation, provide temporary flumes across the excavation while open, and restore the lines when backfilling has progressed to the original bedding lines of the cut sewer.

(6) De-Watering. Do not construct or place structures in the presence of water unless compliance-confirmed. Place pre-cast members, pipe, and concrete only on a dry, firm surface. Remove water by bailing, pumping, well-point installation, deep wells, Rehabilitation of Hidalgo Protective Levee (Modified Phases I and II) and Banker Floodway South Levee

USIBWC Contract No.: IBM09B0003Page 60.10.00 - 3 underdrains, or other compliance-confirmed method.

(7) If structures are compliance-confirmed for placement in the presence of water, remove standing water in a manner that does not allow water movement through or alongside concrete being placed. Do not pump or bail while placing structural concrete or for a period of at least thirty-six (36) hours thereafter unless from a suitable sump separated from the concrete work. Pump or bail during placement of seal concrete only to the extent necessary to maintain a static head of water within the cofferdam. Do not pump or bail to de-water inside a sealed cofferdam until the seal has aged at least thirty-six (36) hours.

(8) If the bottom of an excavation cannot be de-watered to the point that the subgrade is free of mud or it is difficult to keep reinforcing steel clean, place a stabilizing material in the bottom of the excavation. Stabilizing material may be flexible base, cement-stabilized base or backfill, lean concrete, or other compliance-confirmed material. If lean concrete is used, provide concrete with at least two hundred seventy-five (275) pounds of cement per cubic yard, and place to a minimum depth of three (3) inches stabilizing material placed for the convenience of the Contractor will be at the Contractor’s expense.

B. Bridge Foundations and Retaining Walls. Do not disturb material below the bottom of footing grade. Do not backfill to compensate for excavation that has extended below grade. If excavation occurs below the proposed footing grade, fill the area with concrete at the time the footing is placed. The additional concrete placed will be at the Contractor’s expense. If requested, take cores to determine the character of the supporting materials. Provide an intact sample adequate to judge the character of the founding material. Take these cores when the excavation is close to completion. Cores should be approximately five (5) feet deeper than the proposed founding grade. If the founding stratum is rock or other hard material, remove loose material, clean, and cut to a firm surface that is level, stepped, or serrated. Clean out soft seams, and fill with concrete at the time the footing is placed. If the material at the footing grade of a retaining wall, bridge bent, or pier is a mixture of compressible and incompressible material, do not place the foundation until the Government has inspected the excavation and authorized changes have been made to provide a uniform bearing condition.

C. Cofferdams. The term “cofferdam” designates any temporary or removable structure constructed to hold surrounding earth, water, or both out of the excavation whether the structure is formed of soil, timber, steel, concrete, or a combination of these. Cofferdams may require the use of pumping wells or well points for dewatering. For sheet-pile or other types of cofferdams requiring structural members, submit details and design calculations bearing the seal of a licensed professional engineer for review before constructing the cofferdam. The Government reserves the right to reject designs. Design structural systems to comply with the AASHTO Standard Specifications for Highway Bridges or AASHTO LRFD Bridge Design Specifications. Interior dimensions of cofferdams must provide sufficient clearance for the construction, inspection, and removal of required forms and, if necessary, sufficient room to allow pumping outside the forms.

In general, extend sheet-pile cofferdams well below the bottom of the footings, and make concrete seals as well braced and watertight as practicable. For foundation seals, use Class E concrete unless otherwise specified. Place concrete foundation seals in accordance with SPECIFICATION 60 20 00, “Concrete Structures.” Seals placed for the convenience of the Contractor will be at the Contractor’s expense. When the Government judges it to be impractical

Rehabilitation of Hidalgo Protective Levee (Modified Phases I and II) and Banker Floodway South Levee

USIBWC Contract No.: IBM09B0003Page 60.10.00 - 4 to de-water inside a cofferdam and a concrete seal is to be placed around piling driven within the cofferdam, make the excavation deep enough to allow for swelling of the material at the base of the excavation during pile-driving operations. After driving the piling, remove swelling material to the bottom of the seal grade. Where it is possible to dewater inside the cofferdam without placing a seal, remove the foundation material to exact footing grades after driving piling. Do not backfill a foundation to compensate for excavation that has been extended below grade; fill such areas below grade with concrete at the time the seals or footings are placed. Unless otherwise provided, remove cofferdams after completing the substructure without disturbing or damaging the structure.

D. Culverts and Storm Drains. When the design requires special bedding conditions for culverts or storm drains, an excavation diagram should be shown on the plans. Do not exceed these limits of excavation. Unless otherwise shown on the plans, construct pipe structures in an open cut with vertical sides extending to a point one (1)-foot above the pipe. When site conditions or the plans do not prohibit sloping the cut, the excavation may be stepped or laid back to a stable slope beginning one (1)-foot above the pipe. Maintain the stability of the excavation throughout the construction period. For pipe to be installed in fill above natural ground, construct the embankment to an elevation at least one (1)-foot above the top of the pipe, and then excavate for the pipe.

(1) Unstable Material. When unstable soil is encountered at established footing grade, remove the material to a depth of no more than two (2) feet below the grade of the structure unless the Government authorizes additional depth. Replace soil removed with stable material in uniform layers at most eight (8) inches deep (loose measurement). Each layer must have enough moisture to be compacted by rolling or tamping as required to provide a stable foundation for the structure.

(2) When it is not feasible to construct a stable foundation as outlined above, use special materials such as flexible base, cement-stabilized base, cement-stabilized backfill, or other compliance-confirmed material.

(3) Incompressible Material. If rock, part rock, or other incompressible material is encountered at established footing grade while placing prefabricated elements, remove the incompressible material to six (6) inches below the footing grade, backfill with a compliance-confirmed compressible material, and compact in accordance with “Backfill” herein.

3.2 SHAPING AND BEDDING

For precast box sections, the Contractor shall place at least two (2) inches of fine granular material on the base of the excavation before placing the box sections. For pipe installations, the Contractor shall use bedding as shown in Figure 1; use Class C bedding unless otherwise shown on the plans. The Government may require the use of a template to secure reasonably accurate shaping of the foundation material. Where cement-stabilized backfill is indicated on the plans, undercut the excavation at least four

(4) inches and backfill with stabilized material to support the pipe or box at the required grade.

3.3 BACKFILL

Rehabilitation of Hidalgo Protective Levee (Modified Phases I and II) and Banker Floodway South Levee

USIBWC Contract No.: IBM09B0003Page 60.10.00 - 5

A. General. As soon as practical, the Contractor shall backfill the excavation after placement of the permanent structure; use backfill free from stones large enough to interfere with compaction, large or frozen lumps that will not break down readily under compaction, and wood or other extraneous material; obtain backfill material from excavation or from other sources. In areas not supporting a completed roadbed, retaining wall, or embankment, the Contractor shall place backfill in layers at most ten (10) inches deep (loose measurement). In areas supporting a portion of a roadbed, retaining wall, or embankment, the Contractor shall place backfill in uniform layers at most eight (8) inches deep (loose measurement); compact each layer to meet the density requirements of the roadbed, retaining wall, embankment material, or as shown on the plans;

bring each layer of backfill material to the moisture content needed to obtain the required density;

use mechanical tamps or rammers to compact the backfill. Rollers may be used to compact backfill if feasible. Cohesionless materials such as sand may be used for backfilling. Compact cohesionless materials using vibratory equipment, water-ponding, or a combination of both.

B. Manholes. Do not place backfill against the structure until the concrete has reached the design strength required in SPECIFICATION 60 21 00, “Hydraulic Cement Concrete.” Rock or gravel mixed with soil may be used if the percentage of fines is sufficient to fill all voids and ensure a uniform and thoroughly compacted mass of proper density. Where backfill material is being placed too close to the structure to permit compaction with blading and rolling equipment, use mechanical tamps and rammers to avoid damage to the structure. Avoid wedging action of backfill against structures. To prevent such action, step or serrate slopes bounding the excavation. Place backfill uniformly around bridge foundations. Place backfill along both sides of culverts equally and in uniform layers. The Government may require backfilling of structures excavated into hard, erosion-resistant material, and subject to erosive forces, with stone or lean concrete.

C. Pipe. After installing bedding and pipe as required, the Contractor shall bring backfill material to the proper moisture condition and place it equally along both sides of the pipe in uniform layers at most eight (8) inches deep (loose measurement); compact each lift mechanically. The Contractor shall thoroughly compact materials placed under the haunches of the pipe to prevent damage or displacement of the pipe; continue to place backfill in this manner to the top-of-pipe elevation;

place and compact backfill above the top of the pipe in accordance with “General” herein. The Government may reject backfill material containing more than twenty percent (20%) by weight of material retained on a three (3)-inch sieve; with large lumps not easily broken down; or that cannot be spread in loose layers. Material excavated by a trenching machine will generally meet the requirements of this Part as long as large stones are not present. Where pipe extends beyond the toe of slope of the embankment and the depth of cover provided by backfill to the original ground level is less than the minimum required by the specifications for the type of pipe involved, place and compact additional material until the minimum cover has been provided.

D. Cement-Stabilized Backfill. When shown on the plans, the Contractor shall backfill the excavation to the elevations shown with cement-stabilized backfill. Use cement-stabilized backfill that contains aggregate, water, and a minimum of seven percent (7%) hydraulic cement based on the dry weight of the aggregate, in accordance with Tex-120-E; use clean sand as

Rehabilitation of Hidalgo Protective Levee (Modified Phases I and II) and Banker Floodway South Levee

USIBWC Contract No.: IBM09B0003Page 60.10.00 - 6 aggregate for cement-stabilized backfill unless otherwise shown on the plans; use only compliance-confirmed aggregate; place cement-stabilized backfill equally along the sides of structures to prevent strain on or displacement of the structure; fill voids when placing cement-stabilized backfill; use hand operated tampers if necessary to fill voids.

E. Flowable Backfill. When shown on the plans, the Contractor shall backfill the excavation with flowable backfill to the elevations shown; prevent the structure from being displaced during the placement of the flowable fill, and prevent flowable fill from entering culverts and drainage structures.

3.4 EXCAVATION / BACKFILL FOR FLOODWALL TIE-IN TO EARTHEN LEVEE

In addition to the requirements included herein, special attention is directed to the tie-in of the floodwall to the earthen levee:

• All excavation into the existing levee on the west end of this project shall be limited to excavation for the new wall structure and shoring protection.

• Back fill of the existing levee shall consist of a cement stabilized backfill. The amount of cement shall be 3 percent (3%) by weight.

• Place cement stabilized back fill equally along the sides of the structures to prevent strain on or displacement of the structure. Fill voids when placing cement stabilized backfill. Use hand operated tampers if necessary to fill voids.

Unless shown on the plans as a pay item, structural excavation quantities shown are for information purposes only. When structural excavation is specified as a pay item, structural excavation for pipe headwalls, inlets, manholes, culvert or storm drain extensions less than fifteen (15) feet long, bridge abutments, retaining walls, and side road and private entrance pipe culverts will not be measured. No allowance will be made for variance from plans quantity incurred by an alternate bid. When specified as a pay item, structural excavation will be measured by the cubic yard as computed by the average end areas method. Excavation diagrams on the plans take precedence over the provisions of this Part.

4.2 PAYMENT

The Work performed by the…