IFC Specs 170331.pdf

US Forest Service – Hells

Canyon Creek Visitor Center Boating Facility Repairs

Final Technical Specifications

Prepared For: USDA Forest Service

Prepared By: River Structures Consulting, LLC and Matrix Engineering, Inc

March 31, 2017

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USFS – HELLS CANYON CREEK BOATING FACILITY REPAIRS MARCH 31, 2017

BOAT LAUNCH UNDERPINNING AND RIPRAP PAGE 1

Section 901. – BOAT LAUNCH UNDERPINNING AND RIPRAP

Description

901.01 This work consists of furnishing, placing, and finishing grout bags and grout underpinning for the concrete boat launch and apron at the Hells Canyon Creek Visitor’s Center.

Material

901.02 Conform to the following subsections

Air-entraining Admixture 711.02

Chemical admixtures 711.03 Coarse aggregate 703.02 Fine aggregate 703.01 Fly ash 725.04 Hydraulic cement 701.01 Water 725.01

901.03 Grout Submittals. Before batching grout, submit the proposed mix proportions for approval. As a minimum, submit the following:

(a) Type and source(s) of all material proposed for use.

(b) Material certification for all material proposed for use.

(c) Saturated surface dry mass of the fine and coarse aggregate per cubic yard of grout.

(d) Gradation of fine and coarse aggregate.

(e) Mass of mixing water per cubic yard of concrete.

(f) Mass of cement per cubic yard of concrete. Fly ash or ground iron blast-furnace slag may be substituted for cement according to Subsection 552.03(g).

(g) Entrained air content of plastic grout in percent by volume.

(h) Maximum slump of plastic grout in inches.

901.04 Grout Composition. Grout shall meet the following requirements:

(a) Grout for grout bags and underpinning shall be composed of cement, fine aggregate, coarse aggregate (optional), water, and admixtures proportioned specifically for underwater placement with anti-washout admixtures. Grout shall also be formulated specific for pumping and used with the manufacturer’s grout bag system.

(b) Grout shall contain a minimum of 564 pounds of cement per cubic yard with a maximum water cement ratio of 0.45.

(c) Grout air content shall be 5-8%.

(d) Minimum compressive strength of grout at 28 days shall be 3,000 psi.

(e) Grout shall include an anti-washout admixture when placed underwater. Anti-washout admixture shall be MasterMatrix UW 450 by BASF, Eucon AWA by The Euclid Chemical Company, or approved equal. Admixture shall be used in accordance with the manufacturer’s recommendations.

(f) At the Contractor’s option, coarse aggregate may be used provided that the mix design is suitable for pumping and the proposed application. If used, coarse aggregate shall be graded as follows:

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Table 901-1

Grout Coarse Aggregate Gradation

U.S. Standard Sieve Size Percent By Weight Passing

1/2 in 100

3/8 in 90-100

No. 4 20-55

No. 8 5-30

No. 16 0-10

No. 30 0

901.05 Grout Bags. Grout bags shall meet the requirements in Table 901-2. Manufacturer’s grout bag information shall be submitted for approval.

Table 901-2 Grout Bag Specifications

Property Test Method Value

Composition High Tenacity Nylon

Weight ASTM D-5261 8 oz/yd^3 (Minimum)

Thickness ASTM D-5199 30 mils

Grab Tensile Strength ASTM D-4632 Warp 510 lbs

Fill 520lbf

Grab Tensile Elongation ASTM D-4632 Warp 25%

Fill 25%

Apparent Opening Size (AOS) ASTM D-4751 60 (U.S. Standard)

901.06 Turbidity Curtain.

Turbidity curtains shall be Type III, designed for moving water and moderate wind and wave action. The curtain shall be adequately anchored to prevent damage during the anticipated work and site conditions.

The Contractor shall submit fabric grout bag material specifications and the required material certification for review and approval.

The turbidity curtain shall meet the requirements in Table 901-3.

BOAT LAUNCH UNDERPINNING AND RIPRAP PAGE 3

Table 901-3 Turbidity Curtain Specifications

Property Minimum Value

Fabric 22 oz PVC

Floatation 12” Foam Filled Floats

Tension Cable Dual 5/16” or 3/8” Galvanized Steel Cable

Bottom Ballast Chain 5/16” Galvanized Steel Chain

Construction Requirements

901.07 Turbidity Curtain Installation

The turbidity curtain shall be installed prior to commencing any in-water work.

The turbidity curtain shall be attached to the river bank and bed as necessary to provide a protected working area around the boat launch.

Dewatering of the installation area is not required.

Turbidity Curtain shall be kept in place one full day after the work has been completed.

901.08 Grout Bag Installation

Immediately following receipt of fabric on the job site, fabric bags shall be inspected and stored in a clean, dry area where they will not be subject to mechanical damage or exposure to moisture or direct sunlight. Fabric allowed to become wet and then dried before installation will be subject to shrinkage.

The area specified for grout bag installation shall be cleared of all sticks, loose debris, and sharp objects.

Hand-placed fabric bags filled with grout shall be packed into the undermined location(s) identified on the Plans.

Pump filled fabric grout bags shall be placed over the existing stream bed or prepared locations indicated in the Plans. Hand shovel work may be required to prepare the designated location for grout bag installation. Grout bag placement area shall be prepared to provide uniform bearing for the filled grout bags without tearing or excessive deformation around existing boulders or debris.

Grout injection ports shall be installed facing upward. The grout pump shall be capable of delivering 10 gal/min.

Place one grout bag at a time and fill before moving on to the next grout bag location. Grout bags should be snugly butted up against the void and each other to minimize any gaps.

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The Contractor shall follow the manufacturer’s recommendations for the specific fabric grout bag material approved. If material specifications and installation requirements differ between the manufacturer and the Contract Documents, they shall be brought to the attention of the Contracting Officer for review and concurrence prior to installation.

901.09 Grout Installation

Grout tremie tubes shall be installed between the grout bags and the existing concrete prior to filling grout bags. Grout tubes shall extend into the void beneath the existing concrete and behind the furthest extent of the grout bags to allow grouting of voids after the grout bags have been filled. Grout tubes shall extend a minimum of 12-inches above the maximum anticipated water surface elevation during the underwater grouting work. The contractor shall contact the Idaho Power Company to determine predicted flows during the proposed work period.

Underpinning grout shall not be placed until the grout bags have been in place for a minimum of 48 hours.

Underpinning grout shall be placed using the grout tremie tubes and as shown in the Contract Documents. Grout shall be placed until it begins to appear in the core holes in the existing concrete. Any excess grout protruding from the top of the core holes shall be struck off flush with the existing concrete to provide a uniform concrete surface after the grouting is complete.

Any core holes which are not completely filled with grout after grouting shall be patched and filled with an underwater repair mortar. The Contractor shall propose the type of mortar and procedures to be used to fill the core holes for approval prior to ordering materials. Patching or filling of core holes shall be considered as incidental to the work.

After the grout has hardened the grout tubes shall be cut off flush with the top of the adjacent concrete or grout bags.

901.10 Riprap

Riprap shall conform to Section 251 of the Standard Specifications for Construction of Roads and Bridges on Federal Highway Projects, except as noted in this specification.

After the grout has been placed and cured for a minimum of 7 days, the Contractor shall furnish and install the size and quantity of riprap specified in the contract documents. Riprap shall be placed on the existing stream bed. Specific surface preparation and geotextile is not required for riprap placed around the boat launch.

The riprap shall be placed to the approximate limits shown on the Plans. If the volume of riprap specified in the contract documents does not reach the extents shown on the drawings, it shall be placed uniformly around the boat ramp and apron. It will not be acceptable to place a disproportionate quantity of riprap in one location if it does not provide an equivalent volume in other locations.

The riprap placed at the end of the boat ramp and apron shall be placed level or sloping downward from the ramp to prevent damage to boats when loading or unloading at low water. It will not be acceptable to place the riprap in a manner which leaves ridges or humps around the boat launch.

If heavy equipment is used to install riprap from the concrete boat ramp or apron, the Contractor shall take measures to prevent damage to the concrete boat ramp surface. The Contractor shall submit the proposed method of protecting the existing boat ramp and apron prior to furnishing

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the riprap. Any damage to the concrete, including breaking the existing concrete texture, shall be approved at no additional cost to the Forest Service.

The Contractor shall meet all of the requirements of the 404 permit, other project permits, and all applicable laws and regulations during the placement of the riprap. Any questions regarding permitting requirements or limitations shall be directed to the Forest Service prior to performing the work.

Measurement

901.11 Measure the Section 901 items listed in the bid schedule according to Subsection

109.02 and the following as applicable.

If grout is delivered from a batch plant, measure grout by the cubic yard as documented on delivery batch tickets. The quantity of grout remaining in the truck after the placement is completed will be estimated by the Contractor and the USFS Representative and will be paid at 50% of the bid price.

If grout is mixed on-site, the quantity will be measured based on the number of sacks of cement used and the yield of the approved mix design.

Measure the grout bags by the number of bags used in the structure.

Riprap will be measured by the Ton based on scale tickets to be provided with each truck delivered to the Site.

Payment

901.12 The accepted quantities will be paid at the contract price per unit of measurement for the Section 901 pay items listed in the bid schedule. Payment will be full compensation for the work prescribed in this Section. See Subsection 109.05.

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RAIL AND TROLLEY REPAIR PAGE 1

Section 902. – RAIL AND TROLLEY REPAIR

902.01 This work consists of repairing the boat dock trolley and guide rail system. Repairs include straightening bent or damaged members, replacing individual members, and servicing pulleys and trolley wheels.

Materials

902.02 Conform to the following Sections and Subsections:

Structural Shapes 717.01 Structural Bolts 717.01(d) Welding AWS D1.1

902.03 General. Fabricate structural steel in accordance with the AISC Steel Construction Manual.

Perform welding according to the provisions of ANSI/AWS D1.1 Structural Welding Code – Steel.

902.04 Soil Removal. Remove soils from over and around the steel trolley rails and support framing. Soils shall be removed from between the trolley rails and the access stairway. Some of the soils to be removed may be submerged in shallow water. The intent is not to require divers for the soil removal, but to remove the soils manually at low water and in shallow water as required. Soils shall be removed and deposited on the river bank beside the steel structure at a location specified by the USFS Representative.

Utilize BMP’s as required to meet all contractual and legal requirements for the soil removal.

902.05 Rail Repair. Straighten and repair the W10 trolley rails.

The trolley rails shall be straightened to the following criteria:

(a) Rails shall be straightened to the extent that all of the horizontal and diagonal bracing is straight without any buckling or sign of distress.

(b) Rails shall be straightened to the extent that the trolley travels the full extent of the rails without binding or rubbing on the face of the beams.

Repair the bent sections of the rail top flange (one location on each rail). Bent flanges may be repaired by heating and bending the flange back into its original orientation, or it may be removed and replaced by cutting out the damaged portion of the flange and welding in a new piece with full penetration welds. If replacement by welding is selected all welding, including weld preparation and testing, shall meet the requirements if AWS D1.1.

RAIL AND TROLLEY REPAIR PAGE 2

902.06 Member Replacement. Remove and dispose of the damaged diagonal member shown in the drawings.

Replace the removed member with a new member matching the size, shape, orientation, and connection of the adjacent similar members. Field verify the size and connection details prior to ordering materials.

902.07 Trolley Wheel Maintenance. To the extent feasible by unbolting, the trolley wheels shall be removed, cleaned, and reassembled.

If the wheels are confined within the welded framework of the trolley wheel assembly, it is not necessary to cut and reweld the wheel support structure. In this case the wheel shall be cleaned and serviced in-place to the extent feasible.

After servicing, the trolley shall travel up and down the rails without binding or undue friction within the trolley wheel assemblies.

902.08 Trolley Pulley Rehabilitation. Remove, service, and reassemble the trolley counterweight cable pulleys. At the contractor’s option, the pulleys may be replaced and the old pulleys disposed of offsite.

902.09 Counterweight Re-Balancing. After the dock has been installed and attached to the existing trolley (see Section 903), the counterweight shall be rebalanced to ensure the dock and trolley travel along the trolley frame with variations in water surface elevation.

Measurement

902.10 Measure the Section 902 items listed in the bid schedule according to Subsection

109.02 and the following as applicable.

902.11 The accepted quantities will be paid at the contract price per unit of measurement for the Section 902 pay items listed in the bid schedule. Payment will be full compensation for the work

FURNISH AND INSTALL DOCK PAGE 1

Section 903. – FURNISH AND INSTALL DOCK

903.01 This work consists of furnishing and installing a new floating dock in accordance with the Plans and this specification. The dock shall be constructed from a structural steel, and shall be galvanized after fabrication. The completed dock shall be installed at the Site and include all hardware and components required for a fully functional dock.

Contractor shall provide the shop drawings and fabrication details for approval as part of the Work.

Materials

903.02 Materials shall conform to the following Sections and Subsections.

Steel Framing – Structural dock framing shall conform to ASTM A36. Structural dock framing shall be fabricated from steel angles, channels, plates, and rods as shown in the Plans. Structural dock framing shall be Hot Dipped Galvanized after fabrication.

Bolts – Bolts shall be ASTM A307 or A325 Hot Dipped Galvanized Steel fasteners for use in outdoor and marine applications. Bolts shall be no longer than necessary to meet minimum length requirements such that a minimum of two threads extend beyond the nut when the bolt is tightened. Each bolt shall have a standard galvanized flat washer under the bolt head and under the heavy hex nut.

Decking – Dock decking shall be pultruded fiberglass grating (minimum 60% open area) with an aggressive high traction grit or non-skid walking surface. Grating shall be Fibergrate Pultruded SI60 fabricated with ISOFR resin with an integrally applied grit traction surface as manufactured by Fibergrate Composite Structures Inc., or approved equal. Grating color shall be gray. Grating clips shall be Type 316 stainless steel. Clips shall be provided at 2’-0” on center maximum spacing (or closer if recommended by grating supplier). Grating shall be 100% edge supported. Grating shall be attached in accordance with the manufacturer’s recommendations using minimum ¼-inch stainless steel machine screws or USFS approved alternative. The attachment method shall allow removal and reinstallation of the grating from above the dock deck.

Fascia (Rub) Strip – Composite fascia shall be manufactured for outdoor use, including exposure to weathering, rainfall, and submergence in water. Composite fascia shall be ChoiceDek, solid composite boards, or approved equal. Fascia boards shall be stacked 2x8 and 2x6 (top & bottom) to completely cover the side of the dock deck and truss.

Fascia shall be located on the perimeter of all dock structures.

Fascia Fasteners –Fascia fasteners shall be suitable for use with composite board material and structural steel in an outdoor environment, including exposure to submerged and splash zone conditions. Fascia shall be attached using recessed or hidden fasteners which are corrosion resistant.

Dock Cleats – Dock cleats shall be 12-inch hot-dipped galvanized steel, hex head, as manufactured by Sea Dog, Henderson Marine Supply, or approved equal. The cleats may be installed on the dock in the field.

FURNISH AND INSTALL DOCK PAGE 2

Floatation Units – Floatation units shall consist of an outer encasement barrier constructed of 100% virgin grade linear low density polyethylene, black in color, with a minimum nominal wall thickness of 0.125-inches. Floatation material within the encasement barrier shall be 100% virgin grade polystyrene with a density of 0.8 to 0.941 g/cm^3. Floatation units shall be Eagle Floats manufactured by Hendenson Plastics, or approved equal.

903.03 Submittals. The Contractor shall furnish the following submittals for approval:

(a) Dock manufacturer’s qualifications in accordance with Section 903.04.

(b) Dock framing shop drawings in accordance with Section 903.05.

(c) Dock decking shop drawings in accordance with 903.05.

(d) Composite Fascia.

1) Manufacturer’s product data sheets.

2) Manufacturer’s installation instructions.

3) One 12-inch sample of each type and color of deck and fascia board proposed for the project.

(b) Dock cleat manufacturer’s data including the cleat size, material, and mounting details at a minimum.

903.04 Contractor Qualifications. The dock manufacturer shall be experienced in the design and fabrication of floating docks similar to the size and configuration of the dock shown in the Plans. The Contractor shall have fabricated a minimum of five (5) docks of similar size in the last three (3) years. Submit the dock manufacturer’s qualifications for approval prior to producing the shop drawings.

903.05 Shop Drawings. Develop and submit dock shop drawings for approval. Shop drawings shall include all of the member and connection details for the fabrication of the dock. The shop drawings shall include the methods to be used to ensure proper fit-up of the dock modules in the field. This may include shop pre-assembly, match drilling for connectors, or other techniques. A description of dock section fit-up considerations and details shall be incorporated into the shop drawing details for approval.

Shop drawings shall also include the type, location and spacing of the grating and cleats.

903.06 Dock Fabrication. Fabricate structural steel in accordance with the AISC Steel Construction Manual – “Specification for the Design, Fabrication, and Erection of Structural Steel for Buildings”, latest edition, plus all referenced code requirements. The dock frames shall be fabricated from galvanized steel shapes as shown on the drawings. Steel components in the structural dock frames shall be notched and fitted prior to welding. Overlapping in corners is not allowed.

Perform welding in accordance with the provisions of ANSI/AWS D1.1 Structural Welding Code

– Steel. Welding of steel dock truss shall be performed by welders certified in accordance with AWS D1.1. All welded connections shall use new material, clean and free of any contaminants.

All welded connections shall be smooth and free of sharp edges.

Structural steel shall be galvanized in accordance with ASTM A123 – Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products, and ASTM A780-01 – Standard Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings. Galvanizing shall occur after all fabrication has been completed. Welding through the galvanizing will not be allowed. Should

FURNISH AND INSTALL DOCK PAGE 3

any welding be required after galvanizing, remove galvanized surface to the base metal before welding. Repair removed galvanizing in accordance with ASTM procedures.

Dock framing shall be supported by floatation units. Each floatation unit shall be attached to the dock framing using a minimum of (6) 3/8-inch diameter self-threading bolts approved for submerged and splash zone use.

Decking shall be installed in accordance with the following requirements:

Grating shall be mechanically fastened with hold down clips to prevent siding. Each grating panel shall be fastened to each supporting structure using a minimum of four Type “M” style (or Type “FC-3” if appropriate) hold down clips. Use ¼” x 2¼” bolt/washer/nut for Type “M” clips, and ¼”-20 x 1 ½” bolt/washer/nut for Type “FC” clips.

Deck grating panels shall be installed in a manner to reduce the number of cuts and joints while maintaining the structural integrity of the panels. The grating may be cantilevered from the centerline of the last supporting structural element a maximum of 6-inches. Any cantilevered sections of grating must be held down with a minimum of two supports and have a minimum of three hold down clips at each interior support. The holes in the supporting structures shall be field drilled.

The decking grating shall cover the entire dock frame, and each panel shall fit tightly against the adjacent panel.

The dock surface shall include cleats along the perimeter of the dock where boat moorage could be reasonably expected. Cleats shall be provided at a maximum spacing of 10-feet between cleats and shall be located at a maximum of 2-feet from each corner.

Fascia shall be supported by structural framing and shall cover the entire side face of the dock so that there are no gaps between the fascia and dock framing. Fascia attachments shall provide support along both edges of the fascia to prevent warping, bending or twisting of the fascia. Fascia support fasteners shall be suitable for splash zone and underwater service.

903.07 Dock Shipping. Dock frames shall be fabricated to facilitate lifting and shipping of the dock sections to the Site. Additional lifting eyes or reinforced sections may be required for lifting and shipping, and shall be included on the shop drawings if required.

Schedule delivery to minimize long-term storage at the project site and to prevent overcrowding of construction spaces. Notify the Forest Service of Contractor’s delivery timeframe.

Deliver products to the project site in an undamaged condition, properly protected until installation. In the event of damage immediately make repairs and replacements, as approved by the Forest Service, at no additional cost to the Forest Service.

Docks temporarily placed in the river shall be floated and securely tied to avoid damage until permanent connections are made.

Use means necessary to protect the installed work of other trades.

903.08 Dock Installation. Dock installation shall include delivering and installing the dock sections in the river, field assembly of dock components, and the attachment of the dock to the existing trolley. The dock installation shall include all materials, components, and assembly required to provide a fully functional dock at the Site. See Section 902 for additional trolley repair requirements.

FURNISH AND INSTALL DOCK PAGE 4

Measurement

903.09 Measure the Section 903 items listed in the bid schedule according to Subsection 109.02.

903.10 The accepted quantities will be paid at the contract price per unit of measurement for the Section 903 pay items listed in the bid schedule. Payment will be full compensation for the work