P-678 Dry Dock 8 Saltwater System BOD Final Submittal 01182022.pdf

P-678 DRY DOCK 8 SALTWATER SYSTEM FOR CVN-78

NORFOLK NAVAL SHIPYARD, PORTSMOUTH, VIRGINIA

BASIS OF DESIGN

FINAL SUBMITTAL

NAVAL FACILITIES ENGINEERING SYSTEMS COMMAND MIDLANT

eProject Number: 1364315

18 January 2021

P-678 DRY DOCK 8

SALTWATER SYSTEM

BASIS OF DESIGN

FINAL SUBMITTAL

Prepared for

NAVFAC MIDLANT

NORFOLK, VA

Contract No. N40085-18-D-1100 eProject #1364315

18 January 2022

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Basis of Design Final Submittal Table of Contents

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TABLE OF CONTENTS

1.0 GENERAL ......................................................................................................... 1-1

2.0 ENVIRONMENTAL ........................................................................................... 2-1

3.0 GEOTECHNICAL .............................................................................................. 3-1

4.0 CIVIL ................................................................................................................. 4-1

5.0 LIFE SAFETY .................................................................................................... 5-1

6.0 ARCHITECTURAL ............................................................................................ 6-1

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7.0 STRUCTURAL .................................................................................................. 7-1

8.0 MECHANICAL .................................................................................................. 8-1

9.0 ELECTRICAL .................................................................................................... 9-1

10.0 CYBERSECURITY .......................................................................................... 10-1

11.0 SUSTAINABILITY ........................................................................................... 11-1

12.0 ANTITERRORISM ........................................................................................... 12-1

APPENDICES

Appendix A – Navy Region Mid-Atlantic Environmental Checklist ......................................... A-1 Appendix B – Commonwealth of VA Department of Historic Resources Memorandum ..........B-1 Appendix C – Mixing Zone Study Plan Technical Memo ..........................................................C-1 Appendix D – HPSB Checklist ................................................................................................... D-1 Appendix E – System Safety Checklist ...................................................................................... E-1

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Appendix F – Cybersecurity Pump Station Monitoring and Control ......................................... F-1 Appendix G – Hazardous Material Inspection Report ................................................................ G-1 Appendix H – Geotechnical Memorandum for Proposed Pump Stations, New Substations, Generators, Fuel Tanks, and Upgrades to the Existing Pumpwell .................... H-1 Appendix I – Report of Subsurface Investigation......................................................................... I-1 Appendix J – P678 Existing 35.5kV Circuit Analysis .................................................................. J-1 Appendix K – Underwater Investigation DD8 Flood Flume and PS6 Report ............................ K-1

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Basis of Design Final Submittal List of Abbreviations

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LIST OF ABBREVIATIONS

Abbreviation Term/Phrase/Name

ACI American Concrete Institute ACM Asbestos Containing Materials ADA/ABA Americans with Disabilities Act / Architectural Barriers Act ASCE American Society of Civil Engineering AISC American Institute of Steel Construction AO Authorizing Official AST Above Ground Storage Tanks ATFP Antiterrorism Force Protection ATO Authority to Operate ATS Automatic Transfer Switch BFE Base Flood Elevation BMP Best Management Practices CCI Control Correlation Identifiers CDW Concept Design Workshop CERCLA Comprehensive Environmental Response, Compensation, and Liability Act of CFR Code of Federal Regulations CIA Controlled Industrial Area CCI Control Correlation Identifier CVN Aircraft Carrier, Nuclear Powered DD Dry Dock DFE Design Flood Elevation DRSL DoD Regionalized Sea Level DODI Department of Defense Issuances DP Drain Pump ECC Estimated Construction Cost FRCS Facility Related Control System HAZMAT Hazardous Materials HAZWOPER Hazardous Waste Operations and Emergency Response HDPE High Density Polyethylene HMI Human Machine Interface HVAC Heating, Ventilating, and Air Conditioning IBC International Building Code ICC International Code Council IES Illuminating Engineering Society JPA Joint Permit Application LID Low Impact Development MCS Marine Chemist Service MIDLANT Mid -Atlantic MILCON Military Construction

Basis of Design Final Submittal List of Abbreviations

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MIL-STD Military Standard MLLW Mean Lower Low Water Level MDP Main Drain Pump MN+BMcD JV Moffatt & Nichol + Burns & McDonnell Joint Venture MMM Moderate-Moderate-Moderate NAVFAC Naval Facilities Engineering Systems Command NAVSEA Naval Sea Systems Command NEMA National Electrical Manufacturer’s Association NEPA National Environmental Policy Act NESHAP National Emission Standards for Hazardous Air Pollutants NIST National Institute of Standards and Technology NFPA National Fire Protection Association NHPA National Historic Preservation Act of 1966, as amended NNSY Norfolk Naval Shipyard NPDES National Pollutant Discharge Elimination System OPHM Other Potentially Hazardous Materials PW-8 Pumpwell 8 PS Pump Station RCRA Resource Conservation Recovery Act RFI Request for Information RMF Risk Management Framework SAES Statement of Architectural and Engineering Services SCADA Supervisory Control and Data Acquisition SF Square Feet SHPO State Historic Preservation Office SLR Sea Level Rise SW Saltwater SWPPP Stormwater Pollution Prevention Program TPC Third Party Certification TSCA Toxic Substance Clean Air Act UFC Unified Facilities Criteria UFGS Unified Facilities Guide Specifications US or U.S. United States USACE US Army Corps of Engineers VDEQ Virginia Department of Environmental Quality VDHR Virginia Department of Historic Resources VOC Volatile Organic Compound VMRC Virginia Marine Resource Commission VSMP Virginia Stormwater Management Plan

Basis of Design Final Submittal General

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1.0 GENERAL

1.1 Project Scope

The P-678 Dry Dock 8 Saltwater System project will increase the dry dock saltwater supply and discharge systems’ pumping capacity to serve the increased saltwater cooling requirements needed to support the CVN 78’s reactor cooling, component and personnel cooling and provide firefighting capability for the vessel while in dry dock. The existing Dry Dock 8 saltwater pump stations and distribution system cannot support the increased demand and will be demolished. This system will be replaced by two (2) larger saltwater supply pump stations that will employ multiple pumps supplying a total of 20,000 GPM flow from either side of the dry dock and will provide redundant cooling water sources as required by the project scope criteria. The current saltwater distribution system around the dry dock and in the gallery area, will also be replaced.

In addition to the saltwater supply system improvements, the project includes drainage improvements for the dry dock. In Pumpwell 8, the project replaces the main drain pump (MDP) motors, provides larger capacity dry dock drainage pumps, upgrades electrical power distribution to meet the new drainage pump requirements and improve efficiency and upgrades the pump control system.

The project will be divided into two (2) phases to allow the dry docking of an aircraft carrier between the phases. Project requirements include:

Phase 1 - Site Electrical Distribution and Pumpwell Drainage pump and Main Drain Pump Improvements

• Site electrical distribution upgrades and related sitework and utility relocations

• SCADA system upgrades

• Pumpwell 8 Drainage Pump and infrastructure upgrades

• Main Dewatering Pump (MDP) motor replacements

• Replace control room and control console

Phase 2 - Saltwater Supply and Return Distribution

• Pump Stations 6 and 8

• Saltwater supply system around the dry dock

• Gallery and coping level saltwater distribution

• Saltwater return system

• Saltwater intakes and outfalls

• Related sitework and utility relocations

1.2 Mission Requirements

Improvements to Dry Dock 8 are necessary to support the USS Gerald R. Ford (CVN-78) and three (3) additional Ford class carriers that are either planned or under construction: USS John F. Kennedy (CVN- 79), USS Enterprise (CVN-80) and USS Doris Miller (CVN-81). These vessels have significantly increased saltwater cooling requirements versus the earlier Nimitz class vessels. Currently there are no dry docks

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owned by the government or the private sector that can accommodate these vessels’ saltwater cooling requirements without significant and costly work arounds and temporary pumping. The shipyard mission is to provide reliability and resiliency for the saltwater supply and return systems, the dry dock drainage system, and the main dewatering system, as well as to standardize the electrical system serving the pump stations and pumpwell with a more efficient 4160-volt system and provide monitoring and control systems.

The upgraded saltwater supply system in Dry Dock 8 must deliver 20,000 GPM flow from each side of the dry dock creating a redundant cooling water source to support shipboard requirements and ship wide fire protection. A total of 40,000 GPM of saltwater (with a redundant capacity included) is required. The upgraded saltwater system shall meet the requirements and performance criteria of the Navy’s Facility Certification Standard MIL-Std-1625D(SH), Department of Defense Standard Practice Safety Certification program for drydocking facilities and shipbuilding ways for U.S. Navy ships.

1.3 Project Background

This project follows the PRI#1 1391 Concept Study for P-678 Dry Dock Saltwater System for CVN-78 completed in February 2020, by the Moffatt Nichol + Burns & McDonnell (MN+BMcD) Joint Venture Team and subsequently approved by NAVFAC Mid Atlantic.

The MN+ BMcD team conducted a Concept Design Workshop (CDW) for the P-678 Dry Dock 8 Saltwater System project on 12-14 January, 2020, with limited in person attendance at the office of Burns & McDonnell, Chesapeake, VA, and also via video conference.

During the CDW, discussions with the key NAVFAC and NAVSEA stakeholders confirmed the major design concepts of the previous study. During this process, several previous design concepts were reevaluated such as the Drainage pump (DP-4) system type, saltwater distribution pump system type and the electrical distribution service to Pump Station 6. Locations and removal of temporary buildings and structures and two (2) permanent buildings which impact the project were also discussed such that the stakeholders are aware of this work. Also reviewed were temporary construction in the pumpwell suction chamber that will be required for pumpwell work to proceed should the caisson be upgraded during the time of the pumpwell renovations, pumpwell drainage pump discharge routing, use of the abandoned flooding flumes for drainage piping and saltwater return piping, the preferred routing of saltwater headers on the gallery level and piping materials.

The 35% design development submittal was submitted on 15 March 2021 and a two-day 35% review meeting was held on 13-14 April 2021. The 65% design submittal was submitted on 23 June 2021 and a two-day 65% review meeting was held on July 27-28, 2021. The prefinal design submittal was submitted on 28 October 2021 and a two-day review meeting was held on December 1-2, 2021.

1.4 Project Schedule

Currently, Phase 1 construction is slated to occur from August 2022 through March 2024. The USS Dwight D. Eisenhower (CVN-69) planned docking is May 2024 through May 2025. Phase 2 construction is currently planned for June 2025 through January 2027. The USS Gerald R. Ford (CVN-78) has a planned docking from June 2028 through June 2029. Docking dates and ship availabilities are subject to change and may affect the timing of the construction schedule.

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1.5 Related Projects

Two (2) additional construction projects will also take place during Phase 1 construction of the P678 project Dry dock Saltwater System project. These projects are:

• Special Project RM 19-0182 NNSY Caisson 8 Install Flood Through Valves: Award - July 2022 Beneficial Occupancy – February 2024

• RM 18-0623 (WON 1632158) Replace Dry Dock 8 Main Dewatering Pump #2: Award - April 2021; Beneficial Occupancy June 2023.

Additionally, a NNSY project to replace Main Dewatering Pump #3 including pumpwell 8 miscellaneous repairs is anticipated to be constructed from June 2024 to December 2024.

The following studies are underway for programming future projects that will be constructed on and adjacent to the Dry Dock 8 Site:

• Special Project RM 17-0052 Repair Wharf 7 Berths 41, 42, 43 Modernization Study (Note:

this project will likely be reprogrammed as a MILCON)

• MILCON Project P732 Electrical Distribution Major Repairs and Modernization Study

1.6 Project Cost

The project SAES dated 25 June 2020 indicated the following budget parameters:

• Project Cost/Program Amount (PA): $156,000,000

• Estimated Construction Cost (ECC): $137,333,863

• Design-to 90% ECC: $123,600,477

The July 2021 65% estimated construction cost was $132,060,057. The November 2021 Pre-Final estimated construction cost is $151,559,000. Quotes received from major equipment and material vendors showed significant escalation since the 65% submission quotes. The Pre-Final estimate carries an escalation of 4% to the midpoint of the construction of the entire project, a 90% productivity factor, a Phase 1 overtime factor of 21.88%, a Phase 2 overtime factor of 12.5%, a Shipyard Security/CIA factor of 15% on labor and equipment, a factor of 4% for lost days due to shipyard operations, and a cost Schedule Risk Analysis contingency factor of 17% which also includes a risk for escalation of materials and equipment.

A summary of these markups and others may be found in the submitted Pre-Final Construction Cost Estimate, dated 22 November 2021. A Final Cost Estimate will be provided after the Final submission under a separate cover. With the continued increase of material and equipment costs and labor shortages, escalation and other risks will be reexamined.

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1.7 Design Criteria

The following codes and standards apply to this project. It should be noted that the codes and standards listed below reference the applicable revisions at the time of the 35% submittal in accordance with UFC 1- 200-01.

International Code Council (ICC)

IBC International Building Code; 2018 IEBC International Existing Building Code; 2018 IMC International Mechanical Code; 2018 IPC International Plumbing Code; 2018 IES Illuminating Engineering Society Handbook; 2011

U.S. Department of Defense (DOD)

FC 1-300-09N Navy and Marine Corps Design Procedures, with Change 5; 09 November 2020 UFC 1-200-01 DoD Building Code, with Change 1; 01 October 2020 UFC 3-101-01 Architecture; 01 January 2021 UFC 3-110-03 Roofing, with Change 5; 12 June 2020 UFC 3-120-01 Design: Sign Standards, with Change 3; 12 December 2017 UFC 3-190-06 Protective Coatings and Paints; 1 March 2021 UFC 3-201-01 Civil Engineering, with Change 4; 28 September 2020 UFC 3-210-10 Low Impact Development, with Change 3; 01 March 2020 UFC 3-220-01 Geotechnical Engineering; 01 November 2012 UFC 3-220-04FA Backfill for Subsurface Structures; 16 January 2004 UFC 3-220-05 Dewatering and Groundwater Control; 16 January 2004 UFC 3-220-10N Soil Mechanics; 08 June 2005 UFC 3-230-01 Water Storage and Distribution, with Change 2; 01 May 2020 UFC 3-240-01 Wastewater Collection and Treatment, with Change 2; 1 May 2020 UFC 3-250-01 Pavement Design for Roads and Parking Areas; 14 November 2016 UFC 3-250-03 Standard Practice Manual for Flexible Pavements; 30 May 2018 UFC 3-250-04 Standard Practice for Concrete Pavements, with Change 2; 29 July 2009 UFC 3-301-01 Structural Engineering; 01 October 2019 UFC 3-400-02 Design: Engineering Weather Data; 20 September 2018 UFC 3-401-01 Mechanical Engineering, with Change 1; 01 October 2015 UFC 3-410-01 Heating, Ventilating, and Air Conditioning Systems, with Change 6; 20 March UFC 3-420-01 Plumbing Systems, with Change 11; 01 November 2019 UFC 3-430-09 Exterior Mechanical Utility Distribution with Change 1; 25 March 2009 UFC 3-501-01 Electrical Engineering, with Change 1; 01 November 2019 UFC 3-520-01 Interior Electrical Systems; 20 March 2019 UFC 3-530-01 Interior and Exterior Lighting Systems and Controls; 01 November 2019 UFC 3-540-01 Engine Driven Generator Systems for Prime and Standby Power Applications With Change 2; 5 November 2019

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UFC 3-540-07 Operation and Maintenance (O&M): Generators with Change 1;

5 November 2019 UFC 3-550-01 Exterior Electrical Power Distribution, with Change 3; 01 November 2019 UFC 3-550-07 Operation and Maintenance (O&M): Exterior Power Distribution Systems;

19 January 2017 UFC 3-560-01 Operation and Maintenance (O&M): Electrical Safety with Change 2;

31 October 2019 UFC 3-570-01 Cathodic Protection, with Change 1; 14 January 2019 UFC 3-570-06 Operation and Maintenance: Cathodic Protection Systems; 15 July 2019 UFC 3-575-01 Lightning and Static Electricity Protection Systems; 01 July 2012 UFC 3-580-01 Telecommunications Interior Infrastructure Planning and Design; 01 June 2016 UFC 3-600-01 Design: Fire Protection Engineering for Facilities, with Change 5; 24 September UFC 4-010-01 DoD Minimum Antiterrorism Standards for Buildings, with Change 1; 19 August UFC 4-010-06 Cybersecurity of Facility-Related Control Systems, with Change 1; 18 January UFC 4-021-02 Electronic Security Systems, with Change 1; 11 September 2019 UFC 4-022-03 Security Fences and Gates; 01 October 2013 UFC 4-150-02 Dockside Utilities for Ship Service; 12 November 2020 UFC 4-150-07 Maintenance and Operation: Maintenance of Waterfront Facilities with Change 1;

1 September 2012 UFC 4-151-10 General Criteria for Waterfront Construction, with Change 1; 01 September 2012 UFC 4-152-01 Design: Piers and Wharves; 24 January 2017 UFC 4-213-10 Graving Dry Docks; 18 May 2020 UFC 4-440-01 Warehouses and Storage Facilities; with Change 1; 01 April 2019 UFC 4-610-01 Administration Facilities, with Change 2; 21 May 2014 UFC 4-860-01FA Railroad Design and Rehabilitation; 16 January 2004

Accessibility Guidelines

ABA DOD ABA Accessibility Standard for Department of Defense Facilities; 31 October 2008 ADAAG Americans with Disabilities Act and Architectural Barriers Act Accessibility Guidelines;

American Concrete Institute (ACI)

ACI 318 Building Code Requirements for Structural Concrete; 2014 ACI 301 Specification for Structural Concrete; 2020 ACI 350.3 Seismic Design of Liquid Containing Concrete Structures; 2006

American Institute of Steel Construction (AISC)

ANSI/AISC 360 Specification for Structural Steel Buildings; 2016 ANSI/AISC 303 Code of Standard Practice for Steel Building and Bridges; 2016

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American National Standards Institute (ANSI)

AWS D1.1 Structural Welding Code; 2015 AWS D1.4 Structural Welding Code – Reinforced Steel, 2011.

ANSI C80.1 American National Standard for Electric Rigid Steel Conduit ANSI\HI 9.8 American National Standard for Rotodynamic Pumps

American Society of Civil Engineers (ASCE)

ASCE/SEI 7 Minimum Design Loads and Associated Criteria for Buildings and Other Structures; 2016 ASCE/SEI 24 Flood Resistant Design and Construction; 2014 ASCE/COPRI 61 Seismic Design of Pile Supported Piers and Wharves; 2014

Institute of Electrical and Electronics Engineers

NECS National Electric Safety Code, 2017 Edition

Building Industry Consulting Service International, Inc.

Telecommunications Distribution Methods Manual; 14th Edition

National Fire Protection Association (NFPA)

NFPA 1 Fire Code; 2018 NFPA 10 Standard for Portable Fire Extinguishers; 2018 NFPA 13 Standard for the Installation of Sprinkler Systems; 2019 NFPA 14 Standard for the Installation of Standpipe and Hose Systems; 2019 NFPA 20 Standard for the Installation of Stationary Pumps for Fire Protection; 2019 NFPA 24 Standard for the Installation of Private Fire Service Mains and Their Appurtenances; 2019 NFPA 30 Flammable and Combustible Liquids Code; 2018 NFPA 37 Standard for the Installation and Use of Stationary Combustion Engines and Gas Turbines;

NFPA 54 National Fuel Gas Code; 2020 NFPA 70 National Electrical Code; 2020 NFPA 70E Standard for Electrical Safety in the Workplace; 2021 NFPA 72 National Fire Alarm and Signaling Code; 2019 NFPA 80 Standard for Fire Doors and Other Opening Protectives; 2019 NFPA 90A Standard for the Installation of Air-Conditioning and Ventilating Systems; 2018 NFPA 101 Life Safety Code; 2018 NFPA 307 Standard for the Construction and Fire Protection of Marine Terminal, Piers, and Wharves;

NFPA 780 Standard for the Installation of Lightning Protection System; 2020 NFPA 2001 Standard on Clean Agent Fire Extinguishing Systems; 2018

American Society of Heating, Refrigeration and Air-Conditioning Engineers (ASHRAE)

ASHRAE 62.1 Ventilation for Acceptable Indoor Air Quality; 2013

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ASHRAE 90.1 Energy Standard for Building Expect Low-Rise Residential Buildings: 2013

ASHRAE Handbooks

Fundamentals; 2017 HVAC Systems and Equipment; 2020

Federal and Industry Guidelines

AACE Recommended Practice 56R-08 American Bureau of Shipping (ABS), Rules for Building and Classing Steel Vessels Under 90 Meters (292 feet) in Length Naval Ship’s Technical Manual, Chapter 997, Technical Instructions and Routine Work in Dry Dock

National Institute of Standards and Technology

NIST SP 800-30, Rev 1 Guide for Conducting Risk Assessments NIST SP 800-37 Guide for Applying the Risk Management Framework to Federal Information Systems: A Security Life Cycle Approach NIST SP 800-53 Security and Privacy Controls for Federal Information Systems and Organizations NIST SP 800-53A Guide for Assessing the Security Controls in Federal Information Systems and Organizations NIST SP 800-82 Guide to Industrial Control Systems (ICS) Security

Occupational Safety and Health Administration

Occupational Safety and Health Act of 1970 with amendments through 2004 with 2017 updates

Base Guidelines

Norfolk Naval Shipyard Infrastructure Optimization: Future Vision (Draft) MIL-STD-1625D(SH) Safety Certification Program for Drydocking Facilities and Shipbuilding Ways for U.S. Navy Ships NAVSEA S9002-AK-CCM-010\6010 Industrial Ship Safety Manual for Submarines NAVSEA Technical Publication S0570-AC-CCM-010\8010, Industrial Ship Safety Manual for Fire Prevention and Response NAVSEA05 Letter Serial #14-0452, SW Supply System 20,000 GPM @ 150-175 psi ECB 2016-01, Preliminary Design Deliverables for Department of Navy Military Construction Projects

Cultural and Archeological Criteria

NNSY Integrated Cultural Resources Management Plan (ICRMP) National Historic Preservation Act, Section 106 36 CFR Part 60 National Register of Historic Places 36 CFR Part 800 Protection of Historic and Cultural Properties HABS/HAER/HALS Recordation Standards Federal Register Vol. 48, No. 190, pp. 44730-34

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Environmental Criteria DOD Criteria

EM 385-1-1, Safety and Health Requirements Manual EP 1110-1-11, Asbestos Abatement Guideline Detail Sheets

Virginia Department of Environmental Quality (VDEQ)

Virginia Erosion and Sediment Control Handbook, 1992 Virginia Stormwater Management Handbook Virginia Stormwater Best Management Practice (BMP) Clearinghouse, 2013 (Draft)

Federal Regulations

Rivers and Harbors Act of 1899, Section 10 Marine Protection, Research and Sanctuaries Act, Section 103 Clean Water Act, Sections 401 and 404 Endangered Species Act of 1973 Resource Conservation and Recovery Act of 1976 Comprehensive Environmental Response, Compensation, and Liability Act of 1980 (CERCLA) 29 CFR 1910.1000 Air Contaminants 29 CFR 1910.1001 Asbestos (General Industry) 29 CFR 1910.1025 Lead (General Industry) 29 CFR 1910.1200 Hazard Communication (General Industry) 29 CFR 1926.21 Safety Training and Education 29 CFR 1926.55 Gases, Vapors, Fumes, Dusts, and Mists 29 CFR 1926.59 Hazard Communication (Construction Industry) 29 CFR 1926.62 Lead (Construction Industry) 29 CFR 1926.65 Hazardous Waste Operations and Emergency Response 29 CFR 1926.103 Respiratory Protection 29 CFR 1926.1101 Asbestos (Construction Industry) 33 CFR 322 Permits for Structures or Work in or Affecting Navigable Waters of the United States 33 CFR 330 Nationwide Permit Program 40 CFR 61 National Emission Standards for Hazardous Air Pollutants (NESHAP) 40 CFR 122.26 Storm Water Discharges (Applicable to State NPDES Programs, see 123.25) 40 CFR 761 Toxic Substances Control Act (TSCA), Polychlorinated Biphenyls (PCBs) Manufacturing, Processing, Distribution in Commerce, and Use Prohibition

Industry Standards

Civil

Virginia Department of Transportation (VDOT) Drainage Manual, 2020 Virginia Department of Transportation (VDOT) Road and Bridge Specifications, 2020 U.S. Department of Transportation Federal Highway Administration, “Manual on Uniform Traffic Control Devices (MUTCD)”, Subsurface Investigation

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Structural

EM 1110-2-2002 Engineering and Design: Evaluation and Repair of Concrete Structures EM 1110-2-2100 Engineering and Design: Stability Analysis of Concrete Structures EM 1110-2-2104 Engineering and Design: Strength Design for Reinforced Hydraulic Structures EM 1110-2-2504 Design of Sheet Pile Walls AASHTO, LRFD Bridge Design Specifications; 7th Edition with 2015 and 2016 Interim Revisions

Architecture and Interior Design

UL Fire Rated Assemblies Directory Gypsum Construction Handbook, USG Corporation Gypsum Construction Guide, National Gypsum Company

Electrical

Illuminating Engineering Society of North America, IESNA, Lighting Handbook Illuminating Engineering Society of North America, IESNA RP, Recommended Practices National Electrical Safety Code, NE (NESC) RP-7-01, Lighting Industrial Facilities RP-33-14, Lighting for Exterior Environments

Corrosion Protection

NACE SP0169-2013 Control of External Corrosion on Underground or Submerged Metallic Piping Systems NACE SP0176-2007 Corrosion Control of Submerged Areas of Permanently Installed Steel Offshore Structures NACE SP0387-2014 Metallurgical and Inspection Requirements for Cast Galvanic Anodes for Offshore Applications Recommended Practice DNV-RP-B401, Cathodic Protection Design

Cybersecurity

FIPS Pub 200, Minimum Security Requirements for Federal Information and Information Systems DODI 8500.01, Cybersecurity DODI 8510.01, Risk Management Framework (RMF) for DoD Information Technology (IT) CNSSI 1253, Security Categorization and Control Selection for National Security

Pumps

ANSI/HI 9.6.6-2016, American National Standard for Rotodynamic Pumps for Pump Piping ANSI/HI 9.8-2018, American National Standard for Rotodynamic Pumps for Pump Intake Design

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Basis of Design Final Submittal Environmental

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2.0 ENVIRONMENTAL

2.1 Hazardous Materials

Hazardous Materials Inspection Report dated May 2021, prepared by AH Environmental Consultants (AH), and conducted by AH and Marine Chemist Service (MCS), is submitted in the Appendices and in the project specifications. This site inspection and assessment involved sampling of suspect asbestos containing materials (ACM), testing of paint/coatings, investigation for other potentially hazardous materials (OPHM) anticipated to be impacted by proposed work. The following areas and buildings were sampled for asbestos containing materials, lead and RCRA 8 metals:

• Pumpwell 8 including the control room

• Flooding Flume Sluice Gate

• Building 828

• Building 829

• Building 1490

• Building 1528

• Dry Dock 8 including gallery and coping level

• Dry Dock 8 utility tunnel

• Exterior ground surface areas around the dry dock

The primary hazardous materials (HAZMAT) concern for planned work activities appears to be paint coatings of some components and soils that contain lead and chromium and are in fair to poor condition.

Hazardous materials, including lead paint, asbestos, Resource Conservation Act (RCRA) metals have been found within the demolition area of existing pump stations, nearby storage buildings that require demolition, Pumpwell 8, Gallery, Dry Dock, Utility Tunnel, and site exterior areas (refer to the Hazardous Materials Inspection Report in the Project Specifications Appendix). Chief concerns are paints that are in poor condition creating lead debris and soils that contain lead and chromium near the rails. A portion of this site is listed as Site 10 in a 2016 Comprehensive Environmental Response, Compensation and Liability Act (CERCLA) report. The means and methods to handle the identified hazardous materials are covered under the project specifications. The hazardous materials inspection cannot verify nor attest to components not accessible (e.g., encased in concrete or presently buried subgrade). Petroleum contaminated soil is known to exist within the LUC boundary. Soil excavated from the LUC shall be reused exclusively within the LUC. Excess soil from the LUC boundary shall be disposed at a Subtitle D landfill as a minimum with the understanding that the analytical testing results shall determine the final disposal facility.

Because some of the construction work of this project will be performed within Site 10 LUC, workers should be appropriately trained for Hazardous Waste Operations and Emergency Response (HAZWOPER) (29 CFR 1910.120) when working within the Land Use Control (LUC) boundary. Appropriate personal protective equipment (PPE) as determined by the construction organization’s HAZWOPER trained subject matter expert should be worn. Any media that is removed/dewatered from within the LUC boundary will require proper storage, characterization, and offsite disposal at an approved waste disposal facility. All waste handling will be coordinated with the installation’s hazardous waste media manager.

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2.2 Environmental Studies and Approvals

The following environmental studies have been initiated after and approvals are required to be obtained prior to construction start.

National Environmental Policy Act (NEPA)

A NEPA study including an Environmental Assessment (EA) is required for this project and will be provided and submitted by NAVFAC with input from the design team. The project was determined by the Commanding Officer delegated Public Works Officer to have a determination of Categorical Exclusion (CATEX). The CATEX review should take 1-6 months versus 12 to 14 months for the full NEPA process.

Cultural Resources

The Norfolk Naval Shipyard (NNSY) has served the United States Navy as a repair and construction facility from its acquisition in 1801 to present day. The shipyard is significant for its association with the development of the US Navy in the 19th and 20th centuries, particularly during the Civil War and World War I and II. The buildings within the district represent the evolution of naval transportation and shipbuilding industry over time. The district is also significant under Criterion C because it is an entity that embodies the distinctive characteristics of naval architecture and engineering, both residential and industrial between 1827 and 1945. The period of significance extends from 1827, when the earliest extant structures were first planned and funded to 1945, when the shipyard evolved into its current layout. Dry Dock 8 (Facility 932) was constructed in 1942, and was designed by Frederic R. Harris, Inc., and Dry Dock Associates. This resource is a contributing structure to the Norfolk Naval Shipyard Historic District.

The proposed work entails improvements to Dry Dock 8 necessary to support the USS Ford (CVN-78) and three (3) additional Ford class carriers are either planned or under construction. These vessels have significantly increased saltwater cooling requirements for their reactors. Currently, there are no dry docks owned by the government or in the private sector that can accommodate these vessels’ cooling requirements. Improvements include, but not limited to, the replacement of two (2) historic pump stations, upgrading dry dock electrical systems, as well as modifications to comply with fire-fighting requirements.

In November 2020, MN+BMcD and CPG staff visited the site of dry dock and associated structures. The facilities were photographed and documented. In addition to the site visit, desktop research was performed to determine previous findings. Dry Dock 8 is a contributing resource to the historic district. The pump houses, which were constructed in 1964, were determined non-contributing but are now over 50 years old.

It was determined during the course of the is study that all eligible and potentially eligible resources should not be considered, therefore the proposed replacement of the historic age pumphouses will not be considered an adverse effect that requires mitigation. Should project design change to include removal of any historic features associated with the dry dock, then impacts would be considered an adverse effect.

On 20 January 2021, the SHPO architectural historian provided concurrence and has indicated in a Memorandum (refer to the Basis of Design Appendix for the Memorandum) that the demolition of the pumphouses of P678 will not have an adverse effect. Once this finding of effect has been mutually agreed

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to by the NNSY Cultural Resources staff and VDHR, both parties will enter into a Memorandum of Agreement.

Natural Resources and Marine Habitat

The project will require a permit for construction in navigable waters, Essential Fish Habitat (EFH) and Endangered Species Act (ESA) consultations, and Marine Mammal Protection Act (MMPA) analysis. A USACE 408 Review will be mandatory.

2.3 Environmental Permitting

This project requires the following construction permit applications will be required prior to start of construction.

National Pollutant Discharge Elimination System (NPDES) Permit

Under the EPA’s Clean Water Act, an NPDES permit is required for water intake and outfall structures.

These structures are designed to prevent fish entrapment. Intake size/water velocity and saltwater return temperature to the river will comply with current EPA regulations, and a monitoring program established.

Intake structures located at Pump Station 6 and Pump Station 8 will be designed to operate with a maximum through-screen intake velocity of 0.5 feet per second with a maximum flow of 20,000 GPM to prevent fish entrapment. Intakes have a stop log for isolation of the intake structure and are fitted with a course screen and two (2) fine screens such that a fine screen can be removed for cleaning while the intake is in operation.

The outfalls will require permitting and monitoring. A mixing zone study is underway to analyze the outfall discharge into the water column and validate appropriate dilution factors.

Four (4) new pipe discharges will be located on the south side of the dry dock in the current flooding flume location. These outfalls are:

• One (1) 36-inch pipe for Drainage Pump (DP) 4 and 5 discharge: 30,000 GPM

• One (1) 36-inch pipe for Drainage Pump (DP) 1, 2 & 3 discharge: 30,000 GPM

• One (1) 30-inch pipe for saltwater return discharge: 15,000 GPM

• One (1) 8-inch pipe for sump pump discharge: 750 GPM

All four pipes are housed in the repurposed south flooding flume which is no longer needed for flooding the dock due to the upcoming Caisson 8 retrofit with flood-through valves. The flooding flumes will be filled with concrete after the pipes are installed. The maximum drainage pump (DP) discharge at any one time will be 30,000 GPM as the pumps are sized at 15,000 gpm each and only two will operate at one time to provide the required dock drainage flow.

• Two (2) new pipe discharges will be constructed on the north side of the dry dock. These outfalls are:

• One (1) 30-inch pipe for saltwater return discharge: 5,000 GPM

• One (1) 16-inch pipe for saltwater return discharge: 15,000 GPM

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• Both pipes are housed in the repurposed north flooding flume.

The outfall permit requirements will be determined based upon locations, type of water being discharged, discharge rates and location in the water column of the outfalls. It is expected that some iteration of the mixing zone study will be required to reach an appropriate dilution ratio that NNSY and the regulatory agency finds acceptable.

Joint Permit Application

A Standard Joint Permit Application (JPA) will be submitted to the USACE, Virginia Marine Resource Commission (VMRC), the Virginia Department of Environmental Quality (VDEQ) and Local Wetlands Board for obtaining a Nationwide Permit, Section 10 (Navigable Waters) Permit, Section 404 (Clean Water Act) Permit, Section 408 Permission, Virginia Water Protection (VWP) Permit, Coastal Zone Management Act Determination, and State-owned Subaqueous Bottoms Permit. The JPA technical documentation will be provided by the Architect-Engineer (AE). The permit will be submitted by NAVFAC. This permit is a critical path item.

USACE is responsible for permitting related to Section 10 of the Rivers and Harbors Act of 1899, Section 103 of the Marine Protection, Research, and Sanctuaries Act of 1972, Section 404 of the Clean Water Act, and 33 USC 408 (Section 408 Authorization).

DEQ administers the Virginia Water Protection Program (VWP) which regulates activities occurring in surface waters. Project activities that require a Virginia Water Protection Permit (VWPP) include dredging, filling, excavating, discharging, and withdrawal of surface waters. VMRC oversees impacts to State-owned subaqueous (river) bottoms. Project activities that require a State-owned Subaqueous Bottoms Permit include dredging, filling, and the construction of structures in/over the subaqueous bottom.

VDEQ Erosion and Sediment Control Permit

The erosion and sediment control permit application is being prepared and will be submitted by

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VDEQ Stormwater Management Program (VSMP) Construction General Permit

A Virginia Stormwater Management Program (VSMP) construction general permit is required and must be obtained by the construction operator for the duration of the project as there will be stormwater discharged from the site during land disturbing operations. The construction operator is required to have a Stormwater Pollution Prevention Plan (SWPPP), as a part of the VSMP construction general permit that must be in accordance with the VDEQ standards. Project specifications indicate the requirements that the construction operator must meet to comply with VSMP standards. The contract specifications require the construction contractor to obtain the permit.

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VDEQ Emergency Generator General Permit

The pump stations’ emergency generators are 3500 kV. The pumpwell generator is 1825kV. An air permit application for Emergency Generator General Permit is required through the Virginia Department of Environmental Quality. NNSY Code 106 will apply for this permit. Permitting time is expected to be at least 6 months and will be factored in the project schedule.

Virginia AST Regulations

The above ground storage tanks (AST) requires registration with the Virginia Department of DEQ within 30 days after being brought into use. NAVFAC will register the storage tanks associated with Pump Stations 6 and 8. NAVSEA will register the storage tank associated with the pumpwell. The AE will provide all pertinent design and technical data for the AST registration form.

Fugitive Emission Standards

Fugitive emission standards shall be met during construction in accordance with the Code of Virginia 9VAC5-40-90 Standard for Fugitive Dust/Emissions to prevent particulate matter generated during construction from becoming airborne. The design will incorporate these requirements into the contract documents, Temporary Environmental Controls specifications.

Liquified Asphalt

Manufacture, mixing, storage, use or application of liquefied asphalt for paving operations will not be allowed unless asphalt is of the emulsified type in accordance with the Code of Virginia 9VAC5-45-780 Standard for Volatile Organic Compounds. The design will incorporate these requirements into the contract documents, Temporary Environmental Controls specifications.

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Basis of Design Final Submittal Geotechnical

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3.0 GEOTECHNICAL

3.1 Reference Documents

Reference documents listed below are included in their entirety in the CDW Report Appendices:

• Report of Subsurface Exploration and Geotechnical Engineering Services, P-678 Dry Dock 8 Saltwater System for CVN-78, GET Solutions Inc., dated June 23, 2021 (GET Project Number VB20-261G)

• Geotechnical Memorandum for the Proposed New Pump Stations, New Substations, Generators, Fuel Tanks and Upgrades to the Existing Pumpwell for P-678 Dry Dock 8 Saltwater System for CVN-78 Class Ships, Portsmouth, Virginia, dated June 21, 2021 (EMI Project Number 20-143)

3.2 Purpose

The geotechnical role is to provide geotechnical engineering design and construction consultation to the design team for the P-678 Dry Dock 8 Saltwater System Upgrade for CVN-78 project located at Norfolk Naval Shipyard (NNSY) in Portsmouth, Virginia. The purpose of this investigation was to obtain information regarding general subsurface conditions, evaluate encountered conditions, formulate engineering assessments, and provide geotechnical recommendations for overall project use. Two geotechnical firms were utilized for the project, namely GET and EMI: GET performed the subsurface investigation, and EMI provided site class information, seismically induced settlement analysis, and deep foundation recommendations for the site foundations based upon the investigation data.

3.3 Existing Conditions

A subsurface site investigation program was performed by GET Solutions Inc. on January 21, 2021. The field exploration included 22 borings made around Dry Dock 8, one (1) thin-walled Shelby tube sample, one (1) seismic cone penetration test with pore pressure and shear wave velocity measurements, and pavement section cores.

Strata encountered at the site in order of increasing depth below pavements or mudline typically consist of uncontrolled fill, loose to medium dense sand, and the Yorktown Formation consisting of sand with varying amounts of silt, clay, and shell fragments. The thickness, depth, and properties of the strata vary by area locations.

The initial groundwater level was observed based upon the wetness of the recovered soil samples and measured. It was noted that the estimated seasonal high-water table fluctuates between years based upon drainage, tidal patterns, and rainfall. Based upon current and historical groundwater data, the seasonal high groundwater table was measured at 5 to 8 feet below the existing site grades at the boring locations, corresponding to approximate EL 95.5’ to 97.5’ NNSD. Additional information is provided within the Appendix.

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3.4 Site Seismicity

Per ASCE 7-16, the project site is classified as Site Class D and E depending on the location. The seismic design parameters for Site Class D and E are presented in the Table 1 below per the EMI memorandum.

Given the variability within the project area, Site Class E was conservatively selected to provide general structural consistency.

Table 3-1: Code-based Design Seismic Parameters for Site Class D and E

3.5 Liquefaction Potential and Seismic Settlement

Based on a groundwater table of EL 98.0’ NNSD and presence of fine-grained clayey soils with plasticity index greater than 7, the site soils are not considered liquefiable. Additionally, seismically induced settlements were evaluated. Based on liquefaction triggering analysis, design shaking levels for the anticipated design events are not sufficient to trigger liquefaction at Pump Station 8 (PS-8) and the Pumpwell. At Pump Station 6 (PS-6), analysis of a Level 2 (2,475-year) event, bearing capacity is anticipated to remain for shallow foundations but a seismically induced differential settlement of 3-inches and a total settlement of four 4-inches is anticipated within the top 25-feet.

3.6 Shallow Foundation Recommendations

From the laboratory testing, the subsurface contained uncontrolled fill material consisting of sand and clay soils around the site. The generators, fuel tanks, and substations may be supported on shallow foundations if the uncontrolled fill material within the footprint of the foundations be removed in its entirety as to mitigate excessive settlement. Based on the site location, excavations of +/- 7-feet and +/- 10-feet would be required. Around Dry Dock 8, the depths of uncontrolled fill vary; a testing agency should monitor excavations to ensure that all the uncontrolled fill has been removed. Given this amount of uncontrolled

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fill, the equipment is better suited on deep foundations to avoid undermining the utilities. All foundations are required to bear at a depth of 18-inches below grade to provide adequate frost protection. The subgrade below the mat foundations should be level and a 12-inch thick layer of VDOT No. 57 stone be provided for more uniform bearing and to achieve the 20-pci subgrade modulus.

3.7 Deep Foundation Recommendations

Two (2) deep foundations elements were evaluated, and axial compression and tensile capacity curves were developed based on the project site conditions. Specifically speaking, common 14-inch x 0.5-inch open ended steel pipe piles are considered for pump station, generator, fuel tank, and substation foundations, and 8-5/8-inch micropiles for the pumpwell foundations. The micropiles are ideal in the pumpwell given the fact that a smaller rig may be used to drive them considering the limited head clearances. With respect to capacity, two (2) micropile installation techniques were considered: gravity grouting and pressure grouting with bond strengths of 10-psi and 20-psi respectively. A factor of safety of 3.0 was considered for the micropiles to forego any test piles given the congestion down in the pumpwell. In general, a factor of safety of 2.5 was used for pipe pile design provided that the pile capacities be verified with pile displacement analyzers during construction. The factor of safety can be reduced to 1.0 for seismic loading conditions.

3.8 Chemical and Environmental Analysis

Soil samples were obtained at geotechnical boring locations for chemical and environmental analysis. In three (3) of the boring locations (20-GETB-03, 20-GETB-11 and 20-GETB-17), concentrations of chlorides and sulfides in the existing soils indicate corrosion potential to ductile iron pipe. In particular, one of the samples (20-GETB-17) appears to be aggressive from a corrosion potential to buried steel reinforced concrete structures. Refer to Table II – Corrosivity Analytical Results in the Geotechnical Report for the test results.

Six (6) composite soil samples were created from the soil samples taken at the boring locations for hazardous chemical evaluation. The soil samples did not produce concentrations of the analytes that would be considered hazardous from a disposal or exposure (construction personnel) perspective. However, composite sample C-5 (created from locations 20-GETB-16, 17, and 18) produced a detectable concentration of TFPH-DRO 64.1 mg/kg, which exceeds the VDEQ clean fill standard of 50 mg/kg. Refer to Table III – Environmental Analytical Results in the Geotechnical Report for the test results.

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Basis of Design Final Submittal Civil

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4.0 CIVIL

4.1 Project Site

Dry Dock 8 is located within the CIA of NNSY. It is located on the southern side of the shipyard and is south of Pier 6 and west of Wharf 7. The primary project site area is approximately 23 acres and is generally bounded by Hitchcock Street to the northwest, Barkley Street to the west, Weaver Street to the south, and the Elizabeth River to the east.

4.2 Existing Conditions

The entire project area is impervious, consisting of asphalt and concrete pavement, buildings, and dry dock floor area.

Crane rails are prevalent in the project area. Crane rails surround the perimeter of the Dry Dock 8, along the north and south sides as well as along the head of the dock to the west. Crane routing originates from Pier 6 on the northeast, through the Dry Dock 8 site and then continues to Wharf 7 to the southeast before terminating. Railroad tracks are also within the site area.

Buildings 828 and 829 are the pump station buildings for the current saltwater distribution loop for Dry Dock 8. Building 829 is located on the northeast portion of the dry dock and Building 828 is located on the southeast portion. Pumpwell 8 is located south of the dry dock and west of Building 828.

The project area contains a diverse range of subgrade and above-grade utilities. Ductbanks and networks of pipes can be found buried in the soil beneath pavement, within utility tunnels encircling the north and south lengths of Dry Dock 8, mounted to the interior wall of the dry dock, and embedded in the concrete floor of the dry dock. For the purposes of this project, existing site civil utilities consist of those direct buried in soil as well as those located within or on top of the pavement. Utilities located in tunnels and within the dry dock will be addressed by mechanical.

Existing site civil utility distribution networks include freshwater, saltwater, sanitary sewer, oily waste/waste oil, compressed air, oxygen, propane, high pressure steam, pumpwell drainage and storm drainage.