Soo Lock - NLC - Briefing to Industry - 1 Oct 20 For Posting on Beta.Sam.pdf

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“The views, opinions and findings contained in this report are those of the authors(s) and should not be construed as an official Department of the Army position, policy or decision, unless so designated by other official documentation.”

INFORMATION CONTAINED IN THIS DOCUMENT IS PRE-DECISIONAL

AND NOT TO BE RELEASED OUTSIDE THE DEPARTMENT OF THE ARMY

Sandra Kenzie Darin H. White, P.E.

1 Oct 20

NEW LOCK AT THE SOO

NEW 3RD LOCK

INDUSTRY DAY PRESENTATION

Procurement Process Justin Bennett & Sandy Kenzie– Contract Specialists Louisville & Detroit districts Office Phone: 502-315-6203 (J. Bennett) & 313-226-6819 (S. Kenzie) Email Justin.K.Bennett@usace.army.mil & Sandra.M.Kenzie@usace.army.mil mailto:Justin.K.Bennett@usace.army.mil mailto:Sandra.M.Kenzie@usace.army.mil

PROCUREMENT SCHEDULE

DATES ARE APPROXIMATE AND SUBJECT TO CHANGE

ISSUE SOLICIATION (STAGGER 1) EARLY JUNE 2021

SOLICITATION CLOSES (STAGGER 1) LATE JULY 2021

EVALUATION BOARD (STAGGER 1) AUGUST 2021

ISSUE STAGGER 2 AMENDMENT AUGUST 2021

SOLICITATION CLOSES (STAGGER 2) OCTOBER 2021

EVALUATION BOARD (STAGGER 2) NOV/DEC 2021

PREPARE FOR AWARD JANUARY 2022

AWARD FEBRUARY 2022

File Name

How to obtain the solicitation:

• BETA.SAM – BETA.SAM.GOV

• Solicitation Number is W911XK20R0013.

• View interested vendors list and register as an interested vendor.

• Register to receive notifications and updates / amendments.

• RFP technical information will be posted on the BETA.SAM website at: beta.SAM.gov.

http://www.fbo.gov/

Obtaining the Issue Documents

• Requirements to download Technical Data Package

1) Need to be registered in Beta.SAM and System for Award Management (SAM)

• Any amendments issued to the RFP will also be posted here.

• Pre-Solicitation Notice – posted to FBO at least 15 days prior to the planned date of advertisement.

• Advertisement – minimum of 30 days to prepare proposals for EACH stagger phase. Offerors must submit a Stagger 1 Proposal in order to be eligible to submit a Stagger 2 proposal.

The Procurement process

• This project will be a Design-Bid-Build (D-B-B) Request for Proposals (RFP).

• Project award will be made on a “Best Value Trade-off” basis as described in the evaluation criteria.

• Proposals must be submitted on time.

* The Detroit District is in the Eastern time zone.

• The Source Selection Evaluation Board (SSEB) will evaluate contractors’ proposals based on specific factors which are defined in the RFP Package.

Proposal Requirements

• Source Selection Criteria for an Unrestricted “Best Value Trade-off” usually consists of these elements:

• Volume I – Factor I: Project Management, Quality Control, Key Personnel, and Schedule

• Volume I – Factor II: Planned Technical Execution of Key Work Elements

• Volume I – Factor III: Past Performance Confidence

• Volume I – Factor IV: Project Labor Agreements

• Volume I – Factor V: Small Business Participation Plan

Submit your best proposal the 1st time. Discussions may not be opened, if we receive an initial proposal that is awardable.

Proposal Requirements (cont.)

• Each offeror is to submit a Small Business Participation Plan

• This is an evaluated element in your proposal (Reference Section 00 22 12 in the RFP).

• Must be submitted by both Large AND Small business offerors.

• Large Business offerors MUST also submit a Small Business Subcontracting Plan.

• Although this is not a rated element as a part of the Source Selection process, it is a condition of award.

Proposal Requirements (cont.)

• Instructions for submitting a Request for Information (RFI) will be included in the solicitation.

• RFIs for these projects will be received and answered through the Projnet system: www.projnet.org o Any RFIs submitted directly to the project team will not receive a response, and will be directed to the Projnet system.

• Each project will have a Projnet Bidder’s Key, which is used to post your RFIs to the proper project.

o The project Bidder’s Key will be included in the Projnet Instructions section of the RFP.

• Requests for Information and their responses will be available for public review through Projnet.

http://www.projnet.org/

Q&A

SOO LOCKS LOCATION & IMPORTANCE 11

Soo Locks

The New Soo Lock would eliminate the single point of failure in our Nation’s iron ore supply chain

BACKGROUND – SOO LOCKS COMPLEX

UNIT 10 &

SLUICEWAY

NORTH

POWER

PLANT

(NPP)

1943 1968 1914 1919

800’ 1200’ 1350’ 1350’

80’ 110’ 80’ 80’

31’ 32’ 23.1’ 23.1’

MacArthur Poe Davis Sabin

Built

Length

Width

Depth

Sault BACKGROUND – SOO LOCKS COMPLEX

NEW LOCK STATUS

FY19 FY20 FY21 FY22 FY23 FY24 FY25 FY26 FY27 FY28 FY29 FY30

* Early completion could be realized with approval of continuing contracts clause, efficient funding, and favorable weather conditions

Design

Contract Procurement

Construction

Phase

Phase

Phase

Upstream Channel Deepening (UCD)

Upstream Approach Walls (UAW)

New Lock Chamber (NLC)

WE ARE HERE

UCD 2020

Work AreaUCD 2021 Work Area

UAW 2021

Work Area

NLC 2022 Forward Work AreaN

UAW 2022 & 2023

Work Area

BACKGROUND - SITE PLAN – OVERVIEW – NEW LOCK

Poe 2.0

INITIAL ACTIVITIES - ACCESS

• Access to the “Island” will primarily be by water for labor, equipment and materials (red arrows)

• During winter months (15 Jan – 25 Mar) navigation ceases and water transportation will not be possible due to ice

• Limited access will be provided through the facility during winter months (yellow arrow)

• Check the weather – it gets cold!

INITIAL ACTIVITIES - SECURITY

• Soo Locks is a secure DoD facility.

• Personnel are subject to rules/regulations to work at an international port and within a DoD facility.

• All Contractor personnel will be subject to a National

Crime Information Center (NCIC) check and FBI fingerprint check.

• Contractor personnel needing access to SCADA and other sensitive areas (Buildings, Operating Shelters, Galleries, Deep Service Tunnel) will require a more extensive background check.

• Contractor personnel must carry picture ID.

• Contractor shall keep a Security Access List.

• Contractor personnel will be issued access cards which will be programmed appropriately.

INITIAL ACTIVITIES - FENCING

• Establish New Fence Line

• Erect a Construction Fence on the South Wall of the Davis Lock

• Erect a Construction Fence south of the Unit 10 Powerhouse

• Erect a Secure Gate at the end of the Bridge to the Main Powerhouse

• Establish concertina wire along Unit 10 Tail Race as needed to establish secure perimeter

• Demolish Existing Security Fence along North Wall of the Sabin Lock

FIRST STEP….GET TO A DEWATERED CHAMBER

Key Activities

• Cofferdam

• Electrical Relocation

• NPP Bridge

• South Davis Wall Stability

COFFERDAMMING SURFACE 20

• Cofferdam Cells – 65’ and 78’ Diameter

• Soil-Cement-Bentonite Wall (green), 1100’ Long, 10’ – 20’ Deep

• Grout Curtain (red) – Top of rock down

• Pipe Pile / Z-Pile Hybrid Wall (pink), 30” Pipe Piles with AZ14 Z-Piles

• South Davis Lock Wall - stability mitigation required

Sabin Lock

Davis Lock

Existing cutoff wall

Cofferdam Cells Cofferdam Cells

Upper Pool 601.6

Lower Pool 580.1

COFFERDAM STRUCTURE AND GROUT CURTAIN

O ld p ow er ho us e

Remove existing timber crib cofferdam

Utilize existing clay cofferdam

Utilize existing concrete training wall

Utilize old powerhouse New

SCB

slurry wall

New SCB slurry wall

New hybrid wall

New Grout Curtain (green)

COFFERDAM STRUCTURE AND GROUT CURTAIN

New Lock Grout Curtain

• Primary holes on 20’ centers, with secondary split spaced between (10’ centers), tertiaries will be installed based on results of the other holes

• The majority are battered at 20°and extend to approximately 10-feet below the nearest monolith foundation elevation

New Well Grout Curtain

UPSTREAM COFFERDAM CELLS

Existing Cell

(To be Removed) Installed by UAW Contractor

DOWNSTREAM COFFERDAM CELLS

Cofferbox: 1) Space truss w/skin

2) Contains discharge pipes

3) Filled with concrete

HYBRID WALL

Existing Cell

Installed by UAW Contractor

U/S Cofferdam Cells

(to be removed)

Upstream Approach

Walls

New Lock Chamber

NPP BRIDGE

Ramp to Crib Dam

Platform

Utility/Pedestrian Bridge

Vehicular Bridge

- Abutment and Piers on Drilled Shafts to rock

- N. Pier in close proximity to existing power plant wall.

- Designed for staged construction with Red portion as Base and Remainder as options

- Design is at 30% phase

SOUTH DAVIS WALL STABILITY

• Rock Anchors

– 28 Monoliths, 54 anchors total.

– (6) 140 kip, 4-strand anchors

– (26) 300 kip, 9-strand anchors

– (8) 440 kip, 13-strand anchors

– (14) 880 kip, 25-strand anchors

• Tie-Bars (South Davis Wall to North Poe Wall) 26 Monoliths, 330K per monolith, 2 per monolith, 165K each

• Alternate Design – Struts in lieu of Tie-Bars

NEXT STEP….DEMOLITION/ROCK EXCAVATION

NEW PUMPWELL

CIVIL

• Demolition of North/South Sabin Wall

• Demolition of Existing F&E System

• Rock Excavation

• Soil Excavation – South Sabin/North Davis

• Fill Davis Chamber

• Disposal: NW Pier, Davis Chamber, North Wall

N

SOO LOCKS- SITE UTILIZATION

• Haul roads/access routes are conceptual and not required by the Contractor

SOO LOCKS - DEMOLITION

Sabin Chamber to be Removed

SOO LOCKS – DEMOLITION/EXCAVATION

Prior to Dewatering

SOO LOCKS – DISPOSAL

Disposition of Materials:

Demolished Concrete – NW Pier/Unit 10 Spoil Site Rock Excavation – NW Pier/Davis Chamber/Haul Roads Soil Excavation – NW Pier/Davis Chamber/North Chamber Fill Area

NW Pier Spoil Site

Unit 10 Spoil Site

North Chamber Fill Area

Davis Chamber Fill

GEOLOGICAL MATERIALS 37

LOCK FOUNDATION CONSIDERATIONS 38

Foundation Elevation sheet series

• Rock bedding dips towards upstream (west) at approximately 3’ per 100’ and towards north approximately 1’ per 100’.

• All rock sections and profiles were interpreted between borings, so much uncertainty exists between borings.

• Based on those interpretations and assumptions, any monolith foundation within 5-feet of a clay seam or weathered shale zone was lowered for their removal.

Upstream Downstream

Stair-stepped foundation trying to maintain consistent elevation

LOCK EXCAVATION METHODS AND CONSIDERATIONS

Excavation Method sheet series • Currently, we anticipate using very controlled excavation, including line-drilling, saw-cutting, and mechanical methods, to avoid dip influenced over-break and to not aggravate locked-up internal stresses which could cause lateral off-set and vertical rebound.

• Poe Excavation required closely spaced line-drilling and “broaching” techniques.

• We currently have many inside and outside corners with different foundation elevations stepping through the foundation, including a centerline drain excavation, resulting in intricate excavation geometries.

Saw cutting Line Drilling

SHAFT #6 EXCAVATION

View Looking Downstream

View Looking South • Geology is assumed based on few nearby borings.

Drilling will be done next month.

• Shaft excavation Is approximately 31’ diameter and 63’ deep.

• Assume vertical shaft excavation will be drill and blast with light charges. Nearby critical structures will have low PPV requirements and seismic recording.

• Initial support will be contractor designed based on their methods.

• Previous shaft excavations were successful (Davis Pump Well, MacArthur, and Poe Pump Well).

LOCK FOUNDATION ELEVATION CONSIDERATIONS 42

Verification Boring sheet series

• Verification borings (PQ core and downhole tele-viewer) will be conducted to verify design foundation elevations prior to excavation.

• It will be encouraged to have the foundation try to stay at the foundation elevation as much as possible, except when chasing clay/weak seams.

• Mud mat placement required for leveling/cover exposed rock.

For Official Use Only

EXISTING PUMPING SYSTEM & NEW PUMP WELL

350 ft between valve vault and cofferdam All discharge lines include flap valve, knife gate valve and check valve.

• Located in the existing Davis Lock chamber just north of the Davis Well

• Replaces Davis Well and Poe Well for dewatering capacity

• Ability to muck in the New Pump Well and the Davis Well

• Dry well when not in use

• Discharge east through DS cofferbox

NEW PUMP WELL

Discharge lines

DS Cofferbox

NEW PUMP WELL EXCAVATION (DAVIS FLOOR)

Contractor will have to cut through steel reinforced concrete floor and culverts to get to the top of rock.

Vertical 2-7/8” twisted steel dowels (10” on center) are 4’-5’ into rock.

• Large amount of structural geometry of features with reinforced steel will need to be demolished prior to rock removal.

• Some of the culverts need to be plugged with some flowable fill or bulkheads to propagate removal in drier conditions within the pits.

• Assume demolition will be conducted with mechanical methods.

NEW PUMP WELL EXCAVATION (BEDROCK)

• Large amount of structural geometry of features with reinforced steel will need to be demolished prior to rock removal.

• Some of the culverts need to be plugged with some flowable fill or bulkheads to propagate removal in drier conditions within the pits.

• Assume demolition will be conducted with mechanical methods.

• Grout curtain will be installed from the floor of the dewatered footprint. There may be some high pressure flow coming back into the boreholes with which will have to be contended.

• The Davis Tunnel will be plugged and abandoned (possibly still used during construction), the Sabin Tunnel will be deepened on both south and north ends adjacent to the New Pump Well to achieve required grade.

Areas of brand new rock excavation areas (red) and rock adjacent to previous excavations (yellow)

Sabin tunnel

Davis tunnel

VARIOUS TUNNEL EXCAVATIONS

• Tunnels associated with the Davis Pump Well and New Lock Dewatering System will involve modification of the interior of existing tunnels, deepening of the floors, and re-establishing a deeper configuration of the tunnel.

• Initial support will be contractor designed based on their methods.

• Previous tunnel excavations have been successful (Davis Pump Well, MacArthur, and Poe Pump Well).

Max area of new rock excavation (red)

• 4’ x 7’ tunnel minimum (same dimensions as existing dewatering tunnels)

• New Lock dewatering pit drains south through new wide wall monoliths, connects to existing North Sabin Tunnel, and into the New Pump Well

• Removable bulkhead located in monolith S36 to provide a positive closure that can be safely inspected

NEW LOCK DEWATERING TUNNEL

• Demo existing pumps, walkway framing, and sluice gates

• Plug existing discharge line and Davis Lock Dewatering Tunnel

• Raise floor of well to match tunnels

• Install staircase

• Install overhead 2 ton monorail crane and construct new floor with opening for mucking

• Dry well when not passing water through to New Pump Well

DAVIS PUMP WELL

Crossover Tunnel South Sabin Tunnel

Concrete fill

New floor (same EL as existing)

Existing discharge (to be plugged)

Mucking opening

POE PUMP WELL

• Demo existing pumps, walkway framing, sluice gates, and plug discharge pipe

• Connect existing dewatering tunnels with 54” diameter pipes and discharge into Crossover Tunnel

• Bonneted knife gate for each dewatering tunnel to control dewaterings

• Removable bulkhead for safety closure

• New 2 ton jib crane

• Final well shape to be “somewhat” circular, built up with new concrete

Poe Dewatering Tunnel

MacArthur Dewatering Tunnel

Bonneted Knife Gate Valves

Crossover Tunnel

Bulkhead

Bulkhead Slot

Ladder

Jib Crane

Existing Discharge Pipe

Sump Pump

For Official Use Only

ELECTRICAL – PUMP WELLS

• New pump well

• Fed from Shaft 6 13.8kv switchgear.

• Power distribution utilizes 5kv switchgear and a 480V MCC.

• Pump motor control via 5kv Allen-Bradley VFD’s

• Poe Well

• Existing MCC A to be demolished and replaced with new.

• Davis Well

• Existing MCC B reused.

• New breakers to be added for new loads.

BREAK

**********TAKE A 10 MINUTE BREAK***********

NEXT STEP….LOCK STRUCTURE:

CONCRETE STRUCTURE/HYDRAULIC STEEL

STRUCTURES/MECHANICAL/ELECTRICAL

CONCRETE STRUCTURES 54

Soo Locks

Crescent Monoliths

Chamber Monoliths

Transition Monoliths

Retaining Wall

Compressor Tunnel

Widewall Monoliths

CONCRETE LOCK WALLS 55

• Widewall Monoliths: Monoliths on the U/S and D/S end of the chamber that house the Bulkhead Recesses, Ship Arrestors, Miter Gates and Culvert Valves. Also, these monoliths have the intake and discharge for the filling and emptying system.

• Chamber Monoliths: Monoliths toward the middle of the chamber that primarily have a culvert and gallery.

CONCRETE LOCK WALLS 56

• Widewall Monoliths: Vary depending on location and purpose.

CONCRETE LOCK WALLS 57

• Chamber Monoliths: Typical.

FILLING AND EMPTYING SYSTEM 58

FLOW

FLOW

Laterals

• Poe Lock Design

• 13’ x 14’ Culverts

• Each wall “feeds” a set of laterals

Intake Discharge

Reverse Tainter Valves

Miter Gates

CULVERT VALVES AND MACHINERY

• Exact copy of existing Poe Lock.

• Reverse Tainter style.

• Vertically-framed.

• Minimal deviation from Poe design as to not affect flow geometry.

HSS – TRASH SCREENS 60

• Culvert intake geometry identical to Poe Lock.

• Existing Poe Lock trash screens have functioned properly.

• New Lock trash screen is identical to Poe Lock using current materials and member sizes.

HSS – U/S & D/S MITER GATES 61

GATE LEAFS

• Same control dimensions as the existing Poe U/S and D/S miter gates.

• Gates are meant to be interchangeable with the Poe Lock.

HSS – U/S & D/S MITER GATES 62

GATE LEAFS

• Horizontally framed miter gates.

• 62’-11” between leaf contact points.

• Horizontal girder depth of 5’-5 1/2” o/o girder flanges.

Downstream Miter Gate Leaf

56.5 ft c/c top/bottom girders

13 horizontal girders

Upstream Miter Gate Leaf

34.8 ft c/c top/bottom girders

8 horizontal girders

MITER GATE MACHINERY

• Poe Lock Design (Rehabilitated)

HSS – CULVERT BULKHEADS 64

• Based on Poe Lock culvert bulkheads.

• Interchangeable with the Poe Lock.

• Designed to dewater culvert valve for maintenance while continuing lock operation.

• Installation and removal under equal hydrostatic head. Cannot be raised or lowered through flow.

• Incorporates sluice gate similar to MacArthur Lock culvert bulkheads for re-watering.

• ASTM A709 Grade 50 Zone 3 material.

• Member size and spacing is optimized to fit within narrow recess.

Sluice Gate

Section

HSS – MAINTENANCE BULKHEAD RECESS

FILLER AND LINER

• Maintenance bulkhead recess geometry required to be similar to existing Poe Lock.

• Poe Lock maintenance bulkheads will be used for dewatering of the New Lock chamber.

• New Lock filler is a 3-D trussed arrangement with skin plate face.

• Entire recess will be lined with steel plate.

New Lock Recess

Poe Lock Recess

Existing Poe Lock Filler

SHIP ARRESTORS

• Intended to protect miter gates from collision with a vessel.

Ship Arrestor

SHIP ARRESTORS

• Consists of an aluminum boom (sacrificial) which carries a 3.5” wire rope.

• 3.5” wire rope is connected to a spiral drum on each Lock Wall

(recessed). Spiral drum has 2 Low Speed High Torque (LSHT) Hydraulic motors (arresting force).

HSS – SHIP ARRESTOR BOOM 68

• Similar design as Poe Lock (see picture)

• Aluminum boom

• Latching issues on the Poe Lock due to excessive lateral displacement from solar thermal effects. Aluminum heat shields shown along sides of the boom.

MECHANICAL – HYDRAULIC SYSTEM

• 4-corner setup with 4 Hydraulic Power Units

– HPUs resemble Poe’s but one pump can run entire corner

– 2nd pump as backup

• Oil overflow tank in gallery with level alarms, breather, and leak shutdown

• Slightly higher working pressure

– Allows higher operating head while maintaining interchangeability with Poe

MECHANICAL - UTILITIES

• Air/steam distribution throughout chamber from compressor tunnel

– Sufficient valving to close off small sections for maintenance without loss of service

• Gallery ventilation

• Two sump pumps per pit for redundancy

ELECTRICAL – LOCK LIGHTING

• High Mast Lighting

• Modeled Using Acuity Visual Lighting Software

• Design Criteria – Minimum of 3 FC at low pool.

• 8 – 80 ft. poles for lock chamber

• 6 – 85,000 Lumen LED Fixtures/Pole (1000 Watt Equivalent)

BUILDINGS

Building Locations

Lock Control Houses

New Lock Chamber Outline

Cells to Close off Davis Chamber

BUILDINGS

Lock Control Houses •Load Bearing wall system consists of pre-cast concrete “sandwich” panels •Roof system will be steel trusses/joists with metal deck and rigid insulation •Buildings are approximately 60ft (E-W), 30ft (N-S) •Finished floor of bldgs will be secondary pour

HANDS FREE MOORING

• Hands free mooring will be partially incorporated into the new lock chamber construction. Recesses and fillers will be installed.

• Dynamic units are used to “grab” the vessels instead of tying the vessels off to the lock walls with lines.

• 4 units will be required on the North and and 3 units on the South.

• Option in the construction contract for equipment

TRAFFIC/PAVE PLAN

• Mobile Crane access to Maintenance Bulkhead slots and closure cells.

• Truck/cart access around lock structure.

• Truck/cart access to Unit 10 tailrace

• Truck/cart access to North Power Plant

From Plans drawings 01-RF101-10

CONCURRENT STEP….APPROACH WALLS

DOWNSTREAM WORK

320LF of End cells w/ fenders both sides; bollards

1200LF Pile & Lagging Wall w/ Bollards at 60’.

1040LF Pile & Lagging Wall w/ Bollards at 60’

DOWNSTREAM APPROACH WALL

New 45’ to 65’ Dia.

Cells with fenders on 3 sides and bollards

New Pile & Lagging Wall (rehab existing timber cribs)

Tie-backs to Poe Guardwall

Tie-backs to Drilled Shafts

PILE AND LAGGING TYPE WALL WITH TIE-BACK

3’ Dia. Rock Core

W18x311 at 8’ spacing

1’ x 4’ Precast Panels

4’ dia. At 8’ spa.

RC Drilled Pier for tie-back

2.5” Dia. Rods

Existing Timber Crib Walls

New Cap and Bollard Foundations, Ductbank, lighting

BASE AND OPTIONS – STRATEGY

BASE:

1. Shaft 6

2. NPP Bridge

3. Damming Surface

4. Unit 10 Electrical

5. South Wall

Stability

6. Dewater

OPTION 4a & 4b:

1. Chamber

Monoliths

2. LateralsOPTION 3:

1. U/S Widewalls

OPTION 2:

1. D/S Widewalls

2. Fabricate MG, CV, SA

4a & 4b3 2

OPTION 1:

1. Demolition of

Existing Sabin Walls

2. Rock Excavation

3. Mud Mat

OPTION 5:

1. Commissioning

2. Installation of MG, CV, SA

3. Site Work

4. Lock Floor

5. Removal of

CofferCells

OPTION 6:

1. D/S Approach

Wall

OPTION 7:

1. East Center Pier

Rehab

5 6

“OTHER OPTIONS”

Option 8: New Pumpwell – Remaining scope.

Option 9: HFM – Equipment including Dynamic Units, Electrical, etc.

Option 10: D/S Ship Arrestors – Equipment (arresting machines, fender boom, etc.)

Option 11: NPP Bridge Ramp – Ramp to Center Pier Option 12: NPP Bridge Widening – “Highway” portion of bridge.

VIRTUAL REALITY