R16PS00018_-_Amend._No._004.pdf

(x)

R16PS00018

x x

1 copies of the amendment; (b) By acknowledging receipt of this amendment on each copy of the offer submitted ; or (c) By separate letter or telegram which includes a reference to the solicitation and amendment numbers. FAILURE OF YOUR ACKNOWLEDGEMENT TO BE RECEIVED AT

THE PLACE DESIGNATED FOR THE RECEIPT OF OFFERS PRIOR TO THE HOUR AND DATE SPECIFIED MAY RESULT IN REJECTION OF YOUR OFFER. If by virtue of this amendment you desire to change an offer already submitted , such change may be made by telegram or letter, provided each telegram or letter makes reference to the solicitation and this amendment, and is received prior to the opening hour and date specified.

x

Sacramento CA 95825-1898 2800 Cottage Way, Room E-1815

R20

Division of Acquisition Services Regional Office Mid-Pacific Region Bureau of Reclamation

03/08/2016004

13. THIS ITEM ONLY APPLIES TO MODIFICATION OF CONTRACTS/ORDERS. IT MODIFIES THE CONTRACT/ORDER NO. AS DESCRIBED IN ITEM 14.

12. ACCOUNTING AND APPROPRIATION DATA (If required) is not extended.is extended, Items 8 and 15, and returning

Offers must acknowledge receipt of this amendment prior to the hour and date specified in the solicitation or as amended , by one of the following methods: (a) By completing

The above numbered solicitation is amended as set forth in Item 14. The hour and date specified for receipt of Offers

11. THIS ITEM ONLY APPLIES TO AMENDMENTS OF SOLICITATIONS

FACILITY CODE CODE

10B. DATED (SEE ITEM 13)

10A. MODIFICATION OF CONTRACT/ORDER NO.

9B. DATED (SEE ITEM 11)

9A. AMENDMENT OF SOLICITATION NO.

CODE

8. NAME AND ADDRESS OF CONTRACTOR (No., street, county, State and ZIP Code)

7. ADMINISTERED BY (If other than Item 6)CODE 6. ISSUED BY

PAGE OF PAGES

4. REQUISITION/PURCHASE REQ. NO.3. EFFECTIVE DATE2. AMENDMENT/MODIFICATION NO. 5. PROJECT NO. (If applicable)

1. CONTRACT ID CODE

AMENDMENT OF SOLICITATION/MODIFICATION OF CONTRACT

02/12/2016

CHECK ONE A. THIS CHANGE ORDER IS ISSUED PURSUANT TO: (Specify authority) THE CHANGES SET FORTH IN ITEM 14 ARE MADE IN THE CONTRACT

B. THE ABOVE NUMBERED CONTRACT/ORDER IS MODIFIED TO REFLECT THE ADMINISTRATIVE CHANGES (such as changes in paying office, C. THIS SUPPLEMENTAL AGREEMENT IS ENTERED INTO PURSUANT TO AUTHORITY OF:

D. OTHER (Specify type of modification and authority) appropriation date, etc.) SET FORTH IN ITEM 14, PURSUANT TO THE AUTHORITY OF FAR 43.103(b).

E. IMPORTANT: Contractor is not, is required to sign this document and return __________________ copies to the issuing office.

ORDER NO. IN ITEM 10A.

14. DESCRIPTION OF AMENDMENT/MODIFICATION (Organized by UCF section headings, including solicitation/contract subject matter where feasible.)

A. TITLE: Stampede Dam - Dam Safety Modifications

B. PURPOSE: The purpose of this amendment is to provide the website address for the Final

Environmental Assessment and Finding of No Significant Impact Report, provide various clarifications, and incorporate revised solicitation documents.

16A. NAME AND TITLE OF CONTRACTING OFFICER (Type or print)15A. NAME AND TITLE OF SIGNER (Type or print)

15C. DATE SIGNED 16B. UNITED STATES OF AMERICA 15B. CONTRACTOR/OFFEROR 16C. DATE SIGNED

(Signature of person authorized to sign) (Signature of Contracting Officer)

Dion T. Steele

STANDARD FORM 30 (REV. 10-83)

Prescribed by GSA

FAR (48 CFR) 53.243

NSN 7540-01-152-8070

Previous edition unusable

Except as provided herein, all terms and conditions of the document referenced in Item 9 A or 10A, as heretofore changed, remains unchanged and in full force and effect .

Continuation Page for

Solicitation R16PS00018 Amendment 004

Instructions for SF-30

Block 14 (Continued)

C. DESCRIPTION: This amendment hereby incorporates the following:

Clarifications:

(1) The Final Environmental Assessment (EA) and Findings of No Significant Impact (FONSI) can be located at the following website address:

Uwww.usbr.gov/mp/nepa/nepa_projdetails.cfm?Project_ID=8182

(2) In accordance with (IAW) Section L, Past Performance Questionnaires (PPQ) are to be submitted by email and/or incorporated into Volume I of the proposal by the applicable deadline. Past performance information submitted on Section J, Attachment No. 5, is preferred; however, all UrelevantU past performance information will be evaluated in accordance with Section M of the solicitation.

(3) Section L provides offerors information regarding minority participation in accordance with FAR 52.222-23. The applicable clauses for the resultant contract are incorporated by reference in Section I.

(4) Section J, Attachment No. 2 – FAR 52.219-14, Limitations of Subcontracting – Subcontracting Percentages Worksheet, shall be submitted in Volume I of the proposal by the applicable deadline.

Revised Contract Sections:

Remove and Replace the following specifications in Section C:

Section 32 32 20, Amendment 0003 Section 32 32 20, Amendment 0004 Section 34 71 13 Section 34 71 13, Amendment 0004

Remove Section L and Replace with Section L, Amendment No. 0004

Add Contract Sections:

None

Revised drawings to be removed and replaced:

None

Amendment 0004 Stampede Dam - Dam Safety Modifications Specifications No. 20-C0850

Mechanically Stabilized Earth (MSE) Crest Structure

32 32 20 - 1

SECTION 32 32 20

MECHANICALLY STABILIZED EARTH (MSE) CREST STRUCTURE

PART 1 GENERAL

1.01 MEASUREMENT AND PAYMENT

A. Mechanically Stabilized Earth Crest Structure Design:

1. Payment: Lump sum price offered in the Price Schedule.

a. Payment of the lump sum offered in the schedule will be made incrementally throughout completion of the design for the MSE crest structure. Final payment will not be made until all submittals required of Section 32 32 20 - Mechanically Stabilized Earth (MSE) Crest Structure are approved for construction.

B. Mechanically Stabilized Earth Crest Structure Construction:

1. Payment: Lump sum price offered in the Price Schedule.

a. Includes, but is not limited to:

1) Facing panels or modular blocks.

2) Steel strip, steel mat, or geogrid reinforcement.

3) Leveling pad concrete.

4) Surface drainage collection system and subsurface drainage features.

C. Moment Slab and Vehicular Barrier/Bicycle Guardrail System:

1. Payment: Lump sum price offered in the Price Schedule.

a. Includes, but is not limited to:

1) Contractor-designed moment slab for MSE crest structure.

2) Contractor-designed vehicle barrier/bicycle guardrail system for MSE crest structure.

3) Contractor-designed vehicle barrier/bicycle guardrail system for new spillway crest structure bridge deck.

4) Surface drainage collection system.

b. Does not include W-Beam guardrails and wood posts to be installed on the new embankment crest structure and non-MSE abutment transitions.

Refer to Section 34 71 13 - W-Beam Guardrail with Wood Posts.

D. Deleted.

1. Deleted.

32 32 20 - 2

a. Deleted.

1.02 REFERENCE STANDARDS

A. American Association of State Highway and Transportation Officials (AASHTO)

1. AASHTO SSHB-02 Standard Specifications for Highway Bridges, 17th Edition

2. AASHTO LRFD 2012 LRFD Bridge Design Specifications, Sixth Edition, 2012, including 2013 Interims

3. AASHTO M 32M/M 32-09 Steel Wire, Plain, for Concrete Reinforcement

4. AASHTO M 55M/M55-99 Plain Steel Welded Wire Fabric for Concrete Reinforcement

5. AASHTO M 164-05(2008) High-Strength Bolts for Structural Steel Joints

6. AASHTO M 288-06(2011) Geotextile Specification for Highway Applications

7. AASHTO T 99-10 Moisture-Density Relations of Soils Using a 2.5-kg (5.5-lb) Rammer and a 305-mm (9.120-inch) Drop

8. AASHTO T 104-99(2011) Soundness of Aggregate by Use of Sodium Sulfate or Magnesium Sulfate

9. AASHTO T 180-10 Moisture-Density Relations of Soils using a 4.54-kg (10-lb) Rammer and a 457-mm (18-in.) Drop

10. AASHTO T 288-12 Determining Minimum Laboratory Soil Resistivity

11. AASHTO T 289-91(2008) Determining pH of Soil for Use in Corrosion Testing

B. ASTM International (ASTM)

1. ASTM A123/A123M-13 Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products

2. ASTM A572/A572M-13a High-Strength Low-Alloy Columbium-Vanadium Structural Steel

3. ASTM A780/A780M-09 Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings

4. ASTM A1001-01(2010) High Strength Steel Castings in Heavy Sections

5. ASTM C33/C33M-13 Concrete Aggregates

6. ASTM C140/C140M-13a Sampling and Testing Concrete Masonry Units and Related Units

7. ASTM C150/C150M-12 Portland Cement

8. ASTM C618-12a Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in Concrete

32 32 20 - 3

9. ASTM C979/C979M-10 Pigments for Integrally Colored Concrete

10. ASTM C1262-10 Evaluating the Freeze-Thaw Durability of Dry-Cast Segmental Retaining Wall Units and Related Concrete Units

11. ASTM D1505-10 Density of Plastics by the Density-Gradient Technique

12. ASTM D2000-12 Classification System for Rubber Products in Automotive Applications

13. ASTM D4327-11 Anions in Water by Chemically Suppressed Ion Chromatography

C. Bureau of Reclamation (USBR)

1. USBR Design Standards No. 13 USBR Design Standards No. 13 – Embankment Dams

D. Federal Highway Administration (FHWA)

1. FHWA-NHI-10-024 Design and Construction of Mechanically Stabilized Earth Walls and Reinforced Soil Slopes – Volume I

– November 2009

2. FHWA-NHI-10-025 Design and Construction of Mechanically Stabilized Earth Walls and Reinforced Soil Slopes – Volume II – November 2009

1.03 MSE WALL SYSTEM DESCRIPTION

A. Segmental mechanically stabilized earth wall system consisting of mortarless concrete wall units backfilled with compacted reinforced soil. Any manufacturer’s MSE wall system is acceptable for use provided it meets the requirements of this Section.

1.04 DESIGN REQUIREMENTS – MSE CREST STRUCTURE

A. Contractor has option of designing wall using either precast concrete wall panels or modular block wall units as facing.

B. Contractor has option of designing soil reinforcement using galvanized steel strips, galvanized steel mat, or geogrid for MSE reinforcement.

C. Design in accordance with AASHTO LRFD 2012 and these specifications. In cases of conflicting requirements, these specifications shall govern.

D. For back-to-back MSE crest structure sections, design reinforcement such that alternating reinforcement layers extending from opposite walls overlap a minimum of 30 percent of design height of wall. Do not connect reinforcement layers to both wall facings.

32 32 20 - 4

E. Calculate maximum reinforcement loads using “Simplified Method” in accordance with

AASHTO LRFD 2012.

F. Surface Drainage:

1. Incorporate design of surface runoff drainage system as part of the MSE crest structure design.

2. Design surface drainage system in accordance with AASHTO or CALTRANS requirements for capacity.

3. The surface drainage system shall be completely independent and separate from Government-designed subsurface drainage system.

4. The surface drainage system shall not utilize an internal (inside the wall) drainage system.

5. The surface drainage system shall be designed to sheet-flow off the MSE Crest Structure meeting the following conditions:

a. The moment slab is configured to ensure that no water runs onto the wall panels or modular blocks resulting in water staining.

b. The layout of Dog Valley Road, as shown on the drawings, is not redesigned.

G. Design and provide connection between MSE wall and new spillway such that loss of fill will not occur.

H. Provide walls with subsurface drainage features as shown on drawings.

I. Obstructions in Backfill:

1. General:

a. Where obstructions, such as surface drainage system components, are located in the reinforced backfill zone, cutting of reinforcements to avoid obstructions is not permitted. Special design detailing shall be required for all obstructions subject to the following requirements:

1) Horizontal Deflection of Reinforcements: Grid reinforcements may not be splayed, unless connection has been specifically fabricated to accommodate a splay and connection detail has been approved by the Government. If used, the splay in grid reinforcement is limited to 15 degrees. For obstructions that cannot be accommodated with splayed reinforcement, structural frames and connections shall be required, and shall be designed in accordance with Section 10 - Steel Structures of AASHTO LRFD 2012 for the maximum tension in the reinforcements. The structural frame design shall be such that bending moments are not generated in the soil reinforcement or the connection at the wall face. The design, along with supporting calculations, shall be

32 32 20 - 5 included in the Contractor shop drawings required by

RSN 32 32 20-1.

2. Vertical Deflection of Reinforcements:

a. Vertical deflection of reinforcement to avoid obstructions such as utilities along the wall face shall be limited to a maximum of 15 degrees from normal to face of wall.

b. Bends in reinforcement shall be smooth and gradual.

3. Reinforcement shall not be left unconnected to the wall face, cut or bent in the field to avoid obstructions.

4. Penetrations through the face of the MSE crest structure shall be designed with wall facing elements to fit around the penetrations such that the facing elements are stable and the backfill will not spill through the wall facing elements at the penetration. Differential movement between the facing elements and the backfill should be anticipated and associated downdrag stress shall be considered in the MSE crest structure design.

J. Hydrostatic Pressures:

1. The MSE crest structure system is subject to inundation. The walls shall be designed to be stable under loading conditions associated with the PMF and the phreatic surface indicated in Figure 1 – Typical MSE Crest Structure with Phreatic Surface Plotted. The phreatic surface of Figure 1 shall be used to determine limits where effective unit weights should be used in the calculations for internal and external stability. Additionally, rapid drawdown shall be considered for stability analyses. A drawdown rate of 0.1 foot per hour (2.4 feet per day) shall be assumed for the purpose of rapid drawdown analysis.

K. Backfill Reinforcement for Modular Block Wall Systems:

1. Backfill reinforcement lengths and percent coverage at a given reinforcement level shall be in accordance with the approved Contractor shop drawings required by RSN 32 32 20-1. All backfill reinforcement shall be positively connected to the modular block facing units that are capable of resisting 100 percent of the maximum tension in the backfill reinforcements at any level within the wall.

Detailed documentation for connection strength shall be submitted. The vertical spacing of the soil reinforcement for walls with modular block facing units shall be as follows:

a. The first (bottom) layer of soil reinforcement shall be no further than 16 inches above the top of the leveling pad.

b. The last (top) layer of soil reinforcement shall be no further than 20 inches on the average below the top of the uppermost modular block wall unit.

c. The maximum vertical spacing between layers of adjacent soil reinforcement shall not exceed 32 inches. For walls deriving any part of their connection capacity by friction the maximum vertical spacing of the reinforcement should be limited to two times the block depth (front face to

32 32 20 - 6 back face) to ensure construction and long-term stability. The top row of reinforcement shall be one-half the vertical spacing.

L. Backfill Reinforcement for Precast Panel Wall Systems:

1. The backfill reinforcement lengths and percent coverage at a given reinforcement level shall be in accordance with the approved Contractor shop drawings required by RSN 32 32 20-1. All backfill reinforcement shall be positively connected to the precast panel facing units that is capable of resisting 100 percent of the maximum tension in the backfill reinforcements at any level within the wall.

Detailed documentation for connection strength shall be submitted as noted above. The vertical spacing of the backfill reinforcement for walls with precast panel facing units shall be as follows:

a. The first (bottom) layer of backfill reinforcement shall be no further than 16 inches above the top of the leveling pad.

b. The last (top) layer of backfill reinforcement shall be no further than 20 inches on the average below the top of the uppermost precast panel unit.

c. The maximum vertical spacing between layers of adjacent backfill reinforcement shall not exceed 32 inches. The top row of reinforcement shall be one-half of the vertical spacing.

M. Initial Batter of Wall:

1. The initial batter of the wall, both during construction and upon completion, shall be within the vertical and horizontal alignment tolerances included in this section.

2. The initial batter of the wall at the start of construction and the means and methods necessary to achieve the batter shall be provided on the Contractor shop drawings required by RSN 32 32 20-1. Subject to approval of the COR and the MSE crest structure design engineer, the initial batter may be modified at the start of construction by the manufacturer’s field representative based on the evaluation of the backfill material. Any such changes shall be documented in writing within 24 hours of the approved changes. This written document shall be sealed by the MSE crest structure design engineer who is registered as a Civil Engineer in the state of California. Details of the wedges or shims or other devices, such as clamps and external bracing used to achieve or maintain wall batter, shall be as shown on the approved shop drawings and/or accompanying construction manual.

Permanent shims shall comply with the design life criteria, and shall maintain the design stress levels required for the walls.

N. Supplement Contractor shop drawings required by RSN 32 32 20-1 with all design calculations for the MSE crest structure design as required herein. Installations that deviate from the approved design shall be accompanied by supporting stability (internal;

external; and global/overall) calculations of the proposed modified structure as well as supporting calculations for all special details not contained in the approved design and resubmitted for approval. The MSE crest structure design engineer shall note all

32 32 20 - 7 deviations of the proposed MSE crest structure design from the approved design on the resubmitted shop drawings for approval.

O. Due to the back-to-back MSE wall configuration and overlapping requirement for reinforcement layers, seismic external stability analysis is not required. For internal stability analysis, the horizontal seismic acceleration coefficient at zero displacement, kho = 1.2g (AASHTO LRFD 2012 11.6.5.2) shall be used. The seismic horizontal acceleration coefficient, kh may be reduced to 0.5kho as per AASHTO LRFD 2012

11.6.5.2.2. If a more sophisticated dynamic analysis using numerical modeling methods with commercially available finite element or finite difference computer software is performed in lieu of pseudo static analysis, the seismic ground motion time histories provided in Section 51 00 50 – Earthquake Time Histories shall be applied at the base of the MSE crest structure. The maximum calculated deformation using numerical modeling shall not exceed 2 inches.

1. Deleted.

P. Design Criteria: As provided in Table 32 32 20A – Design Parameters, Table 32 32 20B

– Load Combinations, and Table 32 32 20C – Load Factors.

32 32 20 - 8

Table 32 32 20A – Design Parameters Description Limit State Value Note

Design Life All limit states 100 Years Effective (Drained) Friction Angle:

a. Retained Backfill

All limit states 34 degrees

b. Reinforced Wall Backfill Material

All limit states 34 degrees 1

Bearing Capacity All limit states Calculate using Equation

10.6.3.1.2a-1 in

AASHTO LRFD 2012

Length of soil reinforcement, B All limit states Overlap a minimum of 30 percent of design height of wall

Limiting eccentricity Strength (all) B/4 (soil), 3/8B (rock)

Service I B/6 (soil), B/4 (rock) Coefficient of Sliding Friction Strength (all) 0.60 Moist Unit Weight All limit states 130 lb/ft3 Saturated Unit Weight All limit states 135 lb/ft3 Resistance factors:

a. Sliding Strength (all) 1.0 3

b. Bearing Strength (all) 0.65 Deleted

c. Overall (slope) stability:

I. Deep Seated Stability Service I 0.65 5 II. Compound Stability Service I 0.65 5

d. Pullout resistance:

I. Static Strength (all) 0.90 6 II. Combined static/earthquake Strength (all) 1.20 6 Tensile resistance of geosynthetic reinforcements and connectors:

a. Static Strength (all) 0.90

b. Combined static/earthquake Strength (all) 1.20 Notes:

1. The reinforced and retained backfill will be used for the MSE crest structure construction. Laboratory testing performed on the borrow material is included in Section 53 20 00 – Records of Geologic and Subsurface Investigations and Section 53 30 00 – Memorandum.

2. H is the design height of the wall and is defined as the difference in elevation between the finished grade at the top of wall and the top of leveling pad. The top of the leveling pad shall always be below the minimum embedment reference line as indicated on the drawings for that location. The length of the backfill reinforcement, B, is measured from the backface of the wall facing unit. In case of grid type reinforcements the length of the backfill reinforcement is measured from the backface of the wall to the last full transverse member. For modular block facing units, the total length of the reinforcement, BT, as measured from the front face of the wall is the length B as defined above plus the width of the modular block unit (the horizontal dimension of the block unit measured perpendicular to the wall face).

3. Passive resistance shall not be considered in evaluation of sliding resistance.

4. Deleted.

5. For earthquake loading condition and PMF flood loading, a resistance factor of 0.90 shall be used.

6. Live load due to vehicular traffic shall be included in the computations to determine the maximum tensile forces in reinforcement layers, but shall be neglected in the computations for pullout resistance.

32 32 20 - 9

Table 32 32 20B – Load Combinations

Load Combination Limit State

DC, EH, ES,

EV

LL, LS, S

Use One at a Time

EQ FL CT

Strength I γp 1.75 - - - Extreme Event I (EQ) 1 1 1 - - Extreme Event II (FL) γp γFL - 1 - Extreme Event II (CT) γp 0.5 - - 1 Service I 1 1 - - - Notes:

Extreme Event I includes seismic events.

Extreme Event II includes vehicular impact and flood events.

DC = dead loads EH = horizontal earth loads ES = earth surcharge load EV = vertical pressure from dead load of earth fill CT = vehicular collision force FL = flood load EQ = earthquake load LL = vehicular live load LS = live load surcharge S = snow load γp = load factor for permanent loading. May subscript as γp- EV, γp-EH, etc γEQ = load factor for simultaneously with seismic loads γFL = load factor for simultaneously with PMF loads

Table 32 32 20C – Load Factors

Type of Load Load Factor

Maximum Minimum DC – Components and Attachments 1.25 0.90 EH – Horizontal Earth Pressure 1.50 0.90

EV – Vertical Earth Pressure Overall Stability

Retaining Walls and Abutments

1.00

1.35 n/a

1.00

ES – Earth Surcharge 1.50 0.75

Note: May substitute as γEV-MIN, γEV-MAX, γEH-MIN, γEH-MAX, etc

32 32 20 - 10

1.05 DESIGN REQUIREMENTS – MOMENT SLAB AND VEHICLE BARRIER

A. Design vehicle barrier system for MSE crest structure and spillway crest structure bridge deck using open guardrail system consisting of posts and rail. Concrete barrier system is not allowed.

B. Design concrete moment slab for MSE crest structure and spillway crest structure bridge deck to resist vehicular design loads including barrier system lateral loads. Moment slab concrete shall meet the requirements of spillway slabs concrete mix in Table 03 30 00A – Concrete Mixes in Section 03 30 00 – Cast-In-Place Concrete.

C. Design vehicle barrier system in accordance with AASHTO LRFD 2012, Section 11.10.10.2.

D. Design forces in accordance with Railing Test Level TL-2.

E. Incorporate vehicle barrier into MSE crest structure and spillway crest structure bridge deck.

F. Ensure vehicle barrier transitions between the MSE crest structure, the new spillway crest structure, and the new embankment crest structure are in accordance with State of California regulations.

G. Vehicle barrier system shall include provisions for limiting surface drainage infiltration into the MSE crest structure earthfill, including defensive measures at joints in concrete elements as necessary.

H. Vehicle barrier system shall connect continuously as a smooth transition with W-Beam guardrails and wood posts to be installed on the new embankment crest structure and non-MSE abutment transitions. Refer to Section 34 71 13 - W-Beam Guardrail with Wood Posts.

I. Vehicle barrier system shall connect continuously as a smooth transition with Contractor-designed spillway crest structure bridge deck vehicle barrier system.

1.06 BICYCLE GUARDRAIL SYSTEM

A. Reference to pedestrian guardrail system on the drawings or within these specifications refers to bicycle guardrail system.

B. Incorporate bicycle guardrail system into vehicular barrier system installed for the MSE crest structure and the spillway crest structure bridge deck.

C. Design, fabricate and install bicycle guardrail system in accordance with the following requirements.

1. Resist forces induced by cyclists.

32 32 20 - 11

2. Minimum height of bicycle guardrail: 48 inches (distance from road surface to top of guardrail). Design guardrail such that an 8-inch diameter sphere cannot pass through the guardrail between the tops of vehicle barrier and bicycle guardrail.

3. Deleted.

4. Materials for bicycle guardrail: Aluminum, galvanized steel, or painted steel.

Wood railing or closed face systems are not allowed.

5. Fabricate top rail of bicycle guardrail from pipe or tubing, free from sharp kinks and bends. Grind all welds smooth.

1.07 SUBMITTALS

A. Submit the following in accordance with Section 01 33 00 - Submittals.

B. RSN 32 32 20-1, Designs and Product Data:

1. MSE crest structure design and product data.

a. Include structural analysis and design calculations for walls and foundations, as well as material descriptions and specifications. Include sample analyses and hand-calculations to verify the output from software used by the MSE crest structure designer. Include details of dynamic analysis if performed.

b. If dynamic analyses are performed using numerical modeling methods with commercially available finite element or finite difference computer software, provide input and output files, and results of the dynamic analysis. The input files shall include dimensions and materials properties of the MSE crest structure and the boundary conditions of the numerical model. The provided results shall include, as a minimum, the maximum horizontal acceleration and the maximum horizontal and vertical deformations of the MSE crest structure under seismic loading, the maximum tensile force developed in the MSE crest structure reinforcement, and the maximum force developed at the connection between the MSE facing units and the reinforcement.

c. Sign and seal design data by the MSE crest structure design engineer registered in the State of California.

2. Design and product data for moment slab and vehicle barrier system.

a. Include structural analysis and design calculations, including design loads, material descriptions, strengths and grades, and specifications.

b. Sign and seal calculations and data by the slab and barrier system design engineer registered in the State of California.

3. Design and product data for bicycle guardrail system.

32 32 20 - 12

a. Include structural analysis and design calculations including design loads, material descriptions, strengths and grades, and specifications.

b. Sign and seal calculations and data by the bicycle guardrail system design engineer registered in the State of California.

4. Shop Drawings for MSE crest structure:

a. Show wall layout, designs, alignments, dimensions, cross sections, plan and elevations, galvanized steel strip, galvanized steel mat, or geogrid soil reinforcement, foundation base, drainage zone, perforated pipe drains, detail of north and south spillway crest structure connections, and other installation details.

b. Include design parameters, assumptions, and design life.

c. Show existing ground elevations and utilities impacted by the MSE crest structure, and those to be field verified by the Contractor, for each location.

d. Complete details of all elements and component parts required for construction of the MSE crest structure system at each location; any requirements to accommodate drainage systems, foundation subgrades, and other facilities as shown on the drawings.

e. Details of special design requirements. These may include, but are not limited to:

1) Structural frames to place reinforcements around obstructions such as drainage pipes and guardrail supports.

2) Drainage systems.

3) Placement sequence of drainage and reinforced wall backfill material with respect to retained backfill material behind a wall face using modular block facing units.

4) Post installations for both vehicle barrier system and bicycle guardrail system.

5) Scour protection.

6) Foundation subgrade modification.

7) All corner details including acute, obtuse, and 90 degrees, slip joints, and joint details of MSE crest structure with other cast-in-place structures.

8) Wedges, shims, and other devices such as clamps and bracing to establish and maintain vertical and horizontal wall facing alignments.

9) Transition details associated with the abutment transitions and transitions with the new embankment crest structure.

f. Bearing pads information:

32 32 20 - 13

1) Calculations: Substantiating calculations verifying the stiffness (axial and lateral), size, and number of bearing pads assuming, as a minimum, a vertical loading at a given joint equal to 2 times the weight of facing panels directly above that level.

2) Certified laboratory test results: In the form of vertical load-vertical strain and vertical load-lateral strain curves for the specific bearing pads proposed for use. The vertical load-vertical strain curve should extend beyond the first yield point of the proposed bearing pad.

g. Complete listing of components and materials specifications.

h. Other site specific or project specific information.

i. Sign and seal design computations and analysis methods for conformance to specifications requirements by the MSE crest structure design engineer registered in the State of California.

j. Sign and seal each Contractor shop drawing required by RSN 32 32 20-1 by the MSE crest structure design engineer registered in the State of California.

5. Structural drawings for moment slab and installation drawings for vehicular barrier systems.

a. Structural drawings of moment slab showing locations, overall dimensions, reinforcement locations and details, and typical plans and cross sections.

b. Installation drawings of vehicle barrier system showing plans, sections, typical cross sections, splices and anchorage details, and complete list of components and materials specifications.

c. Sign and seal structural and installation drawings by moment slab and vehicle barrier system design engineers registered in the State of California.

6. Shop drawings for bicycle guardrail system.

a. Show layout, alignments, dimensions, typical cross sections, splice and anchorage details, and complete list of components and materials specifications.

b. Sign and seal shop drawings by bicycle guardrail system design engineer registered in the State of California.

C. RSN 32 32 20-2, Approval Samples for MSE Crest Structure:

1. One Precast Wall Panel.

a. Notify COR, in writing, of date and time of precast wall panel sample construction at least 7 days before construction.

b. Construct sample in presence of COR.

32 32 20 - 14

c. Approved sample will be quality standard for completed work. Use same materials, equipment, methods, and workmen to be used in work.

d. Textured Form Surface and Concrete Stain:

1) Submit manufacturer’s data sheet for the textured form pattern for acceptance prior to fabricating precast wall panel sample.

2) Submit manufacturer’s data sheet for the concrete stain for acceptance prior to fabricating precast wall panel sample.

3) Provide a full size panel with the textured form surface and concrete stain using the same materials to be used for the precast wall panel.

a) Form liner, minimum: 1 manufactured size panel.

4) Construct precast wall panel sample with sufficient time to allow the concrete to cure before observation.

e. Obtain Government approval of the precast wall panel sample before proceeding with work. Remove rejected sample and remake sample until approval is obtained.

f. Disposal: After completion and acceptance of work, remove and dispose of sample in accordance with Section 01 74 00 - Cleaning and Waste Management. Obtain permission from COR to remove and dispose sample.

2. Provide three modular blocks (segmental) facing units with specified color and meeting shape requirements for unit core fill placement between blocks for approval.

D. RSN 32 32 20-3, Certifications:

1. MSE Crest Structure Manufacturer’s Certification:

a. Manufacturer's certification that wall units meet specified requirements.

b. Attach one set of results from specified sampling and testing to each certification.

2. MSE Crest Structure Designer’s Certification:

a. Designer’s certification that design parameters meet specified requirements.

3. Geosynthetic Manufacturer’s Certification:

a. Supplied geosynthetic is of the approved type and meets all test methods and standards specified herein. Manufacturer’s certificate shall state that the furnished geosynthetic meets the requirements of the specifications, as evaluated by the manufacturer’s quality control program. COR may require the Contractor to supply supporting test data from an approved laboratory to support certified values submitted.

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4. Modular Block Connection Certification:

a. Provide certification of analysis for modular block facing units.

1) Include detailed calculations in accordance with AASHTO LRFD 2012.

2) Certification demonstrates that all connections, including block-to-reinforcement and block-to-block connections, and all related components meet or exceed the current AASHTO 100 year design life requirements and are capable of resisting 100 percent of the maximum tension in the soil reinforcements at any level within the wall.

5. Unit Core Fill Gradation and Certification.

a. Gradation and supplier certification (required only if Unit Core Fill is used).

6. Vehicle Barrier System and Bicycle Guardrail System Certifications.

a. Manufacturer’s certification that vehicle barrier system meets specified requirements.

b. Designer’s certification that design parameters meet specified requirements.

E. RSN 32 32 20-4, Final Drawings (Government Format):

1. Final drawings of vehicle barrier system and bicycle guardrail system consisting of detailed shop drawings, erection plans, and bills of materials.

2. Show revisions made to drawings up to time fabrication is completed.

F. RSN 32 32 20-5, Test Reports and Results:

1. Modular Block Units Test Results.

2. Modular Block Connection Test Results:

a. Laboratory test results performed in accordance with Section B.3 in Appendix B of FHWA NHI-10-025.

3. Metallic Wall Reinforcement:

a. Mill test report for galvanized steel strips containing the ultimate tensile strength of the soil reinforcement and galvanization coverage.

b. Mill test report for galvanized metallic mat wall reinforcement containing the ultimate weld strength and galvanization coverage.

G. RSN 32 32 20-6, Instructions for MSE Crest Structure:

1. Manufacturer's storage, handling, and installation instructions.

H. RSN 32 32 20-7, Installation Plan for MSE Crest Structure:

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1. Installation plans and details.

2. Equipment to be used.

3. Quality control plan criteria for installation processes.

I. RSN 32 32 20-8, Haul Route Frequency and Construction Plan for MSE Crest Structure:

1. Number of truck passes per lift placement.

1.08 QUALIFICATIONS – MSE CREST STRUCTURE

A. Manufacturer's Qualifications:

1. Established manufacturer of mechanically stabilized earth systems of specified type.

2. Minimum of 5 years of continuous experience in manufacture of mechanically stabilized earth systems.

B. MSE Crest Structure Designer Qualifications:

1. Experienced professional engineer registered in State of California.

C. Installation Supervisor Qualifications:

1. Minimum of 3 years of continuous experience in installation of mechanically stabilized earth systems similar to that required herein.

1.09 PRE-INSTALLATION MEETING

A. Date: No later than 60 days before beginning mechanically reinforced earth crest structure installation and prior to performing any work on the RSN for the mechanically reinforced earth crest structure installation plan.

B. Location: Onsite at Government’s Field Office

C. Purpose: Review with Government personnel installation plan and technical requirements for the mechanically reinforced earth crest structure installation.

D. Attendees: Responsible engineering representatives who have been fully informed of specifications requirements with respect to technical requirements and MSE crest structure to be installed. Representatives shall include:

1. One from Contractor.

2. One from mechanically stabilized earth system manufacturer.

3. MSE crest structure design engineer.

E. Within 30 calendar days after conclusion of pre-installation meeting, Government will furnish Contractor a letter regarding items discussed at meeting with enclosed copies of all pertinent drawings and data marked with Government’s comments.

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F. No MSE crest structure construction activity shall be performed until the Contractor’s installation plan submittal has been approved and all review comments have been resolved, and the pre-installation meeting has been held.

1.10 DELIVERY, STORAGE, AND HANDLING

A. Ship, store and handle system materials in accordance with manufacturer's instructions and the following:

1. Ship, store, and handle concrete wall units in such a manner to eliminate chipping, discoloration, cracking, fracturing, and excessive bending stresses.

B. Store wall units and accessory materials off ground and protect from damage.

1. Support panels or modular block units in storage on firm blocking to protect connection devices and exposed exterior finish.

C. Store metallic reinforcement in separate piles or racks raised above the ground.

D. Protect metallic reinforcement from contaminants such as grease and oil.

E. Provide for metallic reinforcement identification after bundles are broken and tags removed.

F. Protect geogrids from exposure to sunlight.

PART 2 PRODUCTS

2.01 PRECAST CONCRETE WALL PANELS

A. Cast-in-Place Concrete: Materials in accordance with Section 03 30 00 - Cast-In-Place Concrete except as provided below.

B. Mix:

1. Manufacturer shall design and adjust concrete mix.

a. The Government reserves the right to adjust mix proportions when need for adjustment is indicated by results of materials testing.

C. Compressive Strength:

1. At 28 Days, Minimum: 4,000 pounds per square inch (lb/in2).

2. Do not ship or place panels in wall until a compressive strength of at least 3,400 lb/in2 is attained.

D. Cast wall panels in accordance with approved Contractor shop drawings required by RSN 32 32 20-1.

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1. Cast on a flat and level area and fully support facing elements until a minimum compressive strength of 1,000 lb/in2 is attained.

E. Set in place all embedded components prior to casting to required dimensions and within allowable tolerances.

F. Concrete Testing and Inspection: Precast concrete wall panels are subjected to compressive strength testing and inspection for meeting dimensional tolerances and surface conditions in accordance with Section 03 30 00 - Cast-In-Place Concrete.

G. Casting:

1. Cast face panels on a horizontal textured form surface with the front face of the panel at the bottom of the form. Set connection hardware in the rear face. Place concrete for each precast panel without interruption and consolidate by deploying vibrator supplemented by hand tamping as necessary to force concrete into corners of forms. Eliminate formation of stone pockets or cleavage planes. Use form release agents compatible with textured form on all form faces for all casting operations.

2. Notify the COR at least 14 days before beginning casting operations.

H. Finishes:

1. Non-Exposed Surfaces: Rear faces of panels shall meet Formed Surfaces Finish F1 in accordance with Section 03 30 00 - Cast-In-Place Concrete.

2. Exposed Surfaces:

a. Concrete panel finish:

1) Provide textured surface.

2) Use form liner having the following essential characteristics:

a) Thermoformed rigid polymer alloy sheets.

b) Produces a uniformly textured, fractured granite design surface.

c) Produces a relief height of fractures of 7/8-inch, maximum.

3) Use one type of textured form surface.

4) Construct forms to produce a uniform and consistent texture and pattern on face of concrete. Metal patches on forms are not permitted.

I. Concrete Stain:

1. Penetrating concrete stain designed for permanently staining concrete and suitable for exterior use.

a. Water-based.

b. Environmentally friendly.

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c. Ultraviolet resistant.

2. Concrete stain to be earth tone, tan-brown similar to Federal Colors 33440, 33446, 33448, or 30266.

3. Final selection of MSE crest structure stain color will be made by Government after submittal, review, and approval of product samples in field.

J. Concrete Stain Sealer:

1. Clear, penetrating sealer that provides breathable, protective film used to protect concrete stain.

2. As recommended by the concrete stain manufacturer.

K. Tolerances:

1. Connection Device Placements: Within plus or minus 1-inch of dimensions shown on approved Contractor shop drawings required by RSN 32 32 20-1.

2. Panel Squareness: As determined by the difference between the two diagonals shall not exceed 1/2-inch.

L. Identification and Markings:

1. Inscribe the following on a non-exposed surface of each panel:

a. Date of manufacture.

b. Production lot number.

c. Piece number indicator.

M. Panel Joints:

1. General: Where the wall wraps around an inside corner, provide a corner block with flange extension that allows for differential movement without exposing the panel joints. Cover the back faces of vertical and horizontal joints with approved geotextile filter. Joint filler, bearing pads, and geotextile filter shall be as recommended by the MSE manufacturer and in accordance with the approved Contractor shop drawings required by RSN 32 32 20-1. If required on the approved Contractor shop drawings required by RSN 32 32 20-1, use flexible open-cell polyurethane foam strips for filler in the vertical joints between panels, and in horizontal joints where pads are used.

2. Geotextile Filter:

a. Cover all joints between panels on the back side of the wall with a geotextile meeting the requirements for filtration applications as specified by AASHTO M 288.

b. Width, minimum: 1-foot.

3. Bearing Pads:

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a. Bearing pads to be included in all horizontal and diagonal joints between panels. Bearing pads shall meet or exceed the following requirements:

1) Preformed EPDM (Ethylene Propylene Diene Monomer) rubber pads conforming to ASTM D2000 Grade 2, Type A, Class A with a Durometer Hardness of 70.

2) Preformed HDPE (High Density Polyethylene) pads with a minimum density of 0.946 grams per cubic centimeter in accordance with ASTM D1505.

b. The stiffness (axial and lateral), size, and number of bearing pads shall be determined such that the final joint opening shall be 3/4+1/8 inch unless otherwise shown on the approved Contractor shop drawings required by

RSN 32 32 20-1.

2.02 REINFORCEMENT

A. Galvanized Steel Reinforcing Strips and Tie Strips:

1. Reinforcing Strips: Hot-rolled from bars to the required shape and dimensions.

Physical and mechanical properties conforming to ASTM A572, Grade 65 minimum.

2. Tie Strips: Shop fabricated of hot-rolled steel conforming to the requirements of ASTM A1001, Grade 50 minimum. Minimum bending radius shall be 3/8-inch.

Galvanization applied after the strips are fabricated, inclusive of punch holes for bolts as shown on approved Contractor shop drawings required by RSN 32 32 20-1.

B. Geosynthetic Reinforcement:

1. Geosynthetic soil reinforcement shall be limited to geogrids. The geogrid shall be a regular network of integrally connected polymer tensile elements, with aperture geometry sufficient to permit significant mechanical interlock with the surrounding soil. Geogrid structure shall be dimensionally stable and able to retain its geometry under manufacture, transport and installation.

2. Nominal long-term tensile design strength (Tal) of specific geosynthetic material shall meet or exceed minimum strength required for the geosynthetic reinforcement consistent with design.

C. Steel Mat Reinforcement:

1. Reinforcing mesh shall be shop fabricated of cold-drawn steel wire conforming to the requirements of AASHTO M 32, and shall be welded into the finished mesh fabric in accordance with AASHTO M 55.

2.03 STEEL COMPONENTS FOR GALVANIZED STEEL REINFORCING

A. Connector Pins:

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1. Connector pins and steel mat bars shall be fabricated and connected to the soil reinforcement mats as shown on the approved Contractor shop drawings required by RSN 32 32 20-1. Connector bars shall be fabricated of cold drawn steel wire conforming to AASHTO M 32.

B. Fasteners:

1. Connection hardware shall conform to the requirements shown on the approved Contractor shop drawings required by RSN 32 32 20-1. Connection hardware shall be cast in precast concrete panels such that all connectors are in alignment and able to transfer full and even load to the soil reinforcement. Once the reinforcement is connected to the panel, the amount of slack shall not exceed 1/8-inch between the connector and the reinforcement during field installation.

Fasteners shall be galvanized and conform to the requirements of AASHTO M 164 or equal.

C. Galvanizing:

1. Soil reinforcement steel shall be hot-dip galvanized in accordance with ASTM A123. Connection hardware steel may be galvanized by hot-dipping or other means, provided the method satisfies the requirements of ASTM A123. A minimum galvanization coating of 2.0 oz/ft2 (605 g/m2) or 3.4 mils (85 μm) thickness is required. Soil reinforcement steel shall be adequately supported while lifting and placing such that the galvanization remains intact.

2. Steel reinforcement with damaged (peeled) galvanization shall be repaired in accordance with ASTM A780 and as specified on the approved Contractor shop drawings required by RSN 32 32 20-1, at no additional cost to the Government.

2.04 REINFORCED WALL BACKFILL MATERIAL

A. In accordance with Section 31 24 14 - Mechanically Stabilized Earth Fill, Zone 2A Material.

2.05 RETAINED BACKFILL MATERIAL

A. In accordance with Section 31 24 14 - Mechanically Stabilized Earth Fill, Zone 2A Material.

B. Backfill behind the limits of the reinforced backfill shall be considered as retained backfill for a distance equal to 50 percent of the design height of the MSE crest structure or as shown on the approved Contractor shop drawings required by RSN 32 32 20-1 and except as otherwise specified for back-to-back MSE crest structure sections.

2.06 CAST-IN-PLACE CONCRETE LEVELING PADS

A. In accordance with Section 03 30 00 - Cast-In-Place Concrete, except the minimum compressive strength at 28 days may be 2,000 lb/in2.

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2.07 MODULAR BLOCK (SEGMENTAL) FACING UNITS

A. General:

1. Includes dry-cast hollow and solid concrete masonry structural retaining wall units, machine made from Portland cement, water, and suitable mineral aggregates.

2. The units are intended for use as facing units in the construction of mortarless, modular block walls (MBW) also known as segmental retaining walls (SRW).

B. Materials:

1. Cementitious material in the modular block facing unit shall be Portland cement conforming to ASTM C150, Type II.

2. If pozzolan is used it shall not exceed 20 percent by weight of the total cement content and shall conform to ASTM C618.

3. Aggregates used in concrete blocks shall conform to ASTM C33 for normal weight concrete aggregate.

4. Efflorescence control agent shall be used in concrete mix design to prevent efflorescence on the block.

C. Casting Notification:

1. Contractor shall notify COR at least 14 days ahead of start date for modular block casting.

D. Physical Requirements:

1. At time of delivery to work site, modular facing units shall conform to the following:

a. Compressive strength, average for 3 units, minimum: 4,000 lb/in2.

b. Compressive strength, individual unit, minimum: 3,500 lb/in2.

c. Oven dry weight, minimum: 125 pcf.

d. Water absorption: 5 percent in accordance with ASTM C140.

e. Number of blocks per lot, maximum: 2,000.

f. Frequency of tests on blocks: One set per lot.

E. Testing:

1. Acceptance of the concrete block, with respect to compressive strength, water absorption and unit weight, will be determined on a lot basis.

2. The lot shall be randomly sampled and tested in accordance with ASTM C140.

3. At no additional expense to the Government, the manufacturer shall perform the tests at an approved laboratory and submit results as required above to the COR for approval.

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4. Compressive strength test specimens shall be cored or shall conform to the saw-cut coupon provisions of ASTM C140.

5. Block lots represented by test units that do not reach an average compressive strength of 4,000 lb/in2 will be rejected.

F. Freeze-Thaw Durability:

1. The units shall be tested to demonstrate freeze-thaw durability in accordance with

ASTM C1262.

2. Freeze-thaw durability shall be based on tests from five specimens made with the same materials, concrete mix design, manufacturing process, and curing method, conducted not more than 18 months prior to delivery.

3. Specimens used for absorption testing shall not subsequently be used for freeze-thaw testing.

4. Specimens shall comply with both of the following acceptance criteria:

a. The weight loss of four out of five specimens at the conclusion of 150 cycles shall not exceed 1 percent of its initial weight when tested in water.

b. The weight…