Rough River Industry Day Slides.pdf

ROUGH RIVER DAM SAFETY

MODIFICATION PHASE 2: NEW OUTLET

WORKS AND CUTOFF WALL PROJECT

DATE: 23 October 2024

TIME: 1:00 PM EST

MICROSOFT TEAMS:

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Meeting ID: 993 735 589 063 Passcode: iU5Gbj

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

• Please ensure that you have signed in

• Company Name, POC Name, Email, Phone

• Are you interested in being the Prime or Subcontractor

• No recording

• This briefing and the attendee roster will be posted to SAM

• Please be advised that none of the information discussed today is contractually-binding

ADMINISTRATIVE ANNOUNCEMENTS

CONTRACTING

Richard Van De Linde, III Contracting Officer USACE, Louisville District richard.vandelinde@usace.army.mil

Andrew (AJ) Fleming Contract Specialist USACE, Louisville District andrew.j.fleming@usace.army.mil

ISSUE SOLICIATION: November 2024

SOLICITATION CLOSES: January 2025

EVALUATION BOARD: January 2025

AWARD: May 2025

PROCUREMENT SCHEDULE

DATES ARE APPROXIMATE AND SUBJECT TO CHANGE

• SAM.gov – www.sam.gov

• Solicitation Numbers will begin with “W912QR”

• Rough River Dam Safety Modification Phase 2: New

Outlet Works & Cutoff Wall Solicitation is

W912QR24R0048

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

• Register/Follow to receive notifications and updates / amendments

• RFP technical information will be posted on www.sam.gov

HOW TO OBTAIN THE SOLICITATION

• Requirements to download Technical Data Package:

• Need to be registered in System for Award Management

(SAM) database. You must sign up and sign-in to your account to use many features of SAM.gov (saving searches, viewing solicitations, etc.)

• You must register your business entity (you as an individual or your organization) to be able to propose on contracts or apply for federal assistance (grants, loans, etc.) from the federal government.

• Any amendments issued to the RFP will also be posted on www.sam.gov

• Pre-Solicitation Notice – will be posted on www.sam.gov at least 15 days prior to the initial issuance of the Solicitation package.

• Advertisement – minimum 30 days to prepare proposals.

OBTAINING THE ISSUE DOCUMENTS

• The Rough River project will be a Design-Bid-Build (DBB) Request for Proposal (RFP)

• Project award will be made via a “Firm Fixed Price (FFP) contract using a Best Value Tradeoff” basis as described in the evaluation criteria.

• Proposals must be submitted on time.

• The Louisville District is located within the Eastern time zone.

• The Source Selection Evaluation Board (SSEB) evaluates contractors' proposals based on specific factors which are defined in the RFP package.

THE PROCUREMENT PROCESS

• Source Selection Criteria for “Best Value” will consist of the following factors:

• Prime Contractor’s Past Performance (Recent projects, similar in size and scope)

• Technical Approach

• Small Business Participation Plan

• Price Evaluation

• All Evaluation factors, other than price, when combined are considered approximately equal to price.

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

• Read evaluation criteria carefully and be sure to fully comply with the evaluation criteria submission requirements for each.

PROPOSAL REQUIREMENTS

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

• RFI’s for this project will be received and answered through the ProjNet system, http:www.ProjNet.org/ProjNet

• Any RFI’s submitted directly to the project team will not receive a response and will be directed to the ProjNet system.

• ProjNet Bidder’s Key for this project is QKBQE4-

E6SZZW.

PROPOSAL REQUIREMENTS (cont.)

• Project Labor Agreement : All offerors are required to submit an executed Project Labor Agreement. All offerors shall submit a Project Labor Agreement in accordance with FAR Solicitation Provision 52.222-33 and FAR Clause 52.222-34. To be acceptable, the agreements must adequately address the required statutory elements and provide sufficient information to enable the Contracting Officer to answer affirmatively the requirements laid out in FAR 22.504(b).

• FAR 22.504(b) states:

A project labor agreement shall-

(1) Bind all contractors and subcontractors engaged in construction on the construction project to comply with the project labor agreement;

(2) Allow all contractors and subcontractors to compete for contracts and subcontracts without regard to whether they are otherwise parties to collective bargaining agreements;

(3) Contain guarantees against strikes, lockouts, and similar job disruptions;

(4) Set forth effective, prompt, and mutually binding procedures for resolving labor disputes arising during the term of the project labor agreement;

(5) Provide other mechanisms for labor-management cooperation on matters of mutual interest and concern, including productivity, quality of work, safety, and health; and

(6) Include any additional requirements as the agency deems necessary to satisfy its needs.

PROPOSAL REQUIREMENTS (cont.)

PLA Resource Guide may be found at: https://safe.menlosecurity.com/https://www.dol.gov/general/good-jobs/project-labor-agreement-resource-guide

Crystal Harbin Deputy for Small Business

Louisville District

SBO-LRL@usace.army.mil

Courtney Luckett Small Business Professional

Louisville District

• The Small Business Participation Plan is a rated evaluation factor in all unrestricted procurements

• Both large and small business offerors must submit a participation plan

• The participation plan is based on total contract value

• The Small Business Participation Plan must meet the minimum Total Small Business Participation goal. The percentage will be included the solicitation.

• Small Business primes’ self-performance counts as Small Business Participation.

• Large Business offerors must submit a Small Business Subcontracting Plan

• Mandated by FAR 19.702

• This is not a rated element as a part of the Source Selection process but the offeror shall submit an acceptable plan prior to award

• The subcontracting plan is based on total subcontracted dollars

• Failure to comply in good faith is in material breach of the contract

SMALL BUSINESS PARTICIPATION PLAN &

SUBCONTRACTING PLAN

OBTAIN INFORMATION

• Attend Site Visits, Pre-Proposal Conferences, & Industry Days (Obtain copies of attendee listings for subcontracting opportunities)

• Register as an Interested Vendor on SAM

• Attend Workshops, Conferences, Trade Fairs

• Louisville District Open House: Tentative 05 February 2025

• Review Agency Forecasts (posted on website)

• Construction & IDIQ Forecast is maintained on the Business with Us page of the Great Lakes and Ohio River Division website, https://www.lrd.usace.army.mil/Opportunity-Forecast/.

OPPORTUNITIES

• We anticipate executing approximately $1.4B in FY24 through both small and large businesses.

• Contracting opportunities are posted in the System for Award Management (SAM) website at www.sam.gov. Use “W912QR” to search for Louisville District projects.

• Actively Respond to Sources Sought Notices (Market Surveys) posted to SAM

• Actively Respond to Competitive Requirements posted to SAM (limited number of sole source opportunities)

ROUGH RIVER DAM SAFETY MODIFICATION PHASE

2: NEW OUTLET WORKS AND CUTOFF WALL

TECHNICAL PRESENTATION

24 October 2024

*This presentation is For Information Only and is not part of the Draft RFP

All documents released with the Industry Day Package are subject to revision prior to the official solicitation for the project.

This presentation is For Information Only and is not part of the Draft RFP and will not be part of the official solicitation.

SPECIAL NOTE

Existing Project Overview

Dam Safety Modification Phase 2 Project Overview

Miscellaneous Project Information (FIO)

PRESENTATION OUTLINE

PROJECT LOCATION

Rough River Dam

• Flood Control - Authorized per Flood Control Act of 1938 (Public Law 761, 75th Congress, 3rd Session)

• Recreation - Authorized per Section 4 of the Flood Control Act of 1944 (P.L. 78-534)

• Water Supply - Authorized per the Water Supply Act of 1958 (43 U.S. Code § 390b)

• Water supply agreements

• Leitchfield, KY – 120 acre-feet

• Grayson County, KY – 260 acre-feet

PROJECT AUTHORIZATION

Earth Fill, partial Inclined FilterDam Type

130 feetMaximum Height

1,590 feetCrest Length

~600-ft long, 12-ft x 12-ft Semi-elliptical Concrete Conduit 65-ft wide Rock Spillway

Outlet Features

Outlet Works Construction:

Nov. 1955 to Jan. 1958

Dam & Spillway Construction:

May 1957 to Dec. 1958

Control Tower

Emergency Spillway

Stilling Basin Extension

Retreat Channel

Downstream Embankment

Conduit

Reservoir

Upstream Embankment

Relief Wells

ROUGH RIVER DAM - GENERAL PROJECT LAYOUT

KY79

Project Office 2006 Slurry Wall

Dam Crest Phase IB Exploratory Grouting

Service Bridge

Apron

Historic Channel

Control Sill Top of Active Storage (TAS)

Phase IA Hwy 79 Road Relocation

Rock Toe

GENERAL GEOLOGY AND DAM PROFILE

Beech Creek Limestone DAM GEOLOGIC PROFILE

GENERALIZED

STRAT COLUMN

Golconda Formation

- Beech Creek Limestone Member, Big Clifty Sandstone Member, and Haney Limestone Member.

Spillway

EXISTING DAM PROFILE AT STATION 22+30

El. 523.6 Spillway Sill

El. 489.6 Summer Pool

El. 469.6 Winter Pool

El. 555

100100D 200200D300D 0 300

El. 527.0 Record Pool

Beech Creek Limestone

Big Clifty Weathered Shale

Alluvial Foundation

Impervious Embankment

2’ Blanket and 12” Drains 2’ Blanket and 12” Drains

10’ Inclined Drain

Impervious Embankment

Rock Toe

Cofferdam

2.5:1

3:1

2:1

3:1

8’ 4:1

2:1

Elwren Shale

50’40’

2:1

El. 550 Phase 1 Upstream Rockfill Platform (complete)

2.5:1

Sandstone Spalls

Phase 1 Grout Lines (complete)

El. 558.9 Parapet Wall

Not to Scale

Winter (Flood Pool) = 470

Summer Pool (Restricted) = 490

Summer Pool (Recreational Pool) = 495

Spillway Control Sill = 524

Record Pool = 527.4

Top of Dam = 555

Parapet Wall = 559

ADAS Master Station

111 Automated including 58 VW 11 Manual Read PZ’s 47 Movement Monuments and Carriage Bolts 3 Relief Wells 3 Seismic Instruments

EXISTING DAM INSTRUMENTATION

• ADAS System Installed - 2013 Fully Grouted Vibrating Wire (VW)

• Transducers – 2014/2015

• Post Grouting Instrumentation - 2017

Miscellaneous Project Information (FIO)

PHASE II: NEW OUTLET WORKS AND CUTOFF WALL

27KEY FEATURES OF WORK

Dredged Spoil Area 4

SPECIAL RESTRICTIONS – NO DEVIATION

1. The tunnel excavation heading is from the downstream portal.

2. The tunnel, portals, and final excavations for the foundation of the control tower and stilling basin are limited to mechanical methods only. Blasting may be used at higher elevations for production.

3. The operating gates, bulkheads, and valves on the control tower must be installed in a watertight condition before the tunnel may progress across the dam centerline. Temporary mechanical controls may be implemented to satisfy this requirement.

4. The upstream cofferdam must not be removed until the control tower has been completed and is watertight above elevation 525.

5. Underwater blasting must only occur at reservoir levels below elevation 490 between November and April.

SPECIAL RESTRICTIONS – NO DEVIATION

6. The upstream portal must be constructed as part of the control tower transition section. The control tower excavation must be sequenced to facilitate upstream portal construction.

7. The tunnel excavation must be fully complete before the tunnel lining is allowed to proceed.

8. Cutoff wall panels must not be excavated/installed within 80 feet of the tunnel unless the tunnel liner has reached 75% of the design compressive strength.

9. Abandonment of the existing outlet works cannot commence until 30 days after the new outlet works is fully commissioned and accepted by the Government.

10. Cutoff wall work between Stations 19+50 and 23+50 must start at Critical Area A and/or immediately adjacent elements and can only proceed after the existing outlet works is abandoned and slurry control grouting is completed.

SITE USAGE PLAN

Key Contractor Considerations

1) Contractor Work Limits define site boundaries

2) EA only covers area within Contractor Work Limit

3) Contractor to submit Site Usage Plan.

4) Highway 79 to remain open to public.

5) Spillway Haul Road.

- Connects upstream to downstream construction.

- Conceptual road design provided in plans

- Some subgrade stabilization can be expected.

2) On-Site Batch Plant is Required.

3) Office Trailer Locations by Government Approval.

- Locate QA/QC trailers with Contractor trailers.

4) On-Site Lab and Storage Facility Required.

5) Old Campground Spoil Area.

- Area needs filled, graded, and developed per plans.

- Available for additional laydown.

6) Cutoff Wall Work Platform.

- Designed by Contractor.

- Utilize excavated rock.

- Expected early construction.

7) Dewatering of Tower and Stilling Basin Areas

- Contractor Submittals Required for Approval.

9) Rough River Airport - FAA coordination is required.

10) Upland Spoil/Disposal Area

- Place controlled fill from excavations.

- Cutoff wall spoil processing in same area.

11) Partnering important for:

- Severing the existing outlet conduit.

- Control tower excavation Sequence of Work.

- Reservoir Operations for Flood Control

DEPICTION OF HAUL ROAD AND OLD

CAMPGROUND

Haul Road

Dam

Cutoff Wall

Phase IB Grouting

Cofferdam

Control Tower Control Tower Excavation

U/S Portal

Dredge

Stilling Basin D/S Portal Retreat Apron

Retreat Channel – Rip Rap

Tunnel

Tunnel

Approach Channel

OUTLET WORKS PROFILE

3-D MODEL OF THE

PRIMARY EXCAVATIONS

180’ Dredging

540’ Rock Excavation 6V:1H

300’ Concrete

Apron

Soil Excavation

DamNew Tower

• Cofferdams are required for both the control tower and the stilling basin.

• The amount of underwater excavation will vary based on reservoir levels.

• Excavation extents must be sequenced.

• The majority of excavated material is rock.

Stilling Basin

700’ Retreat Channel

Left Abutment

Rock Excavation 4V:1H Slopes

Dredged Spoils

EXCAVATION AND DISPOSAL AREAS

Abandon Channel Spoil Area 6

Upland Disposal Spoil Area 1

Work Platform Spoil Area 2

Dredged Spoil Area 4

New Tower Access Spoil Area 5

SB Access Spoil Area 7

Abandon Campground Spoil Area 3Haul Road

Spoils Area 8

COFFERDAMS AND EXCAVATIONS

D/S STILLING BASIN

SEEPAGE CUTOFF AND

COFFERDAM

Sheet-Pile to E.453.5 feet

New Retreat Channel

Foundation Bedrock

• Downstream sheet-pile is required for stability and to limit seepage from the Stilling Basin Excavation.

• Cofferdam El is 453.5 feet.

• Sheetpile driven to refusal at top of rock.

– Grouting is required as part of dewatering and cofferdam design.

– Grout lines are 8 feet apart with hole spacing on 10’ centers (lines staggered).

– ~1,000-foot long double line grout curtain (~2,000 lf); additional quantities included for additional holes as directed by the Contracting Officer.

– Grouting in the karstic Haney Limestone.

– Use balanced, stable grout mix.

CONTROL TOWER EXCAVATION – GROUT CURTAIN

CONTROL TOWER EXCAVATION - COFFERDAM

Dental Treatment

• Stage 1 Cofferdam: 300 feet long lime stabilized embankment.

• Purpose: Allow foundation treatment to occur for the Stage 2 Cofferdam.

• Stage 2 Cofferdam: 650 feet long embankment.

• Foundation stripped to bedrock with core trench.

• Double line grout curtain for seepage control.

• Filter construction above dentally treated foundation.

10’ Inspection Trench8’ Core Trench

Grout Curtain

BRIDGE ABUTMENT PLAN VIEW

Advance 11 grout holes shown;

8 to be assigned by COR.

BRIDGE ABUTMENT GROUTING

Advance 11 grout holes shown;

8 to be assigned by COR

BLASTING AND INSTRUMENTATION

OUTLET WORKS

• Controlled blasting with pre-splitting and line drilling.

• Vibrations measured at nearby structures will be limited to 2 in/sec.

• Mechanical excavation is required above foundations and at portal faces.

• Test blasts will be required for each type of bedrock encountered.

• Rock reinforcement and rock fence included in the excavation designs.

CONTROL TOWER AND STILLING

BASIN BLASTING

4v:1H

UNDERWATER EXCAVATION – SEASONAL WORK

• Winter pool is at 470; restricted summer pool at 490;

normal summer pool at 495.

• Approach Channel Invert is 435.

• There is a public beach located approximately 2,000 feet away at the state park.

• Underwater blasting shall be completed at reservoir levels below elevation 490.

Restricted Summer Pool 490

Winter Pool 470

CONTROL TOWER EXCAVATION

• Upstream control, dry-type tower

• 60’x56’ footprint at base, 177 feet high

• Cast against rock excavation from El. 435’ to 482’±

• Tower will be cast against 10H:1V slopes.

• Open excavation will be 6H:1V

• Permanent rock fence: Haney Limestone

• Temporary rock fence: Big Clifty

• Upper shale requires protective bulkhead

BIG CLIFTY UPPER SHALE

BULKHEAD

ROCK

FENCE

(TYPICAL)

• Rock fence and rock reinforcement requirements are shown in the Volume 1 OTW-CG-500 plans.

• Specification 31 68 13 Rock Slope Reinforcement and Permanent Rockfall Protection.

TUNNEL AND

PORTAL EXCAVATIONS

970’ Tunnel 300’ Radius 14’ Diameter

20’ Down-stream Portal

60’ Upstream Portal

60’x56’x177’ Control Tower

115’x40’ Stilling Basin

• Upstream portal constructed integral to control tower as the transition.

CONTROL TOWER RENDERINGS

60’

UPSTREAM PORTAL

Upstream Portal

10V:1H with Rock Fence

Concrete Bulkhead

Upstream Transition MonolithsSupport Columns

Portal Face

6V:1H Permanent Rock Fall Protection

10’ Wide Bench

SERVICE BRIDGE

MAINTENANCE BULKHEAD

(STORAGE LOCATION)

BULKHEAD SLOT

JIB CRANE

STILLING WELL

TRASH RACK

BULKHEAD DOOR

• Central hydraulic power unit is utilized, factory inspection & testing required.

• 14ft x 7.2ft Service & Emergency (passage) Gates, factory inspection & testing required

• 4 Valves in the low flow bypass system (1 hydraulic and 1 manual valve per side)

• 1 Service Platform Bulkhead Door

• Actuators will be hydraulic cylinders.

• Service & Emergency Gates: Mill type cylinder, contractor designed

• Compatible to USACE designed bonnet cover. 350-kip capacity @ 1750 psi

COMPONENTS OF CONTROL TOWER

BRIDGE CRANE (20 TON) WITH 170’ LIFT

PASSAGE AIR VENT

INTAKE

ELEVATOR SHAFT (LADDER

OTHER SIDE)

SERVICE GATE

EMERGENCY GATE

BYPASS OUTLET

OH DOOR

HYDRUALIC CONTROL

STATION (HCS) AND

ELECTRICAL EQUIPMENT

BYPASS VALVES

HYDRAULIC POWER UNIT (HPU) ROOM

UNIT HEATER

EXHAUST FAN AND LOUVER

Service and Emergency Gate Leaves (2 each)

• 14’-6” x 7’-2½”, painted carbon steel

• Aluminum bronze seats and seals

Maintenance Bulkheads (2)

• 24’-3” x 9’-11”, painted carbon steel

• Neoprene seals, UHMW-PE rub blocks

Bypass Bulkheads (2)

• 8’ x 6’ max dimensions, painted carbon steel

• Neoprene seals, UHMW-PE rub blocks

Bypass Trash Screen (2)

• 7’ high x 10’ diameter, stainless steel, sectional

Service Deck Bulkhead Door

• AWWA C560 Cast iron sluice gate with wall thimble.

• Foundry & factory inspection required.

• Capable of 57 ft. reverse seated head.

Stilling basin stoplogs (3)

• 24’-6” x 3’-8”, painted carbon steel

All HSS to be fabricated by AISC IBR, ABR, HYD, or HYDA certified shop, with FCE and

CCE-1.

SERVICE/EMERGENCY

GATE LEAF

MAINTENANCE BULKHEAD

HYDRAULIC STEEL STRUCTURES

BYPASS TRASH SCREEN

BYPASS BULKHEAD

• Post-tensioning used to accommodate large service openings and service loads

• One-way post-tensioned slab on post-tensioned beams

• Strands are fully grouted

• All anchors within tower walls. Beams bear on inner half of walls.

• Conventional reinforcing for negative moment, temperature and shrinkage crack control

POST TENSIONED FLOORS

54DOWNSTREAM PORTAL – STAGE 1 EXCAVATION

Stage 1 Excavation

Stage 2 Excavation

Proposed Tunnel

Proposed Stilling Basin

6V:1H with Rock Fence

10V:1H with Rock Fence

Downstream Portal

20’

55DOWNSTREAM PORTAL SUPPORT

Steel Sets first 20’

• Permanent Suppport – Government.

• Temporary Support - Contractor

• Roadheader used at Yatesville Dam in a sandstone bedrock.

• Tunnel has radius similar to proposed at Rough River.

TUNNEL PROTOTYPE: YATESVILLE DAM

57Upper Big Clifty Shale

Interbedded Big Clifty Sandstone and Shale

Projected Based on ADC-1806 O/ATV

TUNNEL

• Temporary support designed by the Contractor.

• Grouting, shotcrete, and dowels expected.

58Upper Big Clifty Shale

Interbedded Big Clifty Sandstone and Shale

Projected Based on ADC-1806 O/ATV

TUNNELING – EXPECTED

INITIAL SUPPORT

• The tunnel is located withing the Big Clifty Sandstone.

• Thin shale beds will be encountered which require a combination of initial support methods including rock bolts, shotcrete, and other methods as proposed by the Contractor.

• The tunnel excavation must be mapped and documented.

• Neat lines are shown with the payment line defined in the specifications.

• Control of water is the responsibility of the Contractor.

Grouting can be utilized to reduce inflows.

• Water inflows are anticipated to be higher near the reservoir.

• Cast-in-place, 6,000 psi abrasion resistant concrete, with Class B finish.

• 20’ monoliths. Monoliths within the curve are 20’ with a mitered angle every 10’.

• 14’ ID, 1’ minimum liner thickness.

• Non-metallic water stops at contraction joints.

TUNNEL LINER DESIGN

Tunnel Section Tunnel Reinforcement Stilling Basin Headwall

• USBR Type III basin (115’x40’) with 5 monolithic sections.

• Dentated end-sill provides debris sweep out.

STILLING BASIN

Rock Excavation 4V:1H Slopes

Concrete Apron

New Stilling Basin

15’ Bench El 456

El 429.3

El 456

Rock Excavation 10V:1H Slopes Below 456+’

• Stilling basin utilizes mass to resist uplift.

• Redundant foundation drainage system.

• Extended sill slab provides space for dewatering systems at normal tailwater elevations.

Apron

– The stilling basin rock excavation will extend 300 feet downstream from the stilling basin and require a 1-feet thick concrete apron to protect exposed shale in the excavation.

– The outlet channel bottom width is 40 feet.

– Rock side slopes ate 6V:1H and are benched 15 feet wide at both elevation 456 and at top of rock.

– Side slopes in overburden soils are 4H:1V.

STILLING BASIN APRON

STILLING BASIN

Typical cross-section through basin

Isometric of stilling basin, end sill, and completed downstream portal. Stop logs are shown installed.

63RETREAT CHANNEL

Existing Retreat Channel

Riprap Slope Sta 24+20 End Apron Begin Riprap

Concrete apron

Riprap

Riprap

Riprap

Riprap

10V:1H Slopes

KEY FEATURES OF WORK – SERVICE BRIDGE

BRIDGE ABUTMENT

TOWER SERVICE BRIDGE

• 148’-0” long by 16’-0” feet wide, single span composite concrete bridge deck 8 ½” thick with top and bottom steel reinforcement.

• Two, 76 ¾” deep, built-up weathering steel girders with lateral cross-frames and service catwalk between girder bottom flanges.

• Bridge steel to be fabricated by AISC IBR or ABR certified shop, with

FCE

• Reinforced elastomeric bearings seated on reinforced concrete abutment and corbel.

- Fixed bearings at tower and expansion bearings at abutment.

BRIDGE ABUTMENT

• Semi-integral abutment used to isolate joint from bearings and girders.

• Approach slab connected to and supported by abutment to prevent differential settlement at joint.

• Abutment rests on bridge approach engineered fill.

• Access to catwalk provided approx. 10’ from abutment.

KEY FEATURES OF WORK – CUTOFF WALL

WORK PLATFORM – CONTRACTOR DESIGNED

Work Platform

- Contractor Designed

- Filled with processed fill from control tower/stilling basin excavation.

- Does require

- Aggregate surface

- Processed Fill

- Maintenance of ADAS

Aggregate surface

Aggregate surface

ADAS SYSTEM AND WORK PLATFORM

– Use series of slotted grout pipe and valves to ensure complete grouting in 2 Placements.

– Placement 1 placed from tower; Placement 2 from stilling basin headwall.

– Use non-shrinking, flowable material.

ABANDONMENT OF EXISTING CONDUIT

GROUT CURTAIN AT CONDUIT

CRITICAL AREA B3 AND A)

Embankment

Alluvial Soils

Residual Soils

1) Grout Critical Area B3 Before Abandonment of the Conduit.

2) Grout Through the Existing Conduit at Critical Area A.

General Test Section (15+50 – 17+50)Closure (13+50 – 15+50)

Valley Restriction 19+50-23+50

Critical Area B1 10+40-13+00

Critical Area B2 17+50-19+20

Critical Area B3 21+80-22+40

Critical Area A 22+40- 22+70

Critical Area B4 23+80- 25+00

Closure (13+50-15+50) General Test Section (15+50-17+50)

CUTOFF WALL

New Tunnel

Concrete Cutoff Wall

Length: 1,640’

Width: 2’

Depth: 75’ - 190’

74CRITICAL AREA A - AS-BUILT CONDUIT

SEEPAGE BARRIER THROUGH EXISTING CONDUIT

– Completely sever the existing conduit to construct a continuous seepage barrier.

• Dimensions per plans and specifications.

• Requires the conduit to be cored or cut.

– Means and methods for conduit demolition submitted with RFP for consideration.

– The existing outlet works to be fully abandoned.

75CONDUIT DEMOLITION AND

SEEPAGE BARRIER INSTALLATION

Slurry or Casing

DAM SAFETY REQUIREMENTS: Conduit cannot be cut or demolished from the inside. The rebar must be cut, cored, or otherwise severed from the dam crest.

76CUTOFF WALL AT CRITICAL AREA A

ABANDONMENT OF RETREAT CHANNEL

ROCK FILL AT TOE

Backfill area between new retreat Channel and existing retreat channel.

• Construct filter drain in tailwater area (shown in red)

• Place rock spoils as shown in the Grading drawings above the filter and to the limits shown (dashed blue line).

ABANDONMENT OF RETREAT CHANNEL

• Remove work platform and dispose of fill material in existing retreat channel.

• Place rock spoils as shown on the grading plan.

• Extend rock-fill to new retreat channel.

Considerations:

• Abandon to 507 level and re-establish roof drain.

• Unit Weight of CLSM ~90 pcf vs tower flooded design scenario based on unit weight of water.

• Electrical – Maintain power on upper two floors. New transformer on operations level.

• Mechanical – Drain hydraulic system and abandon in place.

ABANDONMENT OF CONTROL TOWER

SITE RESTORATION

Miscellaneous Project Information (FIO)

PROVIDED DOCUMENTS

• Volume 1: New Outlet Works (OTW) [Civil]

• Volume 2: New Outlet Works (OTW) [Facilities]

• Volume 3: Cutoff Wall (CTW) and State Road Relocation (STR)

• Volume 4: Technical Specifications

• Volume 5: Tunneling Geotechnical Baseline Report (GBR) and Tunneling Geotechnical Data Report (GDR), Joint Instrumentation and Monitoring Plan - Contractual Documents

• Volume 6: FIO Miscellaneous Documents - Geologic Interpretive Report (GIR), Rough River Dam Phase IB - Exploratory Drilling and Grouting Completion Report, Phase IB Boring Logs, As-Builts, etc.

* Project SOW is in Volume 4:Technical Specification Section 00 11 00 Summary of Work

Facility Designations on the Plans.

Description Facility Designator Outlet Works OTW Cutoff Wall CTW State Road Relocation STR Control Tower CT Service Bridge BR Tunnel and Portals TU Stilling Basin SB Tailwater Shelter SH Tailwater Restroom RR

DRAWING SET ORGANIZATION

Plan Set Discipline Designations

Discipline Discipline Designator Content General GI General Information – Drawing Cover, Index, Orientation Maps

GS General Site – Haul Routes, staging and spoil, Dewatering, etc GC General Contract – Erosion Control

Survey/Map V Control Points and Contractor work limits Traffic TC Traffic Control Geotech BS Boring Locations and Logs Civil CD Civil Demolition – Structure removal and site clearing

CI Civil Instruments – Piezometers, control stations, etc.

CS Civil Site CP Civil Paving CG Civil Grading CM Civil Pavement Markings CU Civil Utilities

Reference RF Reference Drawings – Historical As-builts, hydrographs, etc.

Electrical E Site Electrical ES Electrical Plan Sheets Communications T Fire Protect F Mechanical M Structural S Architecture A

Sheet Number Designator Sheet Type 100 Plan Views 200 Elevations and Profile Views 300 Volume 3: Cross Sections (CTW and STR) 400 Enlarged Plan Views or Typical Sections 500 Details 600 Volume 1 Cross Sections (OTW) 600 Volume 2: Miscellaneous Details and Schedules 700 Volume 1: Cross Sections (OTW - Continued) 700 Volume 2: Hydraulic Steel Structures and KYTC Standard Details 900 Volume 1: Miscellaneous Drawings and Hydrographs 900 Volume 2: Isometrics and Tunnel Mapping Sheets

Volume 4:

SECTION 00 80 00.00 06 SPECIAL PROVISIONS: Typical USACE Special Provisions

Specification modified with procedures for inspection, demonstration, re-inspection, and acceptance of the new outlet works.

SECTION 01 35 00.00 06 SPECIAL PROCEDURES includes but not limited to requirements for Dam Safety Training, Work time restrictions, emergency preparedness.

SECTION 01 78 23 OPERATION AND MAINTENANCE DATA: Includes but not limited to specific information required for Operations and Maintenance of installed equipment.

CONTRACTOR SPECIAL PROVISIONS AND SPECIAL PROCEDURES

RESERVOIR OPERATION RESTRICTIONS

*Rough River Dam is a flood control reservoir with a fluctuating pool and tailwater.

Additional information is in Volume 4:Technical Specification Section 00 31 19.23 06 WEATHER AND WATER STAGE DATA/RESTRICTIONS and associated references.

- Specification contains weather data and restrictions pertinent to the Contract for both reservoir and tailwater fluctuations.

- Reservoir levels are governed by rainfall and maximum release rates from the reservoir. Review hydrographs and hydrologic data for understanding of rainfall events which result in prolonged elevated pools.

- Contains a provision to request an early drawdown of the reservoir; subject to Government approval and prevailing weather conditions.

- Floating plant operations must allow time to target multiple working seasons.

Volume 4 SECTION 01 33 16.00 06 CONTRACTOR SUBMITTALS REQUIRING ENGINEERING AFTER AWARD including but not limited too:

1) Cutoff Wall methods, Special Panel/Secants at Critical Area A, Conduit Demolition, slurry and slurry handling systems.

2) Work Platform – Sheet-piling, MSE walls, or other methods meeting the performance criteria.

3) Dewatering – excluding the stilling basin well points.

4) Mass Excavation and Disposal.

5) Tunnels and Portals – Excluding permanent support.

6) Area Use Plan/Site Usage Plan – KTR required to obtain SWPPP and KPDES permit.

7) Metal building systems for tailwater and laboratory structure.

8) Additional miscellaneous.

CONTRACTOR SUBMITTALS REQUIRING ENGINEERING

AFTER AWARD

Volume 4 SECTION 31 23 05.00 06 MASS EXCAVATION contains general mass excavation and disposal requirements for the project including but not limited to requirements applicable for:

- Section 31 23 18.00 06 SURFACE BLASTING

- Section 31 23 17.00 06 UNDERWATER BLASTING

- Section 31 68 13 ROCK SLOPE REINFORCEMENT AND PERMANENT ROCKFALL

PROTECTION

- Section 31 60 00.00 06 FOUNDATION PREPARATION

- Section 03 37 13 SHOTCRETE

- Section 31 00 00.00 06 EARTHWORK

The mass excavation and disposal plan includes but is not limited to associated requirements for measurement and payment, definitions applicable to mass excavation, classification of excavation, rock processing plant, processed rock fill, floating plant requirements, rock cut slopes, special excavation requirements, master slope protection plan, and special conditions.

Note: See procedures for completing the retreat channel/tailwater tie-in for the new outlet works.

MASS EXCAVATION

TUNNELING GBR/GDR AND PROJECT GIR

A tunneling specific Geotechnical Baseline Report (GBR) and Geotechnical Data Report (GDR) have been developed specific to the tunnel and portal construction.

The GDR includes pertinent background information and data that led to development of the

GBR.

A project specific Geotechnical Interpretive Report (GIR) has been developed. The GIR describes subsurface conditions and variations at the overall site.

The GIR includes a narrative of the project construction history, boring logs, lab testing, photographs, and other pertinent information applicable to the entire project.

*The GBR and GIR will have some slight revisions prior to solicitation.

Volume 4 SECTION 31 71 16.00 06 ROCK TUNNELING has key references to the following specifications required to construct the tunnel and portals:

Section 00 31 31.13 06 SUBSURFACE INVESTIGATION INFORMATION Section 01 33 16.00 06 CONTRACTOR SUBMITTALS REQUIRING ENGINEERING

AFTER AWARD

Section 03 30 00 CAST-IN-PLACE CONCRETE OUTLET WORKS Section 03 37 13 SHOTCRETE Section 31 23 00.00 06 CONTROL OF WATER AND DEWATERING Section 31 23 05.00 06 MASS EXCAVATION Section 31 60 00.00 06 FOUNDATION PREPARATION Section 31 68 13 ROCK SLOPE REINFORCEMENT AND PERMANENT ROCKFALL

PROTECTION

Section 31 73 00 TUNNEL GROUTING

• Establishes roles and responsibilities for the contractor.

• Differentiates acceptable support methods, control of water, inspections, records, etc.

TUNNEL

Volume 4 SECTION 03 00 00 GENERAL CONCRETE REQUIREMENTS contains all general concrete requirements including but not limited to requirements applicable for:

- 03 70 00 MASS CONCRETE

- 03 30 00 CAST-IN-PLACE CONCRETE FOR OUTLET WORKS

- 03 15 00 BRIDGE CONCRETE ACCESSORIES

- 03 37 13 SHOTCRETE

- 03 37 29 CONCRETE FOR CUTOFF WALL

- 32 16 19 CONCRETE CURBS, GUTTERS AND SIDEWALKS

General Concrete Requirements include but not limited too associated requirements for materials investigations, mix designs, QA/QC, thermal studies and requirements, aggregate quality, cementitious materials, batch plant requirements, measurement and payment, etc., as applicable to other concrete specifications.

Additional specification requirements apply as appropriate in each individual specification.

CONCRETE SPECIFICATIONS

Volume 4 SECTION 31 32 23.00 06 SLURRY CONTROL DRILLING AND GROUTING

• Covers dam grouting and control tower excavation grouting.

• This specification does not cover tunnel grouting.

• Specification includes expanded section on Phase IB Exploratory Drilling and Grouting, anticipated soil conditions, and special coordination requirements.

• Includes grouting measurement and payment items, foundation drilling and grouting work plan, and required use of an instrumented packer. ***Measurement and Payment is under revision***

• Mix designs are prescribed based on successful grouting from Phase IB.

• See Volume 6 Phase IB Exploratory Grouting Contractor Completion Report, Phase IB Boring Logs, As- Builts, etc.

• Volume 3 plans have As-Builts included as Reference drawings.

FOUNDATION GROUTING

Volume 4 SECTION 31 56 10.00 06 CUTOFF WALL CONSTRUCTION includes but is not limited to:

• Subsurface conditions, pertinent history, special coordination, measurement and payment.

• Definitions specific to the cutoff wall and execution of the work as well as submittal requirements, including work plans and requirement to complete the work at Critical Area A, and applicable restrictions.

• General requirements, tolerances, verification.

• Test Section and closure requirements.

• Evaluation and acceptance requirements.

• Existing Outlet Works abandonment procedures.

CUTOFF WALL CONSTRUCTION

AVAILABLE SUBSURFACE INFORMATION AND SAMPLE INSPECTION

• Volume 4 SECTION 00 31 31.13 06 SUBSURFACE INVESTIGATION INFORMATION contains a summary of avalable geotechnical information applicable to the new outlet works, cutoff wall and general dam.

• The Solicitation will include notice for a time period that samples may be inspected at the USACE Storage Facility located in Louisville, Kentucky.

• All appointments will only be issued to Prime Contractor’s/JV’s; the prime is responsible to coordinate the visit date and time with subcontractors.

• Each Prime Contractor will be limited to what rock core can be examined during an 8-hour time period. Prime Contractor’s are limited to a maximum inspection time of 16 hours.

AVAILABLE SUBSURFACE INFORMATION AND SAMPLE INSPECTION

CONTRACTOR REQUIRED EXPLORATIONS

• Volume 4 SECTION 02 32 00 ADDITIONAL INVESTIGATIONS contains requirements for the Contractor to conduct additional field investigations in support of the following:

1) Work platform design and construction.

2) Downstream sheet pile cofferdam drive-ability analysis, pile test section, and piling termination depths.

3) Installation of new dam instrumentation.

THANK YOU!!!