B.08.03 AM 6_31 41 16.pdf

R0006 RIVER BALING DECK CHL020

SECTION TABLE OF CONTENTS

DIVISION 31 - EARTHWORK

SECTION 31 41 16

METAL SHEET PILING INSTALLATION

08/09

PART 1 GENERAL

1.1 REFERENCES

1.2 SUBMITTALS

1.3 QUALITY ASSURANCE

1.3.1 Welder Qualifications

1.4 STORAGE, AND HANDLING

PART 2 PRODUCTS

2.1 METAL SHEET PILING

2.2 PILE DRIVING TEMPLATES

2.3 PILE DRIVING SHOES

PART 3 EXECUTION

3.1 EARTHWORK

3.2 FABRICATION

3.2.1 Structural Steel Fabrication

3.2.1.1 Welding of Structural Steel

3.2.1.1.1 Welding Procedures for Structural Steel

3.2.1.1.2 Welding Process

3.2.1.1.3 Welding Technique

3.2.1.1.3.1 Filler Metal

3.2.1.1.3.2 Preheat and Interpass Temperature

3.2.1.1.3.3 Workmanship

3.2.1.1.3.4 Preparation of Base Metal

3.2.1.1.3.5 Tack Welds

3.2.1.2 Inspection of Structural Steel

3.2.1.2.1 Nondestructive Testing of Structural Steel Welds

3.2.1.3 Welding Repair Plan

3.3 INSTALLATION

3.3.1 Pile Driving Equipment

3.3.1.1 Driving Hammers

3.3.1.2 Jetting Equipment

3.3.2 Placing and Driving

3.3.2.1 Placing

3.3.2.2 Driving

3.3.3 Cutting-Off and Splicing

3.3.4 Inspection of Driven Piling

3.3.5 Pulling and Redriving

3.3.6 Disposal of Scraps

3.4 INSTALLATION RECORDS

3.5 ATTACHMENT

-- End of Section Table of Contents --

SECTION 31 41 16 Page 1

SECTION 31 41 16 Page 2

SECTION 31 41 16

METAL SHEET PILING INSTALLATION

08/09

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2015; Errata 1 2015; Errata 2 2016) Structural Welding Code - Steel

AM#6...

AWS QC1 (2016) Specification for AWS Certification of Welding Inspectors

...AM#6

1.2 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only.

Submit the following in accordance with Section 01 33 00 SUBMITTAL

PROCEDURES:

SD-02 Shop Drawings

Templates and Other Temporary Guide Structures for Installing Piles;

G Welding Procedures; G

SD-03 Product Data

Driving Pile Driving Equipment; G Pulling and Redriving; G Filler Metal

SD-06 Test Reports

Welding Inspection Reports

SD-07 Certificates

Welder Qualifications

Certified Welding Inspector

SD-11 Closeout Submittals

Pile Driving Record

SECTION 31 41 16 Page 3

1.3 QUALITY ASSURANCE

1.3.1 Welder Qualifications

Prior to welding, submit certification for each welder stating the type of welding and positions qualified for, the code and procedure qualified under, date qualified, and the firm and individual certifying the qualification tests. If the qualification date of the welder or welding operator is more than 6 months old, accompany the welding operator's qualification certificate with a current certificate by the welder attesting to the fact that he has been engaged in welding since the date of certification, with no break in welding service greater than 6 months.

Conform to all requirements specified in AWS D1.1.

1.4 STORAGE, AND HANDLING

Store and handle Government-provided sheet piling in the manner recommended by the manufacturer to prevent permanent deflection, distortion or damage to the interlocks; as a minimum, support on level blocks or racks spaced not more than 10 feet apart and not more than 2 feet from the ends. Storage of sheet piling should also facilitate required inspection activities. All handling of sheet piling between the Government stockpile to the project site shall meet these requirements.

PART 2 PRODUCTS

2.1 METAL SHEET PILING

Metal sheet piling will be furnished by the Government. Sheet piling is stored at the Chena River Lakes Flood Control Project Office, approximately 2.8 miles from the project site. Transportation of sheet piling from the storage area to the project work area, and any additional transportation required for fabrication, will be the responsibility of the Contractor. Testing and material certifications for the Government furnished sheet piling are attached to this specification for reference.

2.2 PILE DRIVING TEMPLATES

Submit detail drawings for templates and other temporary guide structures for installing piles, including fabricated sections, showing complete piling dimensions and details, driving sequence and location of installed piling. See subpart 3.3.2.1c for specific template and guide requirements.

a. Include in the drawings details of top protection, splices, and dimensions of templates and other temporary guide structures for installing piling. Provide details of the method for handling piling to prevent permanent deflection, distortion or damage to piling interlocks.

2.3 PILE DRIVING SHOES

It is not anticipated that driving shoes (tip protection) will be required; however, the contractor shall make an independent assessment based on selected means and methods and provide if determined necessary.

SECTION 31 41 16 Page 4

PART 3 EXECUTION

3.1 EARTHWORK

Perform in accordance with Section 31 00 00 EARTHWORK. Pre-excavation will be permitted to remove and stockpile existing rip rap (approx. 2 feet thick) and existing filter rock (approx. 1.5 feet thick). Backfill as indicated.

3.2 FABRICATION

Fabricate junction piles as shown in the Contract Drawings from the Government furnished flat sheet piles. Fabrication shall be performed inside a fabrication shop in accordance of the requirements of this Section. Under no circumstances will field fabrication of junction piles be permitted.

As a cost-saving measure, the Contractor may submit a proposal to the Contracting Officer to procure their own flat sheet piling for fabrication of junction piles and/or pre-fabricated junction piles. Contractor procured sheet piling or pre-fabricated junction piling must meet all other requirements of this section. Material certifications for pile shall be submitted for government approval if the cost-saving proposal is approved.

3.2.1 Structural Steel Fabrication

Structural steel may be cut by mechanically guided or hand-guided torches, provided an accurate profile with a surface that is smooth and free from cracks and notches is obtained. Prepare surfaces and edges in accordance with AWS D1.1/D1.1M , Prequalification of WPSs Clause. Where structural steel is not to be welded, chipping or grinding will not be required except as necessary to remove slag and sharp edges of mechanically guided or hand-guided cuts not exposed to view. Chip, grind or machine to sound metal hand-guided cuts which are to be exposed or visible.

3.2.1.1 Welding of Structural Steel

3.2.1.1.1 Welding Procedures for Structural Steel

Use prequalified welding procedures for structural steel as described in AWS D1.1/D1.1M , Prequalification of WPSs Clause or qualify by tests as prescribed in AWS D1.1/D1.1M , Qualification Clause. For welding procedures qualified by tests, the coupon welding and specimen testing will be witnessed and the test report document signed by the Contracting Officer.

Approval of any welding procedure does not relieve the Contractor of the responsibility for producing a finished structure meeting all requirements of these specifications. The Contractor will be directed or authorized to make any changes in previously approved welding procedures that are deemed necessary or desirable by the Contracting Officer.

a. Submit a complete schedule of welding procedures for each steel structure to be welded prior to commencing fabrication. Provide the schedule in conformance with the requirements specified in the provisions of AWS D1.1/D1.1M .

b. Provide within the schedule detailed procedure specifications and tables or diagrams showing the procedures to be used for each required joint. Include in the welding procedures filler metal, preheat, SECTION 31 41 16 Page 5 interpass temperature and stress-relief heat treatment requirements.

Clearly identify each welding procedure as being prequalified or required to be qualified by tests.

c. All welds on junction piles will receive full verification by nondestructive testing.

AM#6...

d. The Contractor shall provide the services of an independent AWS-

Certified Welding Inspector and non-destructive testing personnel.

Submit certificates indicating that the Certified Welding Inspector meets the requirements of AWS QC1. ...AM#6

3.2.1.1.2 Welding Process

Perform welding of structural steel by an electric arc welding process using a method which excludes the atmosphere from the molten metal and conforms to the applicable provisions of AWS D1.1/D1.1M . Minimize residual stresses, distortion and shrinkage from welding.

3.2.1.1.3 Welding Technique

3.2.1.1.3.1 Filler Metal

Provide the electrode, electrode-flux combination and grade of filler metal conforming to the appropriate AWS specification for the base metal and welding process being used. Submit filler metal product data. Include the AWS designation of the electrodes to be used in the schedule of welding procedures.

3.2.1.1.3.2 Preheat and Interpass Temperature

Perform preheating as required by AWS D1.1/D1.1M , Fabrication Clause or as otherwise specified except that the temperature of the base metal must be at least 70 degrees F. Slowly and uniformly preheat the joint area by approved means to the prescribed temperature, held at that temperature until the welding is completed and then permitted to cool slowly in still air.

3.2.1.1.3.3 Workmanship

Perform welding workmanship in accordance with AWS D1.1/D1.1M , Fabrication Clause and other applicable requirements of these specifications.

3.2.1.1.3.4 Preparation of Base Metal

Prior to welding inspect surfaces to be welded to ensure compliance with AWS D1.1/D1.1M , Fabrication Clause. The Certified Welding Inspector shall perform this inspection. Welding may not commence until the Certified Welding Inspector has inspected and approved the base metal preparation.

Correct any deficiencies to the satisfaction of the Certified Welding Inspector.

3.2.1.1.3.5 Tack Welds

Tack welds that are to be incorporated into the permanent work are to exhibit the same quality requirements as the permanent welds; clean and thoroughly fuse them with permanent welds. Perform preheating as required by AWS D1.1/D1.1M for permanent welds except that the minimum temperature

SECTION 31 41 16 Page 6 must be 120 degrees F. Provide cascaded ends on multiple-pass tack welds. Remove defective tack welds before permanent welding.

AM#6...

3.2.1.2 Inspection of Structural Steel

A Certified Welding Inspector must perform visual inspection on 100 percent of the welds. If the Certified Welding Inspector finds a deficiency, the deficiency must be corrected to the satisfaction of the Certified Welding Inspector before welding continues. Document the inspections in welding inspection reports. Copies of all welding inspection reports will be furnished to the Government.

3.2.1.2.1 Nondestructive Testing of Structural Steel Welds

All welds on junction piles will be tested 100 percent with ultrasonic testing. Ultrasonic testing shall begin after 20 percent of the welding on a given junction pile is completed. Repair all defects found by ultrasonic testing to the satisfaction of the Certified Welding Inspector and the Contracting Officer at no cost to the Government. ...AM#6

3.2.1.3 Welding Repair Plan

Repair welds found to be defective by ultrasonic testing in accordance with AWS D1.1/D1.1M , Fabrication Clause. Remove defective weld metal to sound metal by use of air carbon-arc or oxygen gouging. Thoroughly clean surfaces before welding to the satisfaction of the Certified Welding Inspector. Welds shall be retested by ultrasonic testing. Submit welding repair plans for Government approval prior to making repairs.

3.3 INSTALLATION

3.3.1 Pile Driving Equipment

Submit complete descriptions of sheet piling driving equipment including hammers, extractors, protection caps and other installation appurtenances, prior to commencement of work. Descriptive information includes manufacturer's name, model numbers, capacity, rated energy, hammer details, cushion material, helmet, and templates. Provide pile driving equipment conforming to the following requirements.

3.3.1.1 Driving Hammers

Hammers shall be vibratory type. The driving energy of the hammers shall be as recommended by the manufacturer for the piling weights and subsurface materials to be encountered. Refer to the Geotechnical Engineering Report #31-1-20083-006 by Shannon and Wilson. Repair damage to piling caused by use of a pile hammer with excess delivered force or energy.

3.3.1.2 Jetting Equipment

Jetting will not be permitted.

3.3.2 Placing and Driving

3.3.2.1 Placing

Any excavation required within the area where sheet pilings are to be

SECTION 31 41 16 Page 7 installed shall be completed prior to placing sheet pilings. Pilings properly placed and driven shall be interlocked throughout their length with adjacent pilings to form a continuous diaphragm throughout the circumference of piling wall.

a. Pilings to be placed in cells and connecting arcs shall be picked up and completely threaded to demonstrate that they slide freely in interlock.

b. Pilings shall be carefully located as indicated on the drawings.

Pilings shall be placed plumb with out-of-plumbness not exceeding 1/8 inch per foot of length and true to line. Place the pile so the face will not be more than 6 inches from vertical alignment at any point.

Top of pile at elevation of cut-off shall be within 1/2 inch horizontally and 2 inches vertically of the location indicated.

Manipulation of piles to force them into position will not be permitted. Check all piles for heave. Redrive all heaved piles to the required tip elevation.

c. Provide temporary wales, templates, current deflectors or guide structures to ensure that the pilings are placed and driven to the correct alignment. Use a system of structural framing sufficiently rigid to resist lateral and driving forces and to adequately support the sheet piling until design tip elevation is achieved. Use two templates, at least, when placing each piling not more than 20 feet apart vertically. Templates shall not move when supporting sheet piling. Fit templates with wood blocking to bear against the web of each alternate sheet pile and hold the sheet pile at the design location alignment. Provide outer template straps or other restraints as necessary to prevent the sheets from warping and buckling during installation or wandering from the alignment. Mark template for the location of the leading edge of each alternate sheet pile. If in view, also mark the second level to assure that the piles are vertical and in position. If two guide marks cannot be seen, other means shall be used to keep the sheet pile vertical along its leading edge.

3.3.2.2 Driving

Submit records of the completed sheet piling driving operations, including a system of identification which shows the disposition of approved piling in the work, driving equipment performance data, piling penetration rate data, piling dimensions and top and bottom elevations of installed piling. The format for driving records shall be as directed. Prior to driving pilings in water, paint a horizontal line on both sides of each piling at a fixed distance from the bottom so that it will be visible above the water line after installation. This line shall indicate the profile of the bottom elevation of installed pilings and potential problem areas can be identified by abrupt changes in its elevation. Drive pilings with the proper size hammer and by approved methods so as not to subject the pilings to damage and to ensure proper interlocking throughout their lengths.

a. Maintain driving hammers in proper alignment during driving operations by use of leads or guides attached to the hammer. Caution shall be taken in the sustained use of vibratory hammers when a hard driving condition is encountered to avoid interlock-melt or damages.

Discontinue the use of vibratory hammers and impact hammers employed when the penetration rate due to vibratory loading is one foot or less per minute.

SECTION 31 41 16 Page 8

b. Employ a protecting cap in driving when using impact hammers to prevent damage to the tops of pilings. Remove and replace pilings damaged during driving or driven out of interlock at the Contractor's expense. Store Government furnished pilings, damaged during driving, at the site as directed.

c. Take adequate precautions to ensure that pilings are driven plumb. If at any time the forward or leading edge of the piling wall is found to be out-of-plumb in the plane of the wall, approved corrective measures shall be taken to insure the plumbness of succeeding pilings.

d. Pilings in each run or continuous length of piling wall shall be driven alternately in increments of depth to the required depth or elevation. No piling shall be driven to a lower elevation than those behind it in the same run except when the pilings behind it cannot be driven deeper. Incrementally sequence driving of individual piles such that the tip of any sheet pile shall not be more than 4 feet below that of any adjacent sheet pile. When the penetration resistance exceeds five blows per inch, the tip of any sheet pile shall not be more than 2 feet below any adjacent sheet pile. For cofferdam cells the driving increments shall be such that no piling leads the adjacent piling by more than 6 feet and the direction of advancing the driving hammer shall be reversed after each pass around the cell. If the piling next to the one being driven tends to follow below final elevation it may be pinned to the next adjacent piling.

e. If obstructions restrict driving a piling to the specified penetration, the obstructions shall be removed or penetrated. If the Contractor demonstrates that removal or penetration is impractical, make changes in the design alignment of the piling structure as directed to ensure the adequacy and stability of the structure.

Pilings shall be driven to depths shown and shall extend up to the elevation indicated for the top of pilings. A tolerance of 2 inches above the indicated top elevation will be permitted. At least the first two sheets of the connecting arcs adjacent to the main cells shall be driven in the cofferdam cells prior to filling the cells.

f. Pre-augering or spudding of piles may be used at no additional cost to the Government. Discontinue pre-augering or spudding approximately 20 feet above the indicated pile tip elevation. Drive the pile the final 20 feet of penetration.

3.3.3 Cutting-Off and Splicing

Pilings driven to AM#6... the required tip elevation and ...AM#6 extending above the required top elevation in excess of the specified tolerance shall be cut off to the required elevation. Pilings driven below the required top elevation and pilings damaged by driving and cut off to permit further driving shall be extended as required to reach the top elevation by splicing when directed at no additional cost to the Government. If directed, pilings shall be spliced as required to drive them to depths greater than shown and extend them up to the required top elevation.

a. Pilings adjoining spliced pilings shall be full length unless otherwise approved. If splices are allowed in adjoining pilings, the splices shall be spaced at least 20 feet apart in elevation. Splicing of pilings shall be full penetration welds. Ends of pilings to be

SECTION 31 41 16 Page 9 spliced shall be squared before splicing to eliminate dips or camber.

Pilings shall be spliced together with concentric alignment of the interlocks so that there are no discontinuities, dips or camber at the abutting interlocks. Spliced pilings shall be free sliding and able to obtain the maximum swing with contiguous pilings. Shop and field welding, qualification of welding procedures, welders, welding operators and inspections shall be in accordance with AWS D1.1/D1.1M .

AM#4. . . DELETED TEXT. . . AM#4

b. Cut holes in pilings for bolts, rods, drains or utilities in a neat and workmanlike manner, as shown or as directed. Use a straight edge in cuts made by burning to avoid abrupt nicks. Bolt holes in steel piling shall be drilled or may be burned and reamed by approved methods which will not damage the surrounding metal. Holes other than bolt holes shall be reasonably smooth and the proper size for rods and other items to be inserted.

3.3.4 Inspection of Driven Piling

Perform continuous inspection during pile driving. Inspect all piles for compliance with tolerance requirements. Bring any unusual problems which may occur to the attention of the Contracting Officer. Inspect the interlocked joints of driven pilings extending above ground. Pilings found to be out of interlock shall be removed and replaced at the Contractor's expense. Use divers to inspect underwater interlocked joints of cofferdam sheet piling. Government divers may also inspect the interlocked joints. The inspection of cofferdams shall be performed after driving is completed, prior to filling each cell and connecting arc, and within 48 hours after filling each cell and arc.

3.3.5 Pulling and Redriving

Submit the proposed method of pulling sheet piling, prior to pulling any piling. Pull, as directed, selected pilings after driving to determine the condition of the underground portions of pilings. Any piling so pulled and found to be damaged, to the extent that its usefulness in the structure is impaired, shall be removed and replaced at the Contractor's expense. Pilings pulled and found to be in satisfactory condition shall be redriven when directed. Government furnished pilings pulled and not redriven shall be stored as directed.

3.3.6 Disposal of Scraps

Cutoff pieces and unused sheet piles shall AM#4... remain the property of the Government and be stockpiled near the Chena Project Office at a location designated by the Government. ...AM#4

3.4 INSTALLATION RECORDS

Maintain a pile driving record for each sheet pile driven. Indicate on the installation record: installation dates and times, type and size of hammer, rate of operation, total driving time, dimensions of driving helmet and cap used, blows required per foot for each foot of penetration, final driving resistance in blows for final 6 inches, pile locations, tip elevations, ground elevations, cut-off elevations, and any reheading or cutting of piles. Record any unusual pile driving problems during driving. Submit complete records to the Contracting Officer.

SECTION 31 41 16 Page 10

3.5 ATTACHMENT

Sheet Pile Testing and Material Certification

-- End of Section --

SECTION 31 41 16 Page 11

1.4 STORAGE, AND HANDLING

3.2.1.3 Welding Repair Plan