03 WVA 00 - Machine Foundation Requirements.doc

Watervliet Arsenal 39’ Hollow Spindle Lathe Foundation Facilities Engineering Bldg. 110

TAWV-IMP-F

7OD006

SECTION 03 WVA 00

Machine Foundation Installation Requirements

PART 1 GENERAL

1.01 REFERENCES

The publications referenced within this specification are referred to by the basic designation only.

1.02 SUBMITTALS

A. 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 the “Statement of Work - SUBMITTAL REQUIREMENTS”:

a. SD-01 Preconstruction Submittals

a. Material Safety Data Sheets (MSDS)

b. SD-03 Product Data

a. Epoxy paint specifications and color, G

b. Block Floor/ Adhesive/ Sealer Specifications, G

c. Rebar grout Specifications, G

d. Concrete bonding adhesive specifications, G

c. SD-06 Test Reports

a. Concrete Slump Test Results, G

b. Concrete Compressive Test Results (7 Day and 28 Day cure results), G

c. Laboratory analysis of carbon canisters (if necessary)

d. SD-11 Closeout Submittals

a. Concrete and Soil Bill of Ladings

b. Log book documenting dewatering activities (if necessary)

c. Transportation and disposal documentation for carbon canisters (if necessary)

PART 2 PRODUCTS

2.01 MATERIALS

a. Concrete: Refer to SOW for Compressive Strength, Slump, and other requirements for equipment foundation.

b. Rebar: Refer to SOW for rebar requirements.

2.02 PRODUCTS

a. Block Flooring: Blocks shall be two (2) inches thick, four (4) inches wide, and six (6) inches long. Permissible variations shall not exceed 1/16 inch in depth and 1/8 inch in width and length.

a. Blocks shall be composed of recycled/ reclaimed materials.

b. Blocks shall be Delta Composite Block, or equivalent. The company’s website is www.deltaflooring.com. Any variation must be approved by the government and a sample must be submitted for approval.

PART 3 EXECUTION

3.01 General Requirements

A. Manufacturer Specifications

a. The contractor will be supplied with foundation drawings from the manufacturer. The contractor shall build the foundation in accordance with the manufacturer’s foundation requirements and specifications. The foundation, when constructed, shall allow full and complete installation of the tooling machine by the machine manufacturer, and shall allow for full and complete use of the machine tool by the Arsenal after installation.

b. The manufacturer supplied drawings include a mixture of metric and non-metric dimensions and specifications. The contractor shall use extreme caution to verify every measurement to prevent errors caused by unit confusion or conversion errors.

c. The contractor shall review all contract documents and provide written notice to the Contracting Officer of any discrepancies, problems or issues that are found.

B. Fencing

a. The contractor shall maintain barriers around the work site at all times. Fencing and other barricades shall be in place for safety of building occupants and workers on site.

C. Protection of Surrounding Areas

a. The contractor shall use work practices that minimize debris, water, and other items from traveling out of the work site and into surrounding areas.

b. The contractor shall install plastic on surrounding machines to protect them from debris.

c. The contractor shall use welding curtains on all four sides of the welding operation at all times.

D. Equipment Parking

a. Per the Watervliet Arsenal Instructions for Contractors, all contractor employee vehicles, mobile equipment, support vehicles, and utility trailers directly needed for contract work at the job site shall be parked in a legal parking space. Any parking outside of a legal space must be approved, in advance, by the WVA Emergency Services. The contractor is allowed to utilize the “Contractor Parking and Staging Area” located near the WVA Fuel Tanks.

b. All equipment on site will be required to have a valid Contractor Equipment ID at all times.

E. Equipment Exhaust

a. Contractor shall properly exhaust any diesel, gasoline or LP powered machinery to the outside atmosphere. Flexible duct pipe will be permitted to be installed in such a manner as to not interfere with manufacturing operations or block aisle ways. The use of booster blowers on duct pipe may be necessary to attain adequate air flow.

F. Dust Control

a. Contractor shall use active controls to minimize the airborne dust, dirt and other airborne contaminates. Controls shall include spray mist during such dust creating activities as concrete floor cutting, jack hammering, and wet cleaning/vacuuming of floor and equipment after the dust creating actions are complete.

G. Hazardous Materials

a. The contractor shall contact the COR and the Watervliet Arsenal Spill Hotline (266-5222) without delay for spills of hazardous materials as well as discovery of pre-existing spills, although unlikely, to include soil or groundwater whose smell, texture or appearance indicate contamination. Comply with paragraphs 6, 24, 26, and 27 in the Watervliet Arsenal Instructions for Contractors for any environmental contamination caused or discovered during the project. Any suspect excavated material shall be trucked by the contractor to behind the Watervliet Arsenal boiler plant, kept in a separate pile from all other soil, and be placed on two (2) layers of six (6) mil polyethylene, covered with one (1) layer of six (6) mil polyethylene, batted down and labeled. The Watervliet Arsenal will test and dispose of any contaminated or hazardous material.

3.02 Excavation

A. The contractor shall saw cut around the perimeter of the foundation area, utility trenches, and other construction requirements. The saw cut shall be limited only to the area need to construct the foundation.

B. The contractor shall remove all existing concrete, dirt, rebar, and other materials from the foundation footprint.

C. Buried Infrastructure

a. A search of the existing drawings of the work site and surrounding areas will be conducted prior to the project start. The contractor will be notified of utilities and other known buried infrastructure. While all efforts will be made to identify everything, the contractor shall dig with caution as it is possible for undocumented utilities and other objects to be present in the work area. The contractor shall contact and inform the project COR if any objects are unearthed. If the contractor encounters a buried “live” utility that requires immediate consideration for safety seasons, the contractor shall call the WVA Fire Department at 518-266-5222.

D. Wood Block Floor (If Applicable)

a. Any wood block flooring scheduled for removal on this project will be tested by the government for contaminates. The government will provide a dumpster for the disposal of the wood block flooring if the Environmental Office requires it be disposed as Hazardous Waste. Otherwise the contractor will dispose of as Industrial waste.

E. Accumulated Groundwater

a. Although unlikely, should the foundation excavation require accumulated groundwater dewatering the contractor shall comply with the following requirements and procedures:

b. Pumping: Contractor shall furnish and use an explosive-proof pumping system to dewater the pit, if required by the WVA Fire Department. The contractor, with assistance from the COR, shall coordinate with the WVA Fire Department to obtain their determination. The contractor shall furnish and use a silt-box type silt control device at suction of pump.

c. The contractor shall pump accumulated groundwater from the pit to a storm water sewer catch basin to be designated by the COR. The contractor shall continuously monitor the pH of the pumped water. In the event the pH of the water equals or exceeds 9.0 units, the contractor shall stop the pumping operation without delay and contact the COR and the Environmental Office at 266-4875 immediately.

d. Contractor shall furnish, install, monitor and dispose of carbon canisters for use in the dewatering pits.

e. Contractor shall treat the water using two carbon absorber units arranged in sequence.

f. Contractor shall discharge the treated water exiting the second carbon absorber unit to a storm water sewer catch basin that is designated by the COR.

g. Contractor shall obtain a grab sample of the treated water exiting the second carbon absorber unit each hour of operation and promptly inspect for any visible evidence of petroleum contamination and any petroleum odor. The contractor shall maintain a written log to document the results of these inspections. If these inspections indicate failure of the carbon absorber units (i.e., if the carbon absorbers do not entirely remove petroleum from the water) cease and desist the pumping operation without delay, and contact the COR and the Environmental office (518- 266-4785).

h. Obtain a grab sample of the intermediate water between the two carbon absorber units once per day, promptly inspect for any visible evidence of petroleum contamination and any petroleum odor. Remove the failed primary carbon absorber unit from service, rotate the secondary carbon absorber unit into the primary location, and install a new secondary carbon absorber unit. After this is accomplished, the pump and treat system can be restarted. Maintain a written log to document the change of carbon absorber units. All written logs shall be available to the COR for inspection upon request.

i. Upon completion of the work, the dewatering system shall be removed from Government property. Contractor shall perform laboratory analyses, as necessary, to determine whether or not the spent carbon canister(s) is/are hazardous waste. If determined to be hazardous waste, the spent carbon canister(s) shall be managed via a manifest system, and the Manifest and Land Disposal Restriction (LDR) forms will be signed by duly authorized Watervliet Arsenal Personnel located in the Environmental Office. Laboratory analyses, as necessary, and transportation and disposal of spent carbon canisters(s) shall be arranged and paid by contractor. Copies of all paperwork associated with determinations, regarding transportation, and regarding disposal shall be provided to the Government. Labeling, treatment, storage, transport, and disposal of the spent carbon absorber unit(s) shall be in accordance with all applicable rules and regulations.

F. Soil Bearing Capacity

a. The depth of the excavation shall be limited only to the depth required for construction of the machine foundation. Contractor shall not disturb below the depth required to pour the machine foundation concrete since it is expected that the undisturbed ground will support the machine manufacturer’s calculated bearing capacity of about 1,000 PSF. Should the contractor disturb the soil below the yet to be constructed concrete foundation then the contractor shall compact the disturbed soil to achieve at least 2,000 pounds per square foot (PSF) bearing capacity. Note: the soil beneath the concrete slab is assumed to be medium dense gravel or medium dense gravel and sand with a minimum bearing capacity of 4,000 PSF.

G. Disposal

a. The contractor shall haul the removed soil to Carver Sand and Gravel or Mead Enterprise for recycling. Three copies of the bill of lading shall be submitted to the Arsenal Contracting Officer (CO) to verify where the soil was disposed.

3.03 Concrete Requirements

A. Concrete testing

a. The contractor shall perform slump tests on each truckload of concrete delivered to the site. The contractor shall provide test results to the Government for all slump tests no later than the end of the work day that the concrete was delivered. Truckloads not meeting slump requirements on delivery shall be rejected. Note: No mixing of the concrete shall be internal to the building.

b. The contractor shall perform compressive tests on the concrete with every truck delivery ensuring the batch meets the specified compressive strength. All tests shall be performed according to the American Concrete Institute’s Building Code Requirements for Reinforced Concrete. (ACI 318) Test results shall be provided to the contracting officer when the 7 day and 28 day strength is reached for verification. The concrete test cylinders shall be cured in the same location and manner as the foundation.

B. All concrete shall be ready-mixed concrete and conform to the latest edition of ASTM Specification C94/C94M.

C. Foundation shall be poured in one continuous effort.

D. Contractor shall ensure to eliminate all voids during placement for concrete.

E. Concrete Curing

a. Concrete shall be maintained above 50 degrees F and in a moist condition for at least the first seven (7) days after placement. The curing method shall comply with the applicable sections of the American Concrete Institute’s Standard Practice for Curing Concrete, ACI committee 308. The dusting of finished surfaces with dry materials will not be permitted.

F. Concrete Painting

a. After the concrete has cured the contractor shall paint the horizontal foundation surface, flooring surface and all surfaces of the recessed utility trenches and coolant wells with oil resistant epoxy paint. Paint shall be applied per the paint manufacturer’s specifications and directions. Paint shall be applied to seal the foundation and prevent oil from contaminating the soil under the foundation, trenches, and coolant well.

b. The epoxy paint shall be light to medium gray in color.

3.04 Backfill and Floor Repairs

A. After a minimum of 7 days after the final concrete pour, the contractor shall backfill and compact sand around the exterior of the foundation walls to the bottom of the 8” concrete floor slab.

B. The contractor shall install isolation material, Asphalt-Impregnated Fiberboard, around the foundation where it will meet with the floor slab.

C. The contractor shall install and grout #4 steel rebar dowels six inches into the vertical edges of the existing concrete floor. The rebar shall be installed in the center of the vertical face of the existing floor and spaced at 24” intervals.

D. The contractor shall install 6” x 6” #6 steel mesh as reinforcement for the floor. The mesh shall be set in the middle of the new floor pour.

E. The contractor shall clean the cut vertical edges and apply a concrete bonding agent to all exposed concrete prior to pouring of new slab.

F. The contractor shall pour concrete from the building 35 cut edges to the foundation isolation material at the same thickness of the existing concrete floor. When complete the new concrete floor surface shall be smooth, level, and even with the existing concrete floor from the existing floor to the foundation walls, and shall be as thick as or thicker than the existing concrete floor.

G. Concrete shall have a minimum allowable compressive strength of 5,000 psi in 28 days. Maximum coarse aggregate shall be ¾ of an inch. The slump shall be no more than four (4) inches and not less than two (2) inches.

H. The floor slab shall be a true plane surface with no deviation in excess of 1/8 inch when tested with a 10-foot straightedge. The dusting of finished surfaces with dry materials shall not be permitted. The finished floor shall meet the manufacturers’ surface requirements for the installation of block floor, if necessary.

3.05 Wood Block Flooring Installation (if necessary)

A. The blocks shall be laid tightly together, against the existing block floor edge and matching the existing floor lines as closely as possible. The rows of blocks shall be kept straight and parallel and all joints should be broken by a lap of at least one-inch. Every other course shall start with one half block to provide the proper lap. At the end of each course, the last piece of block to be installed shall be no smaller than one inch. New floor blocks shall be installed to replace all missing floor blocks starting at the existing surrounding floor blocks and ending up next to the machine foundations isolation material.

B. The finished block floor surface shall be level and even to include the transition between the existing non-project area block flooring and the new block flooring, and to include the transition between the new block flooring and the top of the machine foundation utility trenches and coolant unit well walls. Where the existing block flooring has experienced wear this shall require the contractor to shave the edges of the new block flooring to make a smooth transition between the new and old flooring.

C. Contractor shall use an adhesive to glue the blocks to the floor. The adhesive shall be compatible with the installed blocks.

D. Install expansion joints as required or specified by the block-flooring manufacturer.

E. Seal block flooring using two applications of manufacturer’s recommended and Contracting Officer’s approved latex sealer. Apply sealant as specified by the block-flooring manufacturer.

F. The finished color of the block flooring shall be dark gray or black to match the surrounding color.

G. Contractor shall re-paint any aisle lines that were removed by the contractor during this project. Aisle line color and width shall match the existing aisle lines.

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GYPSUM BOARD

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