35 49 23.23 25.pdf

Charleroi Locks and Dam - Upper and Lower Guard Walls

SECTION TABLE OF CONTENTS

DIVISION 35 - WATERWAY AND MARINE CONSTRUCTION

SECTION 35 49 23.23 25

UPPER GUARD WALL

PART 1 GENERAL

1.1 SUMMARY

1.2 RELATED WORK SPECIFIED ELSEWHERE

1.3 REFERENCES

1.4 SUBMITTALS

1.5 UPPER GUARD WALL CONSTRUCTION PLAN

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Welded Headed Studs

2.1.2 Sponge Rubber Sheeting

2.1.3 Corrosion Inhibiting Compound

2.1.4 Non-Shrink Epoxy Mortar

2.1.5 Grout

2.2 MANUFACTURED UNITS

2.2.1 Elastomeric Bearing Pads

2.2.2 High-Strength Steel Bars

2.2.3 Anchorages

2.2.4 Watertight Hatches

2.3 ELASTOMERIC BEARING PADS

2.3.1 General

2.3.2 Fabric Reinforced Elastomeric Bearing Pads

2.3.3 Steel Reinforced Elastomeric Bearings

PART 3 EXECUTION

3.1 SEQUENCE OF CONSTRUCTION

3.2 PREPARATION

3.3 ERECTION

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SECTION 35 49 23.23 25 Page 1 W911WN-09-B-0004 Revised by Amendment No. 0002

SECTION 35 49 23.23 25

UPPER GUARD WALL

PART 1 GENERAL

1.1 SUMMARY

This Section covers the requirements for the construction of the Upper Guard Walls. The Upper Guard Wall consists of a concrete-filled sheet piling cell, permanently cased drilled shafts, precast beams and skirts, and cast-in-place concrete thrust blocks.

1.2 RELATED WORK SPECIFIED ELSEWHERE

Section 01 30 00.10 GENERAL REQUIREMENTS

DIVISION 3 - CONCRETE

Section 05 50 14 STRUCTURAL METAL FABRICATIONS

Section 05 50 15 CIVIL WORKS FABRICATIONS

Section 31 41 16 METAL SHEET PILING

Section 31 63 26.00 10 DRILLED SHAFTS

Section 35 20 23.10 UNDERWATER EXCAVATION

1.3 REFERENCES

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

AMERICAN ASSOCIATION OF STATE HIGHWAY AND TRANSPORTATION OFFICIALS

(AASHTO)

AASHTO HB-17 (2002; Errata 2003; Errata 2005) Standard Specifications for Highway Bridges

ASTM INTERNATIONAL (ASTM)

ASTM A 108 (2007) Standard Specification for Steel Bar, Carbon and Alloy, Cold-Finished

ASTM A 722/A 722M (2007) Standard Specification for Uncoated High-Strength Steel Bar for Prestressing Concrete

ASTM C 881/C 881M (2002) Standard Specification for Epoxy-Resin-Base Bonding Systems for Concrete

ASTM D 1056 (2007) Standard Specification for Flexible Cellular Materials - Sponge or Expanded

SECTION 35 49 23.23 25 Page 2

Rubber

ASTM D 1149 (2007) Standard Test Method for Rubber Deterioration - Surface Ozone Cracking in a Chamber

ASTM D 2137 (2005) Standard Test Methods for Rubber Property—Brittleness Point of Flexible Polymers and Coated Fabrics1

ASTM D 2240 (2005) Standard Test Method for Rubber Property - Durometer Hardness

ASTM D 395 (2003; R 2008) Standard Test Methods for Rubber Property - Compression Set

ASTM D 4014 (2003; R 2007) Plain and Steel-Laminated Elastomeric Bearings for Bridges

ASTM D 412 (2006ae1e2) Standard Test Methods for Vulcanized Rubber and Thermoplastic Elastomers - Tension

ASTM D 624 (2000; R 2007) Tear Strength of Conventional Vulcanized Rubber and Thermoplastic Elastomers

POST-TENSIONING INSTITUTE (PTI)

PTI 8 (1985) Specifications for Unbonded Single Strand Tendons

1.4 SUBMITTALS

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

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Upper Guard Wall Construction Plan; G, ED

The Contractor shall submit to the Contracting Officer a Construction Plan at least 90 days prior to beginning work for construction of the Upper Guard Wall.

SD-07 Certificates

Elastomeric Bearing Pads; G, RE

Certificate of compliance shall be furnished to the Contracting Officer certifying that the elastomeric bearing pads to be furnished conform to the requirements specified. The certificate of compliance shall be supported by a certified copy of the results of tests performed by the manufacturer on the bearing pads.

SECTION 35 49 23.23 25 Page 3

1.5 UPPER GUARD WALL CONSTRUCTION PLAN

The Contractor shall submit to the Contracting Officer a proposed construction plan in accordance with paragraph "SUBMITTALS." The sequence of work and procedures as suggested on the contract drawings, and within these specifications, should be used as a basis for preparation of plan, but the Contractor may propose alternatives to the sequence and procedures as appropriate to promote efficiencies with the construction. The nose cell construction procedure shown on the contract drawings meets stability requirements during construction. If the Contractor proposed other methods or sequences for construction of the nose cell, the construction plan shall included calculations to demonstrate stability under anticipated construction conditions. The plans for the cell construction and accompanying calculations shall be signed by a Professional Engineer registered to practice in the particular professional field involved in a State or possession of the United States, in Puerto Rico, or the District of Columbia. The construction plan shall reflect the proposed procedures and order in which the various components will be constructed or installed, citing sequence of construction, requirements for tolerances and other restrictions, as outlined on the drawings and within these specifications.

The proposed construction plan shall clearly identify any procedures of installation which differ from those shown on the drawings or specified herein. The construction plan shall be presented in sufficient detail to permit a thorough review by the Contracting Officer, and shall be subject to comments by the Contracting Officer. Comments by the Contracting Officer shall not be construed as an approval of the equipment, procedures or methods identified within the plan, and shall not relieve the Contractor of the sole responsibility for satisfactory construction of the Upper Guard Wall. Once finalized, no changes or deviations from the plan shall be permitted without prior written notification to the Contracting Officer, who shall maintain the right to review and comment on any proposed revisions.

PART 2 PRODUCTS

2.1 MATERIALS

Material shall conform to the requirements of the particular sections covering the items of work.

2.1.1 Welded Headed Studs

ASTM A 108, Nelson Studs or approved equal.

2.1.2 Sponge Rubber Sheeting

ASTM D 1056, Grade 2B2.

2.1.3 Corrosion Inhibiting Compound

The corrosion inhibiting compound shall conform to the requirements of Section 3.2.5 of PTI 8.

2.1.4 Non-Shrink Epoxy Mortar

ASTM C 881/C 881M, Type III, Grade 1.

SECTION 35 49 23.23 25 Page 4

2.1.5 Grout

Grout for filling the annulus between the Upper Guard Wall pier cap sleeve and the drilled shaft shall be a highly flowable mix that must consolidate without the use of vibration. All of this grout shall be placed underwater and by gravity flow only. Pumping of this mixture will not be permitted.

Grout shall possess the ability to flow readily through the tremie line, and flow laterally around drilled shafts. The grout shall be self-consolidating under its own weight and shall not segregate during placement or self-consolidation. To limit laitance, the bleed of the mix shall be limited to no more than 1% after 8 hours. Washout loss shall be limited to 8%.

The grout shall have a design minimum unconfined compression strength of the grout is 8,000 psi. In general, a slump of 9 to 11 inches and a slump flow of 18 to 26 inches will be necessary. The grout shall be flowable and non-segregating. The grout shall not exhibit rapid slump loss. The 90 minute slump of the mixture shall not be less than 7.5 inches. The grout shall remain sufficiently flowable to prevent bridging. Initial set time shall be between 6 and 24 hours, and final set shall be less than 30 hours.

2.2 MANUFACTURED UNITS

2.2.1 Elastomeric Bearing Pads

Laminated elastomeric pads shall be steel reinforced neoprene bearings, formed of neoprene layers with steel plates. Neoprene pads shall conform to the requirements of AASHTO HB-17, Section 14. Elastomeric bearing pads shall be of the size shown. Steel reinforcing plates shall be of the sizes and thicknesses shown.

2.2.2 High-Strength Steel Bars

High-strength steel bars shall conform to ASTM A 722/A 722M, Type I or II, meeting all supplementary requirements.

2.2.3 Anchorages

Anchorages shall be metal of proven corrosion resistance and compatible with the bars. Anchorages shall be the nut and thread type and shall be provided with bearing plates.

2.2.4 Watertight Hatches

Watertight hatches shall be factory fabricated items, of steel construction with corrosion resistant hardware. Hatch cover shall be designed to be flush with the surrounding surface. Door shall be furnished with a full perimeter, low durometer neoprene gasket and compression latches. Door shall be watertight under a 25 foot head of water and shall have AASHTO HS20 load rating.

2.3 ELASTOMERIC BEARING PADS

2.3.1 General

At the Contractor's option, the elastomeric bearing pads provided for the Upper Guard Wall box beams shall be either fabric reinforced elastomeric bearing pads or steel reinforced elastomeric bearings.

SECTION 35 49 23.23 25 Page 5

2.3.2 Fabric Reinforced Elastomeric Bearing Pads

Pads shall be laminated. Stacking of individually laminated pads or cold bonding of individual laminated pads will not be permitted. Laminated pads shall consist of alternate layers of elastomer and fabric reinforcement bonded together. The top and bottom layers of reinforcement shall be uniformly covered with a maximum of 1/8 inch of elastomer.

Laminated pads shall have reinforcement every 1/2 inch through the entire thickness. Fabric reinforcement shall be single ply at top and bottom surfaces of the pad and double ply within the pad. The reinforcement shall be parallel to the top and bottom surfaces of the pad. Variations in the location of the reinforcement in excess of 1/8 inch from its theoretical location shall be cause for rejection. The total out to out thickness of a pad shall not be less than the thickness shown on the plans nor more than 1/4 inch greater than that thickness.

Pads with fabric reinforcement may be cut from large sheets. Cutting shall be performed in such a manner as to avoid heating of the material and to produce a smooth edge with no tears or other jagged areas and to cause as little damage to the material as possible. The peel strength test will be performed after immersing the sample in water for a minimum of 10 days.

The bond between elastomer and fabric shall be such that when a sample is tested for separation, the bond shall have a minimum peel strength of 5.3 kN/m (30 pounds per inch) when tested in conformance with the requirements in California Test 663.

Fabric reinforcement shall be woven from 100 percent glass fibers of "E" type yarn with continuous fibers. The minimum thread count in either direction shall be one thread per millimeter {25 threads per inch}. The fabric shall have either a crowfoot or an 8 Harness Satin weave. Each ply of fabric shall have a breaking strength of not less than 800 pounds per inch of width in each thread direction when 3 inch x 36 inch samples are tested on split drum grips. The bond between double plies shall have a minimum peel strength of 20 pounds per inch.

The sole polymer in the elastomeric compound shall be neoprene and shall be not less than 60 percent by volume of the total compound. The elastomer shall be Type CR, Grade 3, and shall have a shear modulus of 750 kPa ± 75 kPa {110 pounds per square inch ± 10 pounds per square inch}, in conformance with the requirements in ASTM ASTM D 4014.

The elastomer, as determined from test specimens, shall conform to the following:

ASTM

Test Designation Requirement

Tensile strength, kPa {psi} ASTM D 412 15 500 {2250} Min

Elongation at break, percent ASTM D 412 350 Min.

Compression set, 22 h at 70°C ASTM D 395 25 Max {158° F}, percent (Method B)

Tear strength, N/m {lb/in} ASTM D 624 31 500 {180} Min (Die C)

SECTION 35 49 23.23 25 Page 6

ASTM

Test Designation Requirement

Hardness (Type A) ASTM D 2240 55 ±5 with 2 kg. wt.

Ozone resistance 20% strain, ASTM D 1149 (except 100 100 h at 40°C ±2°C ±20 parts per {104° F ±3.6° F) 100 000 000) No cracks

Low temperature brittleness, at -40°C {-40° F} ASTM D 2137 Pass

After accelerated aging in conformance with ASTM D 573 for 70 hours at 100°C {212º F}, the elastomer shall not show deterioration changes in excess of the following:

Tensile strength, percent -15

Elongation at break, percent -40; but not less than 300% total elongation of the material

Hardness, point +10

Specimen shall be tested by the manufacturer in conformance with the requirements in California Test 663 METHOD OF TESTING BRIDGE BEARING PADS, and shall meet the requirements for the bond between elastomer and fabric reinforcement laminations.

2.3.3 Steel Reinforced Elastomeric Bearings

Steel reinforced elastomeric bearings shall conform to the requirements for steel laminated elastomeric bearings in ASTM D 4014. The bearings shall consist of alternating steel laminates and internal elastomer laminates with top and bottom elastomer covers. Steel laminates shall have a nominal thickness of 0.075-inch. Internal elastomer laminates shall have a thickness of 1/2 inch, and top and bottom elastomer covers shall each have a thickness of 1/4 inch. The combined thickness of internal elastomer laminates and top and bottom elastomer covers shall be equal to the bearing pad thickness shown on the plans. The total out to out thickness of a pad shall not be less than the thickness shown on the plans nor more than 1/4 inch greater than that thickness. The elastomer cover to the steel laminates at the sides of the bearing shall be 1/8 inch. If guide pins or other devices are used to control the side cover over the steel laminates, any exposed portions of the steel laminates shall be sealed by vulcanized patching. The length, width, or diameter of the bearings shall be as shown on the plans. The total thickness of the bearings shall be equal to the thickness of elastomer laminates and covers plus the thickness of the steel laminates. The shear modulus of the elastomer shall be 110 pounds per square inch +10 pounds per square inch. The elastomer shall be Type CR, Grade 3. The ozone test concentration (partial pressure) shall be 100 MPa, formerly referred to as 100 parts per hundred million.

Specimen shall be tested by the manufacturer in conformance with the requirements in California Test 663 METHOD OF TESTING BRIDGE BEARING PADS, and shall meet the requirements for the bond between elastomer and steel laminates.

SECTION 35 49 23.23 25 Page 7

PART 3 EXECUTION

3.1 SEQUENCE OF CONSTRUCTION

A suggested sequence of construction is shown on the contract drawings.

The Contractor shall develop his construction sequence and methods to complete the work as shown on the drawings and as specified, including consideration of restrictions and conditions specified and other work in progress. The sequence of construction shall be explained in the Upper Guard Wall Construction Plan. The precast components for the Upper Guard Wall between Pier 6 and the new River Wall (RS-7) shall be furnished but not installed under this contract. The precast components shall be stored at the location shown on the drawings for installation under a future contract.

3.2 PREPARATION

Pre-excavation shall be performed in accordance with Section 35 20 23.10 UNDERWATER EXCAVATION. The area of the Upper Guard Wall Nose Cell shall be preexcavated to top of rock as shown on the contract drawings, prior to installing the sheet pile cell. Prior to placing the tremie concrete in the cell, all material inside the shall be removed to rock. Removal of material within the cell shall be performed using a combination of air and/or water jetting and air lifting. Air lift methods shall be used to remove material from areas inaccessible to bucket removal. Air lifting and other construction activities shall be subject to the water control requirements contained in Section 01 57 20.00 10 ENVIRONMENTAL PROTECTION, paragraph "Water and Sediment from River-Based Construction Activities", subparagraph "d". Soundings in combination with visual inspection of localized spaces or other means of verification shall be proposed to ensure that excavation has been performed to the required depth, and that all loose material has been removed such that the maximum depth of materials in any isolated area is no more than 2-inches. The maximum extent of isolated areas of loose material shall be 20 square feet, and the total of such isolated areas shall be less than 20% of the area of the cell. Loose material shall be any alluvial materials or pieces of rock that can be removed by divers. The Contractor shall make suitable and adequate provisions to prevent displacement of the cell from its correct position due to placement of tremie concrete. Any displacement of the cell shall be corrected to the satisfaction of the Contracting Officer before the tremie concrete is placed.

3.3 ERECTION

The Upper Guard Wall shall be constructed as shown on the drawings.

Fabrication and installation of individual components shall be in accordance with the referenced specifications sections.

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SECTION 35 49 23.23 25 Page 8