Technical_Specifications_and_Contract-Reference_Drawings.pdf

STONEWALL JACKSON DAM

REPLACE PYLON BUILDING ROOFS

1. GENERAL REQUIREMENTS

1.1 GENERAL

The work is located at the pylon building on Stonewall Jackson Dam at Weston, West Virginia.

The work includes the removal of existing roofing systems on three roof levels down to the concrete decks and the placement of new tapered insulation and modified bitumen built up roofing system on these roofs at the pylon building on the dam. The general description of the work is to furnish all equipment, labor, layout of work, supervision and materials necessary to complete the work as shown and as specified. Typical detail of the new roof is indicated on the attached “TYPICAL NEW MODIFIED BITUMEN ROOF DETAIL”.

The existing roofs on the pylon building at the dam consist of two lower level roofs that function as observation decks and one upper level penthouse roof.

Details of the building construction are shown on the attached reference drawings, however, the penthouse roofing has been replaced at one time with a spray-applied system over foam insulation. No further information on the penthouse roof is available. The work shall include removal and disposal of all roofing materials over the all three roofs down to the existing concrete decks, including all flashing, roof drains, flashing around penthouse roof scuttle, and installation of new tapered insulation, flashing, roof drains, and all other work to furnish all equipment, labor, layout of work, supervision and materials necessary to complete the work as shown and as specified. The Contractor shall be responsible for transport of materials to the site and to prevent demolished materials from entering the lake. All material provided in the performance of this contract shall be unused and meet the requirements of the specifications. The Contractor shall verify dimensions and clearances in the field before beginning work.

The Contractor shall furnish the submittals required under Paragraph “1.3.1 Bid Submittals” with the bid.

Submittals required under Paragraph “1.3.2 Post-Award Submittals” shall be submitted to the Administrative Contacting Officer (ACO) after award of the contract and Notice to Proceed is issued.

1.2 SAFETY

All work shall be performed in accordance with the Corps of Engineers Safety Manual EM385- 1-1. Latest version is available online at http://www.publications.usace.army.mil/Portals/76/Publications/EngineerManuals/EM_385-1- 1.pdf

The contractor shall complete and submit the Accident Prevention Plan (separate attachment) included with this specification.

Safety Shoes – All employees engaged in construction operations shall wear safety shoes meeting the requirements of EM 385-1-1, Section 05.E.

Protective Eyewear – All workers on the site shall wear, as a minimum, protective eyewear meeting the requirements of EM 385-1-1, Section 05.B. Additional eye protection may be required in accordance with the requirements of EM 385-1-1, Section 05.B.

Hearing Protection – Hearing protection shall be provided for workers in accordance with EM 385-1-1, Section 05.C.

Head Protection – Head protection shall be provided for workers in accordance with EM 385-1-1, Section 05.D.

Personal Fall Protection – Fall protection shall be provided for workers in accordance with EM 385-1-1, Section 21.

Load Handling Equipment - Load handling operations shall be conducted in accordance with EM 385-1-1, Section 16, including the preparation and submittal of any lift plans.

Work Platforms and Scaffolding - Work platforms and scaffolding propped shall meet the requirements of EM 385-1-1, Section 22.

The contractor shall be responsible for providing a fall protection plan to the Administrative Contacting Officer (ACO) for approval, detailing the equipment and methods proposed to ensure the contractor performs the work in a safe manner in accordance with EM385-1-1. Methods of attaching lifelines or other safety devices to the existing structure shall be performed in a manner that does not damage the structure permanently. Any damage shall be repaired at no additional cost to the Government.

1.3 PROJECT SUBMITTALS

The contractor shall provide, as a minimum, submittals indicated below for Government Approval. The Government reserves the right to require the Contractor to resubmit any item found not to comply with the contract. This does not relieve the Contractor from the obligation to furnish material conforming to the contract, and it will not prevent the Contracting Officer from requiring removal and replacement of nonconforming material incorporated in the work.

1.3.1 Bid Submittals

1.3.1.1 Product Data. For evaluation purposes, the bidder shall submit for approval product literature for all roofing materials. Product data shall include catalog cuts, specifications or other descriptive data for materials proposed for use, including copies of Manufacturer’s warranties.

All appropriate descriptive data shall be clearly indicated on the submittal. All roofing materials shall be compatible with each other and recommended by the manufacturer for use as a system.

All materials required by the manufacturer to activate the warranty shall be incorporated into the work.

1.3.1.2 Qualification Of Installer. Roofing system installer shall be approved, authorized, or licensed in writing by the roofing system manufacturer and shall have at least the minimum years’ experience requited by the manufacturer as an approved, authorized, or licensed installer with that manufacturer and be approved at a level capable of providing the specified warranty.

as well as crack sealing materials

1.3.2 Post-Award Submittals

1.3.2.1 Accident Prevention Plan. Contractor shall submit for approval an accident prevention plan in accordance with Paragraph “1.2 SAFETY” before beginning any on-site work.

1.3.2.2 Storage and Laydown Plan. Plan shall include proposed plan for storage and laydown of equipment, supplies and materials at the site. Plans shall also include placement of dumpsters and lifting equipment. The use of any lifting equipment or personnel lifting equipment shall be in accordance with Paragraph “1.2 SAFETY”.

1.3.2.3 Demolition and Removal Plan. Plan shall including plans for temporary removal of air conditioning unit and lightning protection system including qualifications of subcontractors as specified in Paragraph “3.1 DEMOLITION AND DISPOSAL”.

1.3.2.4 Mold Removal and Crack sealing Plans. Proposed methods and qualifications of contractors to perform mold removal and crack sealing shall be in accordance with Paragraph

“3.4 SUBSTRATE PREPARATION”.

1.3.2.5 Warranty. Manufacturer's standard warranty for the roofing system that includes labor and materials shall be provided for not less than 20 years after acceptance of the work. Warranty shall be provided in the name of “Stonewall Jackson Dam”. Warranty shall state that manufacturer shall repair or replace defective materials if the roofing system leaks or allows the insulation to become wet during the period of the warranty. The contractor shall adhere to all the requirements of the roofing manufacturer for activating the guarantee, and shall show proof that the contractor is an authorized installer of the manufacture’s roofing system.

1.3.2.6 Verification Of Field Conditions. The Contractor shall verify all dimensions and conditions in the field and shall advise the Contracting Officer of any discrepancy before performing any work.

1.3.2.7 Quality Control Plan. The Contractor shall complete and submit the Quality Control Plan (separate attachment) included with this specification. The quality control system shall consist of plans, procedures, and organization necessary to produce an end product which complies with the contract requirements, covers all construction operations, both onsite and offsite, and be keyed to the proposed construction sequence. The project superintendent will be held responsible for the quality of work and is subject to removal by the Contracting Officer.

1.4 COORDINATION MEETING AND POINTS OF CONTACT

Prior to commencement of any work being performed on site, the contractor shall participate in a teleconference or meeting with the Administrative Contacting Officer (ACO) and the Lake Resource Manager.

Stonewall Jackson Dam Resource Manager – Jeff Toler, 304-2694588.

ACO – Denise Polizzano, 412-395-7680

1.5 PROJECT/SITE CONDITIONS

1.5.1 Work and Storage Areas

It is noted that the work area is on the roofs of the pylon building on the dam. The top of the dam, the service bridge and the pylon building are accessible by vehicle. The Contractor shall be fully responsible for determining the methods used to transport materials and equipment to and from the roof as well as the removal of waste materials from the roof. The Contractor shall ensure that his operations will not interfere with the operation of the project or the duties of project personnel. It is noted that access to the penthouse roof may be obtained by stairs to the roof scuttle or by use of ladders, scaffolding or man lift from outside the building. Lifting equipment and storage of materials will be allowed on the service bridge or in the parking area at the top of the dam. Placement of dumpsters, equipment and staging and storage of materials in any area shall be coordinated with and approved by the ACO and the Resource Manager.

Scaffolding and transport of materials and equipment shall be the responsibility of the Contractor. The Government requires access past the pylon building at all times. Storage of materials and placement of dumpsters, ladders, scaffolding and lifting equipment will be allowed on the service bridge near the pylon building as long as one lane of traffic is maintained to allow access past the pylon building by Government vehicles. Contractor shall be responsible for providing a fall protection plan to the ACO for approval, detailing the equipment and methods proposed to ensure the contractor performs the work in a safe manner in accordance with EM385-1-1. The Contractor will be allowed to access the pylon building from the service bridge only and will not be allowed use of the elevator. It is noted that the work area is considered a restricted area and the Contractor will be provided access by Government personnel to the work area and the Contractor will only permitted access to the work area in accordance with paragraph “1.5.3 Time Of Performance”. It is also noted that no potable water nor restroom facilities are available at the dam. Public restroom is available at the Resource Managers Office/Visitors Information Center.

1.5.2 Public Use

The Contractor's attention is directed to the fact that the work to be performed is located in areas used by the public. It shall be the responsibility of the Contractor to provide the controls necessary to prevent any interference by the public to his operations. The Contractor shall take all necessary and reasonable precautions to secure the area against vandalism and to ensure the safety and well-being of the public until final acceptance by the Government.

1.5.3 Time Of Performance

The Contractor shall confine all operations at the work site between the hours of 7:30 AM and 4:00 PM, Monday through Friday, unless otherwise approved. Work will not be permitted on weekends or Federal holidays unless otherwise approved. Work shall be scheduled so that all work shall be completed in one construction season.

1.6 PROTECTION OF GOVERNMENT PROPERTY

The contractor shall protect all government property during the performance of this contract. All damage to existing government property as a result of the contractors work shall be repaired or replaced to the satisfaction of the Contracting Officer. Exposed roof and building interior shall be protected at all times. At areas where existing roofing materials have been removed, the Contractor shall install and maintain temporary protection from the weather until permanent installation of roofing materials can be made. Any damage caused by inadequate or unapproved temporary protection shall be repaired at no additional cost to the Government. The Contractor shall coordinate roof demolition with the Contracting Officer. Work area shall be cleaned by the Contractor after construction is complete. In no case shall materials be permitted to fall into the lake.

1.7 PROTECTION OF PERSONNEL

The Contractor shall insure that adequate measures are in place to protect workers, facility operation personnel and the public from injury due to the operations being performed. All protective measures shall be in accordance with EM 385-1-1.

1.8 SECURITY REQUIREMENTS

1.8.1 Access and General Protection and Security Policy and Procedures

The contractor and all associated subcontractors' employees shall comply with applicable installation, facility, and area commander installation and facility access and local security policies and procedures (provided by the Government Representative). The contractor shall also provide all information required for background checks to meet installation access requirements to be accomplished by the installation the USACE Security Office. The contractor workforce must comply with all personal identity verification requirements as directed by DoD, HQDA, and/or local policy. In addition to the changes otherwise authorized by the changes clause of this contract, should the Force Protection Condition (FPCON) at any individual facility or installation change, the Government may require changes in contractor security matters or processes. The contractor must submit the full name, Social Security Number or valid state driver's license number (with state of issue), Date of Birth, and Place of Birth for all associated contractor or subcontractor employees to the USACE Security Office, Stephen Davidson, 412-395-7504, stephen.davidson@usace.army.mil or Joseph M. Bali, 412-395-7162, joseph.m.bali@usace.army.mil . The information may be submitted via email directly to the security office or by fax at 412-395-7173, all requests for background checks must contain the required identifying information, the location of work (USACE Project Name), and the USACE COR . The District retains the right to deny any contractor and subcontractor employee from working on one of its contracts based on final background investigation results.

1.8.2 Access Control

All contract employees, including subcontractor employees who are not in possession of the appropriate security clearance, will be escorted in areas where they may be exposed to classified and/or sensitive materials and/or sensitive or restricted areas.

1.8.3 AT Level I Training

All contractor employees, to include subcontractor employees, requiring access to Army installations, facilities, controlled access areas, or require network access, shall complete AT Level I awareness training within 30 calendar days after contract start date or effective date of incorporation of this requirement into the contract, whichever is applicable. Upon request, the contractor shall submit certificates of completion for each affected contractor employee and subcontractor employee, to the COR or to the contracting officer (if a COR is not assigned), within 5 calendar days after completion of training by all employees and subcontractor personnel. AT Level I awareness training is available at the following website:

http://jko.jten.mil/courses/atl1/launch.html ; or it can be provided by the RA ATO in presentation form which will be documented via memorandum."

1.8.4 Suspicious Activity Reporting Training

The contractor and all associated sub-contractors shall receive a brief/training (provided by the RA) on the local suspicious activity reporting program. This locally developed training will be used to inform employees of the types of behavior to watch for and instruct employees to report suspicious activity to the project manager, security representative or law enforcement entity. This training shall be completed within 30 calendar days of contract award and within 30 calendar days of new employees commencing performance with the results reported to the COR NLT 5 calendar days after the completion of the training.

1.8.5 Instant Verification of Employment Eligibility (E‐Verify)

The Contractor must pre‐screen Candidates using the E‐verify Program (http://www.uscis.gov/e-verify ) website to meet the established employment eligibility requirements. The Vendor must ensure that the Candidate has two valid forms of Government issued identification prior to ensure the correct information is entered into the E‐verify system. An initial list of verified/eligible Candidates must be provided to the COR no later than 3 business days after the initial contract award.

1.8.6 Employee Identification and Background Check

The Contractor shall be responsible for furnishing an identification badge/card to each employee prior to the employee working on-site and for requiring each employee engaged on the work to display identification. Identification shall consist of name tags with the name of the Contractor and the employee's name. Additionally, a valid state driver's license or other Government-issued photo identification card is required for positive identification. Each employee will be subject to a background check in accordance with "Homeland Security Presidential Directive 12: Policy for a Common Identification Standard for Federal Employees and Contractors" (HSPD-12). Only those individual employees that were specifically identified and approved will be cleared to work on Government property.

1.9 REFERENCE DRAWINGS

Reference drawings show existing conditions to the best knowledge of the Government. As noted earlier, the original penthouse roof was replaced at one time with a spray applied roof system over foam insulation. Unless otherwise noted, dimension, elevations, and other features shown on contract drawings, are generally based on the reference drawings supplemented by field surveys. The Government cannot guarantee the accuracy of the dimensions, elevations, and features shown on reference drawings or on contract drawings which are based on the reference drawings, and it shall be the responsibility of the Contractor, whenever necessary, to verify all elevations and the dimensions by measurements in the field. All elevations are referenced to the local datum used for the original construction of the structure. The Contractor shall verify elevations and dimensions before laying out the work. The Contracting Officer shall be notified of any discrepancies prior to commencing work.

2. PRODUCTS

2.1 BITUMINOUS MATERIALS

Bituminous materials shall conform to the following requirements:

2.1.1 Asphalt Bitumen

ASTM D 312, Type III or IV, in accordance with modified bitumen membrane manufacturer requirements and compatible with the slope conditions of the installation.

2.1.2 Asphalt Roof Cement

ASTM D 4586, Type II for vertical surfaces, Type I for horizontal surfaces, compatible with the modified bitumen roof membrane and as recommended by the modified bitumen membrane manufacturer.

2.1.3 Asphalt Primer

ASTM D 41, or other primer compatible with the application and as approved in writing by the modified bitumen membrane manufacturer.

2.2 COLD-APPLIED MEMBRANE ADHESIVE

Adhesive for application of the membrane plies shall be as recommended by the membrane manufacturer and be compatible with all other roofing materials, including primer (if required) and cold tar pitch..

2.3 INSULATION

Insulation shall be compatible with the roofing system, as recommended by the roofing system manufacturer's printed instructions. Insulation shall be a standard product of the manufacturer and shall be factory marked with the manufacturer's name or trade mark Boards shall be marked individually. The insulation manufacturing process shall not include chlorofluoro carbons (CFC) or formaldehydes. Insulation and fiberboard shall conform to EPA requirements for recycled/recovered materials. Tapered insulation shall be installed to maintain constant slope to the roof drains. Minimum thickness of insulation shall be 2 inches. Where tapered insulation is specified, the finish slope of the roof shall be 1/4-inch per foot. Insulation shall be Polyisocyanurate meeting ASTM C 1289, Type I, or ASTM C 1289 Type II.

2.4 FASTENERS

Nails, screws and other fasteners shall be an approved type recommended by the manufacturer of the insulation, roofing felt or membrane and flashing or as otherwise compatible with the roofing system.

2.5 CANTS AND WOOD NAILERS

Treated wood cants and nailers shall be treated in accordance with AWPA C2 with waterborne preservatives intended for above ground use. Cants shall be made from treated wood or treated fiberboard and cut to reduce change in direction of the membrane to 45 degrees or less.

Fiberboard shall conform to ASTM C 208, treated with sizing, wax or bituminous impregnation.

When membrane or flashing is to be torch applied, cants shall be fire resistant. Edge nailers shall be of thickness to finish flush with the top surface of the insulation. Surface mounted nailers shall be the full thickness of the insulation.

2.6 FLASHING

Lead, lead-coated metal, and galvanized steel shall not be used. New material shall be compatible with existing adjacent materials. Accessories and other items essential to complete the sheet metal installation, though not specifically indicated or specified, shall be provided.

Modified bituminous sheet shall be used for flashings where the roof deck abuts angles, vertical surfaces, edge metal, and penetrations, unless otherwise specified or indicated. Flashing shall be installed as the work progresses.

2.6.1 Aluminum Extrusions

ASTM B 221M ASTM B 221, Alloy 6063, Temper T5.

2.6.2 Sealant

Elastomeric sealants shall conform to ASTM C 920 and the following:

a. Polysulfide Sealant: Type S, Grade NS, Class 25, Use NT, A.

b. Polyurethane sealant: Grade NS, Class 25, Use NT, A.

c. Silicone sealant: Type S, Grade NS, Class 25, Use NT, A.

2.6.3 Polyvinyl Chloride (PVC) Reglets

ASTM D 1784, Class 14333D, 1.9 mm 0.075 inch minimum thickness.

2.6.4 Roof Drains

Roof drains shall conform to ASME A112.21.2M, with dome and integral flange, and shall have a device for making a watertight connection between roofing and flashing. Design shall be similar to the original. The Contractor shall ensure new roof drain is adequate and can be installed without demolition of the roof deck.

2.7 MODIFIED BITUMEN SHEET

Modified bitumen sheet shall be a bitumen modified by styrene butadiene styrene (SBS); or modified by SBS which has been further modified with styrene ethylene butadiene styrene (SEBS). Sheets shall be uniform in thickness and appearance, and free from blisters or tape splices. Sheets shall not stick to the roll or stack, and shall be suitable for joining along the entire length by the procedure recommended by the manufacturer. Materials provided shall be suitable for the service and climatic conditions of the installation. Modified bitumen sheets shall be watertight and visually free of pinholes, particles of foreign matter, non-dispersed raw material, factory splices, or other conditions that might affect serviceability.

a. Venting Base Sheet: ASTM D 4897, Type II, with perforations and as approved by the modified bitumen roof membrane manufacturer.

b. Fiberglass Felt Base Sheet: ASTM D 4601, ASTM D 1668 Type II, with perforations and as approved by the modified bitumen roof membrane manufacturer.

c. SBS Base Sheet: ASTM D 6162 or ASTM D 6164 or ASTM D 6163, Type II, Grade S, 80 mils thick.

d. SBS Cap Sheet: ASTM D 6162 or ASTM D 6164 or ASTM D 6163; Type II, Grade G, minimum 145 mils thick at selvage edge, and as required to provide specified fire safety rating.

2.7.1 Surfacing Material

Surfacing shall be factory applied granules requiring no further coating. The surfacing material shall be white.

2.8 FLAME HEATED EQUIPMENT

Flame heated kettles shall not be placed on the roof. Torch application shall be approved by the membrane manufacturer for the specific modified bitumen. Open flame equipment shall not be left unattended while ignited.

2.9 ELECTRIC-HEATED EQUIPMENT

Adequate electrical service shall be provided as required by the manufacturer of the equipment, to insure proper application of the roofing materials. Electric service is not available at the pylon building and the contractor shall be responsible for furnishing electric generator for this purpose.

3. EXECUTION

3.1 DEMOLITION AND DISPOSAL

All existing roofing materials shall be removed. All existing reglets, metal sealing strips , membranes and other material shall be removed and disposed of, without damaging the underlying concrete deck. All materials removed in the performance of this contract and not reused shall become the property of the contractor and be disposed of offsite in accordance with Federal, State and Local regulations. On-site burning will not be permitted, and materials will not be permitted to fall into the lake. Placement of dumpsters and other equipment shall be as specified in paragraph “1.5.1 Work Areas

3.1.1 Lightning Protection System

The Contractor shall utilize the services of a lightning protection system contractor to temporarily remove the existing lighting protection system on the penthouse roof and reinstall it in accordance with the roofing system manufacturer’s recommendations and all applicable Codes.

3.1.2 Roof-Mounted Air Conditioning Unit

The Contractor shall utilize the services of an HVAC contractor to temporarily move the roof mounted outdoor unit from its pad and replace it after application of new roofing over the pad.

The unit is not permanently anchored to the pad and shall be set back in place over the new roofing, the refrigerant lines purged and recharged and the air conditioning unit tested for proper operation..

3.1.3 Other Roof-Mounted Equipment

The existing non-operational Generator load bank and satellite transmission antenna, as well as other antennas and other devices on the roof not specifically required to be removed by the contractor will be removed by the Government prior to the work.

3.1.4 Existing Roof Pavers

The lower level observation decks have pavers for walking surface. The pavers shall be removed and turned over to the Government. The pavers shall be lowered from the roof to the service bridge and stacked for Government use.

3.2 COORDINATION REQUIREMENTS

Insulation and roofing membrane shall be finished in one operation up to the line of termination at the end of each day's work. Phased construction will not be permitted.

3.3 ENVIRONMENTAL CONDITIONS

The temperature of the roofing materials shall be as required by the manufacturer. Air temperature shall be above 40 degrees F and there shall be no visible ice, frost, or moisture on the roof deck when the insulation and roofing are installed. Wind conditions shall be suitable for installation of insulation: Wind chill may affect the proper application temperatures of materials;

hot materials may be blown about, creating safety dangers; insulation boards may become difficult and hazardous to handle; wrappers, coverings, and other debris may become airborne, and possibly contaminate laps and seams.

3.4 SUBSTRATE PREPARATION

The substrate preparation of shall be completed before insulation work is begun thereon. It is known that the upper penthouse roof has leaked and that the underside of the concrete deck has become covered in mold. It is suspected that mold exists under the roofing materials. All mold, dirt or other deleterious materials shall be removed from the upper penthouse roof and the lower observation deck roofs, the decks allowed to dry thoroughly and all surface preparation as required by the roofing system manufacturer shall be performed prior to installation of insulation. Existing roofing shall be completely removed. Roof drains and other items penetrating the roof shall be secured in position and properly prepared for flashing. Substrate surface shall be smooth, clean, and dry at time of application.

It is known that there are some hairline cracks in the concrete roof deck over the penthouse portion of the control tower, and the Contractor shall be required to pay special attention to properly seal these cracks as recommended and approved by the roofing system manufacturer.

All materials shall be compatible with the roofing system.

3.5 HEATING OF ASPHALT

Asphalt shall not be heated higher than 105 degrees F above the EVT or 50 degrees F below the flash point, or 525 degrees F, whichever is lower. EVT and flash point temperatures of asphalt in the kettle shall be conspicuously posted on the kettle. Kettle shall be provided with automatic thermostatic controls and an accurate thermometer. Kettle operators shall be in attendance at all times during heating to ensure that the maximum temperature is not exceeded. Flame-heated equipment shall not be placed on the roof.

3.6 INSTALLATION OF WOOD NAILERS

Nailers shall be provided as necessary for the attachment of finish materials as recommended by the roofing system manufacturer. Nailers shall be secured as recommended by the insulation or roofing manufacturer. Bolt anchors shall have nuts and washers countersunk, and bolts shall be cut flush with top of nailer. Powder-actuated fasteners, sized and spaced for nailer anchorage equivalent to that specified and indicated, may be used when approved.

3.7 APPLICATION OF INSULATION

Insulation shall be laid in two or more layers. Units of insulation shall be laid in courses parallel with the roof slope. End joints shall be staggered. Insulation shall be cut to fit neatly against adjoining surfaces. Joints between insulation boards shall not exceed /4 inch. Joints in successive layers shall be staggered with respect to joints of preceding layer. Insulation which can be readily lifted after installation is not considered to be adequately secured. Insulation shall be applied so that all roof insulation applied each day is waterproofed the same day. Phased construction will not be permitted. Insulation shall be installed with adhesive in accordance with the manufacturer’s instructions. The insulation shall be kept dry at all times. Insulation boards shall not be kicked into position. Phased construction will not be permitted. Application of impermeable faced insulation shall be performed without damage to the facing.

3.8 FLASHING

Roof edges, projections through the roof and changes in roof planes shall be flashed. Vertical masonry or concrete surfaces such as chimneys or parapet walls shall be flashed. The installed flashing shall be secured at the top of the flashing a maximum of 12 inches on centers under the counterflashing or cap. Where possible, prefabricated components shall be used for pipe seals and flashing accessories.

3.8.1 Protection Of Aluminum

Aluminum surfaces shall not directly contact other metals except stainless steel, zinc, or zinc coating. Where aluminum contacts another metal, paint the dissimilar metal with a primer followed by two coats of aluminum paint. Where drainage from a dissimilar metal passes over aluminum, paint the dissimilar metal with a non-lead-pigmented paint.

3.8.2 Connections And Jointing

Joints in aluminum sheets 0.040 inch or less in thickness shall be mechanically made. Flat-lock seams shall finish not less than 1 inch wide. Plain-lap seams shall lap not less than 3 inches unless otherwise specified. Flat seams shall be made in the direction of the flow.

3.8.3 Flashing at Roof Drains

Set flashing on finished felts in a full bed of asphalt roof cement, ASTM D 2822. Extend roofing plies to edge of drain bowl opening at roof drain deck flange. Neatly fit and press primed roof drain flashing into heavy coat of asphalt roof cement applied to top of roofing plies. Strip in and completely cover flashing with two layers of modified bitumen sheet, extending the first sheet 6 inches on the roofing beyond the edge of flashing. Extend the cap sheet 6 inches beyond the previous flashing ply. Bond the two layers to the metal flashing and to each other with hot asphalt. Securely clamp membrane, metal flashing, and strip flashing in the flashing clamping ring. Secure clamps so that strip flashing and metal flashing are free from wrinkles and folds.

Trim membrane, flashing, and stripping flush with inside of clamping ring.

3.8.4 Reglets

Reglets shall be a factory fabricated product of proven design, complete with fittings and special shapes as required. Open-type reglets shall be filled with fiberboard or other suitable separator to prevent crushing of the slot during installation. Reglet plugs shall be spaced not over 12 inches on centers and reglet grooves shall be filled with sealant. Friction or slot-type reglets shall have metal flashings inserted the full depth of slot and shall be lightly punched every 12 inches to crimp the reglet and counter flashing together. Polyvinyl chloride reglets shall be sealed with the manufacturer's recommended sealant.

3.8.5 Metal Cap Flashing

Metal cap flashing shall be fabricated of continuous sheet of aluminum generally formed as shown on the attached “TYPICAL NEW MODIFIED BITUMEN ROOF DETAIL”. Cap flashing may be secured with wood nailers or adhered with a suitable bonding adhesive as recommended by the manufacturer. Edges of flashing shall be bent outward to form a drip edge.

3.9 PRIMING

Concrete, masonry and metal surfaces to receive bitumen shall be uniformly coated with primer at a rate of not less than1 gallon per square and allowed to dry. Primer shall be as recommended by the manufacturer and be compatible with all other roofing materials proposed.

3.10 APPLICATIONS OF BASE SHEET

Base sheet shall be applied, shingle fashion, in a continuous operation, with side laps in accordance with manufacturer's printed instructions. End laps shall be not less than 6 inches and staggered a minimum of 24 inches. Base sheets shall be applied at right angles to the slope and laps shall face down the slope. Venting base sheet shall be mechanically fastened in conformance with requirements of the manufacturer's printed instructions.

3.11 MODIFIED BITUMEN MEMBRANE APPLICATION

Ensure proper sheet alignment prior to installation. Bucking or backwater laps are prohibited.

Fully adhere membrane sheets to underlying substrate materials. Provide minimum 3 inch side laps and minimum 6 inch end laps and as otherwise required by membrane manufacturer.

Stagger end laps minimum 36 inches. Offset side laps between membrane layers a minimum of 12 inches. Offset end laps between membrane layers a minimum of 36 inches. All membrane layers shall be installed the same workday, unless supported otherwise by roof membrane manufacturer application instructions and approved by the Contracting Officer. Provide tight smooth laminations of each membrane layer without wrinkles, ridges, buckles, kinks, fishmouths, or voids. Ensure full membrane adhesion and full lap seals. Rework to seal any open laps prior to application of subsequent membrane layers. The completed membrane application shall be free of surface abrasions, air pockets, blisters, ridges, wrinkles, buckles, kinks, fishmouths, voids, or open seams.

3.12 HEATING OF ASPHALT

Break up solid asphalt on a surface free of dirt and debris. Heat asphalt in kettle designed to prevent contact of flame with surfaces in contact with the asphalt. Kettles shall have visible working thermometer and thermostatic controls set to the temperature limits specified herein.

Keep controls in working order and calibrated. Use immersion thermometer, accurate within a tolerance of plus or minus 2 degrees F, to check temperatures of the asphalt frequently. When temperatures exceed maximums specified, remove asphalt from the site. Do not permit cutting back, adulterating, or fluxing of asphalt.

3.12.1 Temperature Limitations for Asphalt

Heat and apply asphalt at the temperatures specified below unless specified otherwise by manufacturer's printed application instructions. Use thermometer to check temperature during heating and application. Have kettle attended constantly during heating process to ensure specified temperatures are maintained. Do not heat asphalt above its finished blowing temperature (FBT). Do not heat asphalt between 500 and 525 degrees F for longer than four consecutive hours. Do not heat asphalt to the flash point (FP). Apply asphalt and embed membrane sheets when temperature of asphalt is within plus or minus25 degrees F of the equiviscous temperature (EVT) but not less than 400 degrees F. Before heating and application of asphalt refer to the asphalt manufacturer's label or bill of lading for FP, FBT, and EVT of the asphalt used.

3.13 TERMINATIONS AT PERIMETERS

The modified bitumen membrane shall extend up abutting surface at least 4 inches or2 inches above the top of the cant.

3.14 MECHANICAL FASTENING OF MEMBRANE

Nails and fasteners for securing base or membrane sheet to wood nailers or deck shall be flush driven through flat metal disks of not less than 1 inch diameter. Metal disks may be omitted where heads of fasteners are equivalent in size to the 1 inch diameter disks. Screw fasteners with disks as specified by the membrane manufacturer shall be used on concrete deck. Nails and fasteners shall be spaced to meet the wind uplift requirement and within the tolerances specified by the manufacturer. Penetration of nails and fasteners will not be permitted through the exposed surface of membrane.

3.15 APPLICATION OF ROOFING MEMBRANE

Complete application of roofing in a continuous operation. Begin and apply only as much roofing in one day as can be completed that same day.

3.15.1 Hot Asphalt Application of Modified Bitumen Membrane

Apply membrane immediately following application of hot asphalt. Apply hot asphalt within 6 feet of roll. Do not work ahead with asphalt. Asphalt shall be completely fluid, with mop temperatures within the asphalt's EVT range, but not less than400 degrees F, at the instant membrane comes into contact with asphalt. Application of bitumen between layers shall be such as to provide full, continuous, uniform coverage and complete contact of hot asphalt with the sheet above and below. Embed sheets in asphalt. As sheets are being rolled into hot asphalt, immediately and thoroughly apply uniform positive pressure by squeegee, roll, or broom to ensure full adhesion and lap seal, eliminate trapped air and to provide tight, smooth laminations.

Avoid excessive extrusion of asphalt at lap areas. Control asphalt bleed out to approximately1 inch maximum.

3.15.2 Cold Adhesive Applied Modified Bitumen Membrane

Apply cold adhesive with airless sprayer or 1/4-inch saw-toothed rubber squeegee to prepared surfaces in accordance with membrane manufacturer's application instructions. Fully cover substrate with adhesive. Roll or lay membrane in adhesive in accordance with manufacturer's recommendations and within the time limitations of adhesive application. Broom the membrane to ensure full contact with adhesive. Seal laps with adhesive or by heat fusing with torch or hot air welder as required by membrane manufacturer. Minimize traffic on installed membrane during the adhesive cure and set time.

3.15.3 Cap Sheet Installation

Underlying applied membrane shall be inspected and repaired free of damage, holes, puncture, gouges, abrasions, and any other defects, and free of moisture, loose materials, debris, sediments, dust, and any other conditions required by the membrane manufacturer prior to cap sheet installation. Do not apply cap sheet if rain or frozen precipitation has occurred within the previous 24 hours. Align cap membrane and apply by the specified method with the proper side and end lap widths. Cap sheet may be set in hot asphalt or torch applied as recommended by the modified bitumen membrane manufacturer. Cut at a 45 degree angle across selvage edge of cap membrane to be overlapped in end lap areas prior to applying overlapping cap membrane.

Minimize traffic on newly installed cap sheet membrane.

3.15.4 Membrane Flashing

Apply two-ply modified bitumen strip flashing and sheet flashing in the angles formed where the roof deck abuts walls, curbs, ventilators, pipes, and other vertical surfaces, and where necessary to make the work watertight. Apply membrane flashing in accordance with the roof membrane manufacturers printed instructions and as specified. Cut at a 45 degree angle across terminating end lap area of cap membrane prior to applying adjacent overlapping cap membrane. Press flashing into place to ensure full adhesion and avoid bridging. Ensure full lap seal in all lap areas. Mechanically fasten top edge of modified bituminous base flashing 6 inches on center through minimum 1 inch diameter tin caps with fasteners of sufficient length to embed minimum one inch into attachment substrate. Apply matching granules in any areas of asphalt or adhesive bleed out while the asphalt is still hot or the adhesive is still tacky. Apply membrane liner over top of exposed nailers and blocking and to overlap top edge of base flashing installation at curbs, parapet walls, expansion joints and as otherwise indicated to serve as waterproof lining under sheet metal flashing components.

3.15.4.1 Membrane Strip Flashing

Set primed flanges of metal flashing's in full bed of modified bituminous cement material and securely fasten through to attachment substrate. Strip-in with membrane flashing so that strip extends not less than4 inches beyond outer edge of flange. Where multiple membrane stripping plies are installed, extend each additional stripping ply minimum 4 inches beyond edge of previous ply.

3.15.4.2 Membrane Flashing at Roof Drain

Extend membrane sheets to edge of drain bowl opening at the roof drain deck flange in accordance with membrane manufacturer's printed application instructions. Securely clamp membrane sheets and metal roof drain flashing and strip flashing in the flashing clamping ring.

Secure clamps so that sheets and metal flashing are free from wrinkles and folds. Trim stripping flush with inside of clamping ring.

3.16 PROTECTION OF APPLIED ROOFING

At end of day's work or whenever precipitation is imminent, the terminated edge of the roofing shall be sealed with two full width strips of roofing felt set in and coated with bituminous cement or hot mopped asphalt. One half-width of strips shall be extended up and over the finished roofing and the other half-width extended out and onto the bare roof deck or existing membrane.

Sealing strips shall be removed before continuing installation of roofing. To facilitate sealing, termination edges may be straightened with pieces of insulation board which shall be removed when work is resumed.

3.17 FLOOD TEST

After the roofing system and the flashing are installed, the drains shall be plugged, any other openings at the level of the roof shall be dammed (including edges of door openings onto observation decks), and the roof shall be flooded with water to a depth of between 2 to 4 inches and left to sit for 24 hours. When water level falls, water shall be removed, the roofing system thoroughly dried and inspected and the roofing repaired or replaced as necessary to provide for a properly installed watertight system at no additional cost. Leaks around roof drains shall require resetting and resealing or replacement of roof drains and flashing as directed by the ACO at no additional cost. The test shall be repeated until there is no water leakage.

Pylon Building at Dam

PENTHOUSE ROOF

Roof Scuttle Waste Stack, Roof Drain A/C Unit A/C Unit Antenans To Be Moved By Gov’t

PENTHOUSE ROOF

Load Bank To Be Waste Stack Roof Scuttle Removed By Gov’t Satellite Transmission Antenna

(To Be Moved By Gov’t)

TYPICAL LOWER ROOF CONDITIONS

3’-6” High Parapet On Left

Wall Of Penthouse On Right

Entry Door Onto Deck

ABBREVIATED QUALITY CONTROL PLAN

Contract Number

STONEWALL JACKSON DAM

REPLACE PYLON BUILDING ROOFS

Contractor Name Contractor Address

1. SIGNATURE SHEET.

This QUALITY CONTROL PLAN was

Prepared By:

Name Title of Preparer

Approved By:

President/Owner

2. BACKGROUND INFORMATION

a. Contractor : Name Address City, State Zip

b. Contract Number W911WN-##-#-####

c. Project Name: Enter Name of Project

d. Project Description: Enter description of work

3. Organization

a. Name of the (QCSM) Person will perform the duties and responsibilities of the Quality Control System Manager (QCSM) for this contract.

b. It is acknowledged that Name of the (QCSM) Person shall conduct 3-phase inspections for all of the definable features of work.

c. The Name of the (QCSM) Person and the Quality Control staff reports to the project manager or someone higher (President or Owner of the Company) in the organization. List the name of the Individual that CQC reports too.

d. The Project Superintendent is Name the Superintendent. (if specs permit, the Superintendent may be the

QCSM)

4. Personnel and Assignments Name of the (QCSM) Person

a. Name of the (QCSM) Person and name the staff all work for the Name of the Contractor.

b. Provide the qualification of QCSM and any staff in a Resume format.

c. Name of the (QCSM) Person has the authority to stop work which is not in compliance with the contract.

(See copy of letter) In addition to the above experience and/or education requirements the CQC System Manager must have completed the course entitled "Construction Quality Management for Contractors".

This course is periodically offered by the Pittsburgh District and sponsored by the Contractors Association of Western Pennsylvania. Completion of the course offered by other Corps of Engineers Districts will be accepted upon presentation of a valid certificate. Submit a copy of the Certificate.

d. Name of Superintendent

e. The Major definable features of work for this contract List the Major definable features of work for this contract. Also list any test that may be required to be performed for each definable feature of work.

A definable feature of work is a task which is separate and distinct from other tasks, has separate control requirements, and may be identified by different trades or disciplines, or it may be work by the same trade in a different environment. Although each section of the specifications may generally be considered as a definable feature of work, there are frequently more than one definable features under a particular section. This list will be agreed upon during the coordination meeting.

5. 3-Phase Control Inspections

The Contractor Quality Control System Manager (CQC-SM) Name of the (QCSM) Person, will conduct a minimum of three phases of control for each definable feature of work to ensure that the construction, including sub-contractors and suppliers complies with the requirements of the contract. The three phases of control are:

Preparatory Phase Initial Phase Follow Up Phase

Three Phase Control Inspections will be tracked by the CQC-SM on the Three Phase Inspection Checklist included in the Attachments Section of this Plan.

a. Preparatory Phase Inspection

i. After all required plans, documents and materials are approved and before work begins on each definable feature of work, a Preparatory Phase Inspection will be performed. The CQC-SM will conduct a meeting attended by the Contracting Officer, project superintendent, other QC personnel (as applicable), subcontractors, and the foreman responsible for the definable feature. The results of the preparatory phase actions will be documented by separate minutes prepared by the CQC-SM and attached to the Daily QC Report. The superintendent and/or foreman responsible for the work will instruct applicable workers as to the acceptable level of workmanship required in order to meet contract specifications.

ii. The CQC-SM will prepare a Preparatory Inspection Checklist (see sample in Attachments Section of this plan) and submit it for approval to the Contracting Officer before any Preparatory Inspection Meetings. At least 48-hour notice will be provided to the government for all Preparatory Inspection Meetings.

iii. Items covered-at- Preparatory Inspection Meetings will-be-as follows, - -

A review of each paragraph of applicable Specifications.

A review of the Contract Drawings.

A check to insure that all materials and/or equipment have been tested; submitted and approved.

A review of provisions that have been made to provide required control inspection and testing.

An examination of the work area to assure that all required preliminary work has been completed and is in compliance with the contract.

A physical examination of required materials, equipment and sample work to verify that all items are on hand, are properly stored and conform to the approved submittals.

A review of the appropriate Activity Hazard Analysis (AHA) to assure safety requirement is met.

A discussion of procedures for controlling quality of the work including repetitive deficiencies.

Document construction tolerances and workmanship standards.

b. Initial Phase Inspection

i. At the beginning of a definable feature of work, Initial Phase Inspections will be performed by the QC

Personnel assigned to the work. Initial Phase Inspections will be repeated for each new crew to work on site, or any time acceptable specified quality standards are not being met.

ii. The Contracting Officer will be notified by the CQC-SM at least 48 hours in advance of beginning the

Initial Phase Inspection. The CQC-SM will prepare an Initial Inspection Checklist (see sample in Attachments Section of this plan) to document the inspection and attach it to the Daily QC Report. The exact location of the Initial Inspection will be indicated for future reference and comparison with Follow- Up Inspections.

iii. Items covered at Initial Phase Inspections will be as follows.

A check of work to ensure that it is in full compliance with contract requirements. Review minutes of the preparatory meeting.

A verification of the adequacy of controls to ensure full contract compliance. Verify required control inspection and testing.

Establish the level of workmanship and verify that it meets minimum acceptable workmanship standards. Compare with required samples as appropriate.

Resolve all…