35_50_56_AMENDMENT_0003_2_JUNE_2016.pdf

SECTION TABLE OF CONTENTS

DIVISION 35 - WATERWAY AND MARINE CONSTRUCTION

SECTION 35 50 56

MITER GATE ANCHORAGES REMOVAL AND INSTALLATION (AMENDMENT 0003 2 JUNE 2016)

PART 1 GENERAL

1.1 REFERENCES

1.2 SUBMITTALS

1.3 SUBMITTAL DESCRIPTIONS

1.3.1 Work Plan

PART 2 PRODUCTS

2.1 MATERIALS AND STANDARD ARTICLES

PART 3 EXECUTION

3.1 SEQUENCE OF WORK

3.1.1 Work Accomplished Prior to Lock Closure

3.1.2 Work Accomplished during Winter Lock Closure

3.2 SURVEY CONTROL SYSTEM

3.2.1 Survey Control Work Plan

3.2.2 Survey Control Records

3.3 INITIAL CONCRETE DEMOLITION

3.4 REPLACEMENT ANCHORAGE AND PIN PLATE INSTALLATION

3.5 CONCRETE PLACEMENT

3.6 INSPECTION OF MITER GATE RECESS

3.7 SHORING AND POSITIONING OF MITER GATES DURING ANCHORAGE DEMOLITION

3.7.1 Shoring of Miter Gates Placed in Recess

3.7.2 Miter Gates Placed at Miter Position

3.8 REMOVAL PROCEDURE FOR MITER GATE ANCHORAGE LINKS AND RELATED

COMPONENTS

3.9 FINAL CONCRETE AND GATE ANCHORAGE DEMOLITION

3.10 INSTALLATION PROCEDURE FOR MITER GATE ANCHORAGE LINKS AND RELATED

COMPONENTS

3.10.1 Installation Of Replacement Bushings and Pins

3.11 MITER GATE ADJUSTING

3.12 DIVING REQUIREMENTS

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SECTION 35 50 56 Page 1

SECTION 35 50 56

MITER GATE ANCHORAGES REMOVAL AND INSTALLATION (AMENDMENT 0003 2 JUNE 2016)

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.

U.S. ARMY CORPS OF ENGINEERS (USACE)

EM 385-1-1 (2014) Safety and Health Requirements Manual

RESEARCH COUNCIL ON STRUCTURAL CONNECTIONS (RCSC)

RCSC S348 (2004) RCSC Specification for Structural Joints Using ASTM A325 or A490 Bolts

1.2 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

Work Plan; G, MVS Dive Operation Plan; G, MVS Dive Safe Practices Manual; G; LRE Dive Activity Hazard Analysis; G; LRE Dive Emergency Management Plan; G; LRE Dive Personnel list with Qualifications; G; LRE

Survey Control Work Plan; G, MVS Survey Control Records; G, MVS Miter Gate Recess Inspection Report; G, MVS Visual Verification Of Shoring System Bushing Hole Measurements

1.3 SUBMITTAL DESCRIPTIONS

1.3.1 Work Plan

The work plan shall include, at a minimum, the following information:

a. Designaton of miter gate(s) to be placed at miter and miter gate(s) to be shored in the recess, and proposed sequence of work; i.e. work to proceed on gates concurrently or consecutively.

b. Shoring information with regard to jack types, blocking plan, and installation of same. Work plan shall include methods and design

SECTION 35 50 56 Page 2 calculations for gate tie-back system prepared and signed by a Registered Professional Engineer. After installation, visual verification of shoring system including images or video. See additional shoring requirements in paragraph 3.7.1 of this section and in the Work Sequence in specification 01 35 13.

c. Delivery plan for materials and assemblies to the lock.

d. Tools and machinery planned for use in demolition and installation of new anchorages, removal and installation of gate anchorage components.

e. Plan for locating anchorage in proper position; templates or patterns planned for use.

f. Plan for assembly of slip-critical anchorage pin plate and shear key connections, including tensioning method and description of required verification testing.

g. Plan for inspection of miter gate recessess.

h. Plan to prevent the miter gates from being frozen in.

PART 2 PRODUCTS

2.1 MATERIALS AND STANDARD ARTICLES

Materials and standard articles shall conform to the respective specifications and other designated requirements. Sizes shall be as specified or shown on the drawings. Where material requirements are not specified, materials furnished shall be suitable for the intended use and shall be subject to the approval of the Contracting Officer.

PART 3 EXECUTION

3.1 SEQUENCE OF WORK

3.1.1 Work Accomplished Prior to Lock Closure

This work shall be conducted with the navigation lock open. The Contractor shall not interfere with operation of the lock. Work prior to lock closure shall be accomplished in the following sequence:

a. Shop fabrication of anchorage frames, as specified in SECTION 05 59 13. Shop fabrication of miscellaneous steel, including pins, bushings, and recess seat angles, as speified in SECTION 05 50 15.

b. Mobilize equipment and materials to the Soo Lock Complex.

c. Establish Survey Control System, as specified herein.

d. Installation of new electrical trench and relocation of electrical circuits.

e. Anchor rod demonstration testing.

f. Initial concrete demolition, as specified herein.

SECTION 35 50 56 Page 3

g. Concrete drilling and installation of anchor rods as specified in SECTION 03 01 33and herein.

h. Installation of replacement anchorage frames, as specified herein.

i. Installation of dowels and concrete, as specified in SECTION 03 31 01.00 10 and herein.

j. Inpsection of miter gate recesses, as specified herein.

3.1.2 Work Accomplished during Winter Lock Closure

Winter lock closure work shall be accomplished in the following sequence:

a. Shoring of gate(s) / placement of gate(s) at miter position; load relief to anchorages, as specified herein.

b. Disassembly of anchorage components, as specified herein.

c. Final demolition of concrete (as necessary) and existing anchorage frame, as specified herein.

d. Installation of pin plates into replacement anchorage frames, as specified herein.

e. Installation of remaining dowels and concrete, as specified herein and in SECTION 03 31 01.00 10.

f. Reassembly of anchorage components with new bushings and pins, as applicable, as specified herein.

g. Removal of shoring / release of mitered gate and adjustment of anchorages, as specified herein.

3.2 SURVEY CONTROL SYSTEM

The Contractor shall create a Survey Control System to re-establish the location of the new gate anchorages in the same location as the existing anchorages. The replacement anchorages shall be installed on the same horizontal alignment as the existing anchorages and the pin plate(s) shall be at the same elevation as the existing pin plates. On drawing SG601, Control Pts. A and B shall be used to define the horizontal alignment of the replacement anchorages. The centerline of the pin plates is also shown on Drawing SG601. The Contractor may add additional control points as necessary to ensure the Survey Control System is adequate to acheive the below specified accuracy. The system shall provide a positional uncertainty based on a 95-percent confidence level. The positional tolerance of all points located, established, or identified as part of this survey shall have a maximum positional uncertainty of 5% relative to all other points located, established, or identified as part of this survey.

The control system may be independent and local at each anchorage replacement location.

3.2.1 Survey Control Work Plan

The Contractor shall prepare a Survey Control Work Plan describing the methods that will be used for the Survey Control System and shall contain, at a minimum, the following information.

SECTION 35 50 56 Page 4

a. Description of the horizontal coordinate system that will be used to locate and measure all survey points. Indentification of projected coordinates systems, if used, shall have a minimum of three recoverable survey reference points.

b. Description of the vertical measurement system used to locate and measure all survey points. Identification of the vertical measurement system shall, at a minimum, shall contain the reference datum and units of measure. Local vertical systems, if used, shall have a minimum of three recoverable reference points.

c. Description of an appropriate error propogation and other measurement design theory to select the proper instruments, field procedures, geometric layouts and computational procedures to control and adjust random and systematic errors in order to achieve the allowable positional tolerance of all survey points.

3.2.2 Survey Control Records

The Contractor shall maintain records of all field measurements, notes, sketches, and computations relating to all survey points recovered, established, or computed. Survey Control Records shall also include a Contractor provided Survey Point Report identifying, at a minimum, point descriptions and recovery information, point establishment methods, and point coordinate values along with positional error estimates.

3.3 INITIAL CONCRETE DEMOLITION

Initial concrete demolition shall be conducted during the navigation season with the lock in operation. During Initial concrete demolition, the existing anchorages shall not be disturbed. Concrete shall be demolished to the extent that anchor rods and the anchorage frames may be fully installed without the pin plates as shown on the drawings. Existing light standards that interfere with concrete demolition shall be removed and stored for later reinstallation. Anchorage recess cover plates shall be removed and retained for later reinstallation. Concrete demolition shall be in accordance with SECTION 02 41 00.

3.4 REPLACEMENT ANCHORAGE AND PIN PLATE INSTALLATION

After initial concrete demolition and anchor rod demonstration tests are complete, anchor rod holes shall be drilled and anchor rods installed. The Contractor shall be aware of embedded conduits and shall have taken previous measures to de-energize any conduits and re-route wiring. The Contractor shall use a template, pattern, or other means to ensure anchor rods are precisely located in order for the anchorage and connecting pin holes to be in the correct locations. After the anchor rods are installed and grouted, the Contractor shall install the anchorage, and, using a template, pattern, or other means, properly position the anchorage. The contractor shall level and vertically adjust the anchorage using the leveling anchors as shown on the drawings. After the anchorage is properly positioned, both horizontally and vertically, grout shall be installed under the anchorage as shown on the drawings. The Contractor shall ensure that grout completely fills the void between the anchorage frame and the concrete below; the Contractor shall also block out the anchor rod holes in the anchorage flange to prevent grout from filling the holes. The Contractor shall ensure that a debonding agent is applied to the anchor rods for the portions shown on the drawings. After the grout has cured, high strength epoxy compound shall be installed in the anchorage anchor rod

SECTION 35 50 56 Page 5 holes as shown on the drawings. After grout and compounds have cured, the anchor rod nuts and washers shall be installed and torqued as shown on the drawings. After final concrete demolition and demolition of the top portion of the existing anchorage frame, the pin plates may be installed;

install the pin plates and shims as shown on the drawings. Please note that as specified on the drawings, all pin plates and shims shall be matched to a particular anchorage frame to provide a clearance fit of 0.01 inches or less at any point within the faying surfaces. Some small adjustments in pin hole location may be accomplished by using the small clearance available in the bolt holes. Pin plates shall be aligned using the actual or dummy pin to ensure that top and bottom pin plates are on the same vertical axis. The Contractor shall ensure that all pin plates and shims are aligned and flush with one another. After proper alignment of the pin plates and shims is acheived, install the connecting bolts and washers as shown on the drawings. The bolts shall be pretensioned in accordance with Research Council on Structural Connections "Specification for Structural Joints Using ASTM A325 or A490 Bolts", for slip-critical joints, RCSC S348. The Contractor shall ensure that faying surfaces for this connection are coated with system no. 1 as specified in SECTION 09 97 13 STEEL COATINGS. The Contractor shall complete preinstallation verification tests in accordance with RCSC S348 Section 7.2. After the placement of the anchorage frame has been approved by the Contracting Officer, a portion of the anchorage frame shall be coated with a debonding agent as shown on the drawings and in the specifications.

3.5 CONCRETE PLACEMENT

The Contractor shall install reinforcing steel and place new concrete into demolished areas as shown on the drawings. The contractor may place concrete into initial demolition areas prior to final demolition. After the pin plates are installed and the pin hole locations have been verified as correct, the Contractor shall install dowels and backfill demolished concrete areas with new concrete as shown on the drawings. Reinforcing dowels shall be installed with epoxy grout as shown on the drawings and as specified. Recess seat angles shall be fabricated and installed as shown on the drawings. New anchors for light standards removed for demolition shall be installed as shown on the drawings. After concrete cure, the Contractor shall install base plates and reinstall light standards as shown on the drawings. Shoring shall not be removed, or hydraulic head shall not be released, as applicable, until all components of the anchorage frame and anchorage link assembly are installed, all new conrete has acheived the specified strength as specified in SECTION 03 31 01.00 10, and the Contractor has received written approval from the Contracting Officer.

3.6 INSPECTION OF MITER GATE RECESS

At least six weeks prior to lock closure, the Contractor shall conduct a dive survey of the miter gate recess floor planned for use in shoring the gates. The survey shall address the condition of concrete and the amount of silt and debris that may have accumulated in the recess. Diving operations shall be in accordance with Paragraph 3.12, Diving Requirements.

The Contractor shall furnish a written miter gate recess inspection report, which shall include images or video of the recess area of this survey to the Contracting Officer. The Contractor shall not proceed with installation of shoring until the survey has been submitted and approved by the Contracting Officer and all materials found during the survey within the recesses are removed.

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3.7 SHORING AND POSITIONING OF MITER GATES DURING ANCHORAGE DEMOLITION

After lock closure, but before final demolition of the existing miter gate anchorages, the miter gates shall be supported by one of two methods. The Contractor may place each leaf of the miter gate in the recesses and install a shoring system OR the Contractor may place the miter gate in the miter position and apply full hydraulic head to the miter gate; see Section 01 35 13 - Special Project Procedures for specific sequence information.

"Full hydraulic head" is defined as the gate supporting the natural upper river level on the upstream face and the natural lower river level on the downstream face of that gate. The chamber will be maintained at either the upper or lower level using the contractor-installed wedges and valve settings adjusted by the government. The approximate dry weight of Gate 1 is 145 tons per leaf and the approximate dry weight of gates 2 and 3 is 220 tons per leaf. The gate weights do not include ice which may accumulate on the gate during the winter season. The shoring plan shall include ice removal as necessary to maintain a stable gate. The Contractor shall install and maintain a system, such as bubblers, to prevent the gates from being frozen in. A description of this system shall be included in the work plan.

3.7.1 Shoring of Miter Gates Placed in Recess

The miter gate leaves placed in the miter gate recesses shall be shored.

Shoring shall consist of hydraulic jacks and an arrangement of wood or steel blocking under the gate leaf and supported on the floor of the miter gate recesses. All Jacks, blocking and related equipment shall be furnished by the Contractor. Jacks and blocking shall be located at the miter gate jacking pads as defined on reference drawings SM-L2-21/3 & 4, and on jacking pedestals located at the floor of the miter gate recess as shown on reference drawings SM-L2-20/9, 12, 13, 14, 17, and 18. The blocking and jacking system must be installed in the wet by divers provided by the Contractor. Diving operations shall be in accordance with Paragraph 3.12, Diving Requirements. Using the jacking system, the miter gate leaf shall be raised only to the point that load to the anchorage links (shown on reference drawing SMR-L2 21/16) is relieved. Load shall be considered relieved when movement in the secondary anchorage link slotted hole is observed. Blocking shall be installed so that load to the anchor links continues to be relieved but load to the jacks is relieved. The Contractor shall also design and provide an arrangement to tie the miter gate leaf to the lock wall in order to stabilize the gate leaf and further relieve load to the anchorage links. A minimum of two tiebacks are required; one near the miter end of the gate leaf and one near the quoin end of the gate leaf. The contractor shall submit a shoring plan, which includes design calculations related to the jacks/blocking and tie-back system prepared and sealed by a Registered Professional Engineer for Government approval in accordance with SECTION 01 33 00 SUBMITTAL PROCEDURES. Shoring shall not be removed until all components of the anchorage frame and anchorage link assembly are installed, all new conrete has acheived the specified strength as specified in SECTION 03 31 01, and the Contractor has received written approval from the Contracting Officer. The Contractor shall provide images or video to confirm the instllation of the shoring system to the Government.

3.7.2 Miter Gates Placed at Miter Position

The miter gate placed at the miter position shall have full hydraulic head placed against it to maintain stability of the gate for the duration of the winter closure work. One miter gate placed at the mitered position is necessary to maintain pool level and to provide a means for personnel to

SECTION 35 50 56 Page 7 cross the lock. Once full hydraulic head is applied to the gate, load to the anchorages is relieved and disassembly of the anchorage components may proceed. Miter gate(s) placed at the miter position with full hydraulic head applied need not have a shoring system installed. Hydraulic head shall not be released until all components of the anchorage frame and anchorage link assembly are installed, all new conrete has achieved the specified strength as specified in SECTION 03 31 01, and the Contractor has received written approval from the Contracting Officer.

3.8 REMOVAL PROCEDURE FOR MITER GATE ANCHORAGE LINKS AND RELATED COMPONENTS

The miter gate leaves shall be placed in the recess and shored or in the mitered position with hydraulic head applied as described above, so that load to the anchorage links is relieved. The Contractor shall record the distances between the centerline of connecting pins on the anchorage links shown on reference drawing SM-L2-21/16 in order to reinstall the links in the same orientation. During the removal procedure, the anchorage links shall be supported by blocking or other means to prevent damage. The Contractor shall disassemble lubrication lines and set them aside for later reinstallation. At this point connecting pins MK 21/18-3, 21/18-6, 21/16-12, and 21/16-16 shall be removed using a crane. Any alternate method of removing the connecting pins must first be approved by the Contracting Officer. After the connecting pins are removed, the gudgeon pin MK 21/16-9 shall be removed by use of an auxiliary crane. Any alternate method of removing the gudgeon pin MK 21/16-9 must first be approved by the Contracting Officer. All associated hardware removed shall be retained for use during the installation, as applicable. After gudgeon pin MK 21/16-9 is removed, the anchorage link assembly shall be rotated until clear of the gate and removed from the recess area. The gate anchorage assembly shall be disassembled. The Contractor shall disassemble the anchorage links by removing the sleeve nuts. The Contractor shall clean and degrease the threads of the link bars and sleeve nuts and deliver same to the Soo Area Shops within 7 working days of removal. The Government will inspect the threads, reassemble the link bars within 4 working days per assembly. The Contractor shall pickup the assemblies at the Soo Area Shops. The lever arm, MK 21/18-1 shall be retained by the Contractor; the Contractor shall remove and replace bushings in the lever arm as shown on the drawings and specified herein. The Contractor shall also remove and replace Gudgeon Pin steel bushings, as shown on the drawings and specified herein. The Contractor shall clean and degrease the gudgeon pin plate area for inspection. The Contractor shall verify the gudgeon yoke pin plates match as-built conditions. If the option for gate 2 is awarded, the Government will furnish new anchorage links for gate 2. The existing anchorage links for gate 2 shall be returned to the Government.

3.9 FINAL CONCRETE AND GATE ANCHORAGE DEMOLITION

Prior to final demolition, the Contractor shall survey the location of all connecting pins in accordance with paragraph 3.2, Survey Control System, and Drawing SG601, Survey Control Points, to ensure that replacement anchorages are properly located. After the Survey Point Report has been submitted, in accordance with paragraph 3.2.2, to the Government and the Contractor has received written approval from the Government, the Contractor may proceed with final demolition. After the miter gate is shored, or mitered with hydraulic head applied, as applicable, and load to the anchorages is relieved, with anchorage links and pins removed, the Contractor shall proceed with final concrete demolition and demolition of the top portion of the existing anchorage as shown on the drawings.

SECTION 35 50 56 Page 8

3.10 INSTALLATION PROCEDURE FOR MITER GATE ANCHORAGE LINKS AND RELATED

COMPONENTS

The Contractor shall ensure that all anchorage links are set to the original distance between connecting pins measured before the links were disassembled. The existing lever arm, or replacment GFE lever arm for gate 2, MK 21/18-1 shall be reinstalled into the primary anchorage and connected to the spring box with new connecting pins. The anchorage bar assembly shall be moved into position and new gudgeon pin MK 21/16-9 shall be installed. At this point the connecting pins to the lever arm and secondary anchorage shall be installed. Connecting pin keeper plates shall be reinstalled. Lubrication lines shall be reconnected to the original locations.

3.10.1 Installation Of Replacement Bushings and Pins

Bushings and pins called out with Mark Numbers on sheet SG701 shall be fabricated and installed. Certain locations where bushings are called out do not currently have bushings installed. At these locations the Contractor shall bore the holes as shown on the drawings to accommodate new bushings. The locations include the spring box lugs for all gates as detailed on sheet SG701, and Gudgeon pin and lever arm pin holes for gate 2 as detailed on sheet SG702. For all locations where existing bushings are to be removed and replaced, the Contractor shall measure the existing holes after bushing removal and submit the bushing hole measurements to the Government.

3.11 MITER GATE ADJUSTING

After the anchorage links have been installed, the shored miter gates shall have the shoring removed. Each gate shall be rotated throughout its full travel range, then the gate shall be moved to the miter position.

Adjustment of the anchor bars shall consist of turning the sleeve nuts on the anchorage links so that the quoin blocks and miter blocks are in firm contact when the gate is in the mitered position and the difference in elevation between the quoin end and miter end is not greater than 1/2-inch in the miter position or the open position. Adjustment of the sleeve nuts for the anchorage links is accomplished with the gate leaf in the mitered position. The Government may conduct strain gage testing of the anchorage links to determine the suitable adjustment of the anchorage links. The Contractor shall make further adjustments based on this testing and as directed by the Contracting Officer. The gate that was mitered shall be completed last, so that at least one gate can maintain pool.

3.12 DIVING REQUIREMENTS

Prior to conducting any dive, the Contractor shall submit for approval a dive operation plan and other submittals listed below and as required in EM 385-1-1. The Contractor shall note in the Dive Activity Hazard Analysis the diving depths necessary and note the posibility of surface skin ice or debris.

Dive Supervisor(s) must have a minimum of 5 years' experience preparing required plans for diving as well as supervising surface supplied air diving and directing hot water machine and suit implementation. Surface supplied experience shall be either high or low pressure as will be relevant to the planned diving operations. Dive Supervisors shall have the same or greater qualifications as the divers conducting work and shall be fully capable of diving. Experience shall be validated through resumes, a

SECTION 35 50 56 Page 9 copy of one dive log for each of the last five years, and dive plans.

a. Dive Safe Practices Manual

b. Dive Operations Plan

c. Dive Activity Hazard Analysis

d. Dive Emergency Management Plan

e. Dive Personnel list with Qualifications

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SECTION 35 50 56 Page 10