Specifications 31 68 13.00 25 dated 2022-08-31.pdf

Willamette Falls Seismic and Safety Upgrades

SECTION TABLE OF CONTENTS

DIVISION 31 - EARTHWORK

SECTION 31 68 13.00 25

SOIL AND ROCK ANCHORS

PART 1 GENERAL

1.1 MEASUREMENT AND PAYMENT

1.2 REFERENCES

1.3 DEFINITIONS

1.3.1 Anchored Structure

1.3.2 Demonstration Test Anchor

1.4 SYSTEM DESCRIPTION

1.4.1 Scope of work

1.4.2 Anchor Design

1.4.2.1 Design Load

1.4.2.2 Design Schedule

1.5 SUBMITTALS

1.6 QUALITY ASSURANCE

1.6.1 Designer Qualifications

1.6.2 Fabricator Qualifications

1.6.3 Installer Qualifications

1.6.4 Core Logging and Soil Sampling

1.7 DELIVERY, STORAGE, AND HANDLING

1.8 SITE CONDITIONS

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Prestressing Steel

2.1.1.1 High-Strength Steel Bars

2.1.1.2 Epoxy-Coated Steel Bars

2.1.1.3 Steel Bar

2.1.1.4 Strand

2.1.1.5 Compact Strand

2.1.1.6 Epoxy Coated Strand

2.1.2 Structural Steel

2.1.3 Steel Pipe

2.1.4 Steel Tube

2.1.5 Ductile Iron Castings

2.1.6 Polyethylene Tubing

2.1.6.1 Smooth Polyethylene Tubing

2.1.6.2 Corrugated Polyethylene Tubing

2.1.7 Smooth Polypropylene Tubing

2.1.8 Polyvinyl Chloride (PVC) Pipe

2.1.9 Polyvinyl Chloride (PVC) Tubing

2.1.9.1 Smooth Polyvinyl Chloride (PVC) Tubing

2.1.9.2 Corrugated Polyvinyl Chloride (PVC) Tubing

2.1.10 Heat Shrinkable Sleeve

2.1.11 Corrosion Inhibiting Compound

2.2 MANUFACTURED UNITS

SECTION 31 68 13.00 25 Page 1

2.2.1 Anchor Head

2.2.2 Prestressing Steel Couplers

2.2.3 Centralizers and Spacers

2.2.4 Casing

2.2.5 Anchorage Covers

2.3 EQUIPMENT

2.3.1 Drilling Equipment

2.3.2 Grouting Equipment

2.3.2.1 Grout Mixer

2.3.2.2 Grout Pump

2.3.3 Stressing Equipment

2.3.4 Testing Equipment

2.4 GROUT

2.4.1 Cement

2.4.2 Water

2.4.3 Aggregates

2.4.4 Admixtures.

2.4.5 Grout for Anchors

2.4.5.1 Cement Grout

2.4.6 Grout for Waterproofing Holes

2.4.7 Grout for Anchor Pads

2.5 TENDON FABRICATION

2.5.1 General

2.5.2 Tendon

2.5.3 Bond Breaker

2.5.4 Vent Tubes

2.5.5 Grout Tubes

2.5.6 Corrosion Protection

2.5.6.1 Anchorage Protection

2.5.6.2 Free Stressing Length Encapsulation

2.5.6.3 Bond Length Encapsulation

2.6 TESTS, INSPECTIONS, AND VERIFICATIONS

PART 3 EXECUTION

3.1 DRILLING HOLES

3.1.1 General

3.1.2 Drilling Through Existing Structures

3.1.3 Casing

3.1.4 Drilling in Rock

3.1.5 Records

3.1.6 Alignment

3.1.6.1 Tolerances

3.1.6.2 Alignment Check

3.1.7 Watertightness Testing

3.1.8 Waterproofing Anchor Holes

3.2 INSTALLATION OF ANCHORS

3.2.1 General

3.2.2 Placing

3.2.3 Cement Grouted Rock Anchors

3.2.4 Anchorage Installation

3.3 STRESSING

3.3.1 General Requirements

3.3.2 Lock-off

3.4 FIELD QUALITY CONTROL

3.4.1 Performance Test

3.4.2 Proof Test

3.4.3 Driller Logs

3.4.4 Anchor Records

SECTION 31 68 13.00 25 Page 2

3.5 ACCEPTANCE

3.5.1 General

3.5.1.1 Creep

3.5.1.2 Movement

3.5.1.2.1 Minimum Apparent Free Length

3.5.1.2.2 Maximum Apparent Free Length

3.5.1.3 Initial Lift-Off Reading

3.5.2 Replacement of Rejected Anchors

-- End of Section Table of Contents --

SECTION 31 68 13.00 25 Page 3

SECTION 31 68 13.00 25

SOIL AND ROCK ANCHORS

PART 1 GENERAL

1.1 MEASUREMENT AND PAYMENT

Measurement and payment will be as specified in Section 01 22 00.00 25, MEASUREMENT AND PAYMENT.

1.2 REFERENCES

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

AMERICAN ASSOCIATION OF STATE HIGHWAY AND TRANSPORTATION OFFICIALS

(AASHTO)

AASHTO M 252 (2009; R 2017) Standard Specification for

Corrugated Polyethylene Drainage Pipe

AMERICAN CONCRETE INSTITUTE (ACI)

ACI 301 (2016) Specifications for Structural

Concrete

ACI 318 (2014; Errata 1-2 2014; Errata 3-5 2015;

Errata 6 2016; Errata 7-9 2017) Building

Code Requirements for Structural Concrete

(ACI 318-14) and Commentary (ACI 318R-14)

AMERICAN PETROLEUM INSTITUTE (API)

API Spec 5CT (2018) Casing and Tubing

ASTM INTERNATIONAL (ASTM)

ASTM A36/A36M (2019) Standard Specification for Carbon

Structural Steel

ASTM A53/A53M (2020) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

ASTM A416/A416M (2018) Standard Specification for

Low-Relaxation, Seven-Wire for

Prestressed Concrete

ASTM A500/A500M (2021) Standard Specification for

Cold-Formed Welded and Seamless Carbon

Steel Structural Tubing in Rounds and

Shapes

ASTM A536 (1984; R 2019; E 2019) Standard

SECTION 31 68 13.00 25 Page 4

Specification for Ductile Iron Castings

ASTM A615/A615M (2020) Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete

Reinforcement

ASTM A722/A722M (2015) Standard Specification for Uncoated

High-Strength Steel Bar for Prestressing

Concrete

ASTM A775/A775M (2017) Standard Specification for

Epoxy-Coated Steel Reinforcing Bars

ASTM A779/A779M (2016) Standard Specification for Steel

Strand, Seven-Wire, Uncoated, Compacted, Stress-Relieved for Prestressed Concrete

ASTM A882/A882M (2020) Standard Specification for Filled

Epoxy-Coated Seven-Wire Prestressing Steel

Strand

ASTM A981/A981M (2011; R 2016) Standard Test Method for

Evaluating Bond Strength for 0.600-in.

Diameter Steel Prestressing Strand, Grade

270 , Uncoated, Used in Prestressed Ground

Anchors

ASTM C33/C33M (2018) Standard Specification for Concrete

Aggregates

ASTM C109/C109M (2020b) Standard Test Method for

Compressive Strength of Hydraulic Cement

Mortars (Using 2-in. or (50-mm) Cube

Specimens)

ASTM C144 (2018) Standard Specification for

Aggregate for Masonry Mortar

ASTM C150/C150M (2020) Standard Specification for Portland

Cement

ASTM C1107/C1107M (2020) Standard Specification for Packaged

Dry, Hydraulic-Cement Grout (Nonshrink)

ASTM D1784 (2020) Standard Specification for Rigid

Poly(Vinyl Chloride) (PVC) Compounds and

Chlorinated Poly(Vinyl Chloride) (CPVC)

Compounds

ASTM D1785 (2015; E 2018) Standard Specification for

Poly(Vinyl Chloride) (PVC), Plastic Pipe, Schedules 40, 80, and 120

ASTM D3350 (2012) Polyethylene Plastics Pipe and

Fittings Materials

ASTM D4101 (2017) Standard Classification System and

Basis for Specification for Polypropylene

Injection and Extrusion Materials

SECTION 31 68 13.00 25 Page 5

POST-TENSIONING INSTITUTE (PTI)

PTI DC35.1 (2014) Recommendations for Prestressed

Rock and Soil Anchors

PTI M10.2 (2017) Specification for Unbonded Single

Strand Tendons

PTI TAB.1 (2006) Post-Tensioning Manual

U.S. ARMY CORPS OF ENGINEERS (USACE)

EM 1110-1-2908 (1994) Rock Foundations

1.3 DEFINITIONS

The following definitions are in addition to those given in PTI DC35.1, Section 2.0:

1.3.1 Anchored Structure

The wall or monolith to which the anchor is to transfer force.

1.3.2 Demonstration Test Anchor

An anchor which is performance tested to verify design assumptions and installation practices.

1.4 SYSTEM DESCRIPTION

Prior to commencing any work on the anchors, the Contractor, including all field personnel to be involved in drilling and installation of the anchors, must meet with the Contracting Officer to review the drawings and specifications, work plans, and submittals. Drilling may commence upon approval of the Installation Plan and procedures described in paragraph

SUBMITTALS and after the conduct of the Preparatory Meeting.

1.4.1 Scope of work

Provide the design of the rock anchor system that will be completely the

Contractor's responsibility. General design criteria are given in paragraph Anchor Design. The materials, design, stressing, load testing, and acceptance must be in accordance with PTI DC35.1, EM 1110-1-2908, and these specifications.

a. Rock anchors may be threaded bar or strand type. Subject to the requirements specified in paragraph Anchor Design, the Contractor is responsible for the design of the anchor and bearing plate, determining top of rock, determining drilling methods, and determining hole diameter and bond length. Submit design computations and data for the rock anchors, bearing plates, and bond zones.

b. The computations must include drawings, design assumptions, calculations, and other information in sufficient detail to verify the design proposed. The design must be certified by a registered

Professional Engineer with proven experience in design of rock anchor components as stated in paragraph Qualifications. Calculations must be included for the stressing frames.

SECTION 31 68 13.00 25 Page 6

c. The Contracting Officer will approve the design calculations.

Approval of the design calculations will not relieve the Contractor of responsibility for unsatisfactory performance of the installed rock anchors. All design computations must be furnished at least 30 calendar days prior to the proposed commencement of drilling. The complete design, including design computations, fabrication and installation drawings and installation plan, must be certified by a registered Professional Engineer and must be submitted for approval.

d. Submit a plan for installing the rock anchors for review and comment. The proposal must describe the sequence for installation and other restrictions as outlined on the drawings or specified. The anchor installation procedures must be determined by the Contractor as part of the anchor design. The installation plan must also include descriptions of methods and equipment to be used for alignment checking of anchor holes.

1.4.2 Anchor Design

Design the individual rock anchors to meet the following criteria:

Anchor Location Field verify or as indicated on plan sheets

Horizontal Spacing Field verify or as indicated on plan sheets

Hole Diameter 8 inches maximum

Design Load Concrete Canal Wall - 230 kips

Masonry Guard Lock Wall - 230 kips

Assumed Ultimate Rock-Grout Bond

Strength

250 psi

Minimum Unbonded Length Bar anchors - 10 feet

Strand anchors - 15 feet

Minimum Required Bond Length Bar anchors - 10 feet

Strand anchors - 15 feet

Maximum Bond Length 35 feet

Corrosion Protection Class I, Encapsulated Tendon

Angle of Anchor Inclination Vertical with a tolerance of 0.02 rad (1 degree) from plumb

Concrete Compressive Strength Top of Canal Wall - 3280 psi

Old concrete of Canal Wall - 880 psi

Bedrock unit weight 166 pcf

Bedrock cohesion 0 psf

1.4.2.1 Design Load

The Design Load must not exceed 60 percent of the ultimate strength of the prestressing steel. The Lock-off Load must not exceed 70 percent of the

SECTION 31 68 13.00 25 Page 7 ultimate strength of the prestressing steel. The maximum Test Load must not exceed 80 percent of the ultimate strength of the prestressing steel.

The designer should include consideration of group effect of closely spaced anchors when determining design load and minimum spacing. Design the bearing plates so that the bending stresses in the plate do not exceed the yield strength of the steel when a load equal to 95 percent of the minimum specified ultimate tensile strength of the prestressing steel is applied and so that the average bearing stress on the structure does not exceed

2500 psi. Design the anchorage assembly connection to the structure in accordance with ACI 318.

1.4.2.2 Design Schedule

Submit a design schedule for the anchors which includes the following:

a. Anchor number.

b. Anchor design load.

c. Anchor hole size.

d. Type and size of tendon.

e. Minimum total anchor length.

f. Minimum bond length.

g. Minimum tendon bond length.

h. Minimum unbonded length.

i. Details of corrosion protection, including details of anchorage and installation.

j. Submit the design schedule at least 30 days prior to commencement of work on the anchors covered by the schedule.

1.5 SUBMITTALS

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

submittals not having a "G" designation are for Contractor Quality Control approval. Submit the following in accordance with Section 01 33 00, SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Fabrication and Installation Drawings; G

SD-03 Product Data

Equipment

Designer Qualifications; G

Fabricator Qualifications; G

Installer Qualifications; G

Core Logging and Soil Sampling; G

SECTION 31 68 13.00 25 Page 8

Installation Plan; G

SD-05 Design Data

Design Computations; G

Anchor Design; G

SD-06 Test Reports

Prestressing Steel

SD-07 Certificates

Prestressing Steel

Epoxy-Coated Steel Bars

SD-11 Closeout Submittals

Driller Logs

Anchor Records

1.6 QUALITY ASSURANCE

Submit anchor designer, fabricator and installer qualifications for approval in accordance with paragraph SUBMITTALS. The submittals must, where applicable, identify individuals who will be working on this contract and their relevant experience. No changes must be made in approved personnel without prior approval of the Contracting Officer.

1.6.1 Designer Qualifications

The anchors must be designed by Professional Engineers who have designed a minimum five rock anchors projects similar in size and scope to this project within the past ten years. The drawings and calculations must be signed by the Professional Engineer.

1.6.2 Fabricator Qualifications

The anchors must be fabricated by a manufacturer that has been in the practice of designing and fabricating rock anchors similar in size and scope to this project for at least ten years.

1.6.3 Installer Qualifications

Submit the qualifications and experience records for approval. Experience records must identify all the individuals responsible for the anchors and must include a listing of projects of similar scope performed within the specified period along with points of contact. Qualifications prior to the installation of any anchors specified in this Section. The anchors must be installed by a firm which is regularly engaged in the installation of rock anchors and has at least ten years experience in the installation of similar anchors. The superintendent must have installed anchors on at least five projects of similar scope and size.

SECTION 31 68 13.00 25 Page 9

1.6.4 Core Logging and Soil Sampling

Logging of core and preparation of drilling logs and records must be performed by a Registered Geologist or Geotechnical Engineer who has at least five years experience in identifying and logging rock core and soil samples. This work is specified separately in Section 02 32 00.00 25, SUBSURFACE DRILLING, SAMPLING, AND TESTING.

1.7 DELIVERY, STORAGE, AND HANDLING

Materials must be suitably wrapped, packaged or covered at the factory or shop to prevent being affected by dirt, water, oil, grease, and rust.

Protect materials against abrasion or damage during shipment and handling.

Place materials stored at the site above ground on a well supported platform and covered with plastic or other approved material. Materials must be protected from adjacent construction operations. Grounding of welding leads to prestressing steel will not be permitted. Reject and remove from the site prestressing steel which is damaged by abrasion, cuts, nicks, heavy corrosions, pitting, welds or weld spatter. Inspect tendons prior to insertion into anchor holes for damage to corrosion protection.

Any such damage must be repaired in a manner recommended by the tendon manufacturer and approved by the Contracting Officer.

1.8 SITE CONDITIONS

Foundation investigation has been made in the past at the site by the

Government and data is presented on the plan sheets. Logs of core borings are shown on the drawings as FOR INFORMATION ONLY. While the foundation information is representative of subsurface conditions at the respective locations, local variations in the characteristics of the subsurface materials may be anticipated. Local variations which may be encountered include, but are not limited to, classification and thickness of rock strata, fractures, and other discontinuities in the rock structure, and variation in the soil classifications. Such variations will not be considered as differing materially within the purview of FAR 36.502

Differing Site Conditions. Additional foundation data must be collected as specified in Section 02 32 00.00 25, SUBSURFACE DRILLING, SAMPLING, AND

TESTING . Contractor must utilize additional subsurface information obtained from this investigation program and update the design as appropriate. The Contractor is responsible for verifying the location of all utilities that may be affected by construction or the installation of the anchors.

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Prestressing Steel

Submit certified test reports for each heat or lot of prestressing steel with materials delivered to the site. Test reports for strands must include bond capacity test results in accordance with ASTM A981/A981M.

Submit five copies of mill reports and five copies of a certificate from the manufacturer stating chemical properties, ultimate strengths, yield strengths, modulus of elasticity, and any other physical properties needed for the required computations, for the type of steel furnished.

SECTION 31 68 13.00 25 Page 10

2.1.1.1 High-Strength Steel Bars

ASTM A722/A722M, Type II, meeting all supplementary requirements.

2.1.1.2 Epoxy-Coated Steel Bars

Submit written certification for coating material and coated bars with the delivery of the bars. ASTM A722/A722M, Type II, conforming to the coating requirements of ASTM A775/A775M, 8 mils minimum thickness. Coating at the anchorage end may be omitted over the length provided for threading the nut against the bearing plate.

2.1.1.3 Steel Bar

ASTM A615/A615M.

2.1.1.4 Strand

ASTM A416/A416M, Grade 270, low relaxation strand. Strand must not be welded.

2.1.1.5 Compact Strand

ASTM A779/A779M, Type 270, low relaxation strand. Strand must not be welded.

2.1.1.6 Epoxy Coated Strand

ASTM A882/A882M, Grade 270, including Supplementary Requirements S1.

2.1.2 Structural Steel

ASTM A36/A36M .

2.1.3 Steel Pipe

ASTM A53/A53M, Type E or S, Grade B.

2.1.4 Steel Tube

ASTM A500/A500M or API Spec 5CT, Grade N-80, Oil Field Seconds / Mill

Secondary Tubing.

2.1.5 Ductile Iron Castings

ASTM A536.

2.1.6 Polyethylene Tubing

2.1.6.1 Smooth Polyethylene Tubing

ASTM D3350.

2.1.6.2 Corrugated Polyethylene Tubing

AASHTO M 252, with wall thickness no less than 0.06 inch.

SECTION 31 68 13.00 25 Page 11

2.1.7 Smooth Polypropylene Tubing

ASTM D4101, designation PP 210 B5542-11.

2.1.8 Polyvinyl Chloride (PVC) Pipe

ASTM D1785, Schedule 40.

2.1.9 Polyvinyl Chloride (PVC) Tubing

2.1.9.1 Smooth Polyvinyl Chloride (PVC) Tubing

ASTM D1784.

2.1.9.2 Corrugated Polyvinyl Chloride (PVC) Tubing

Manufactured from rigid PVC compounds conforming to ASTM D1784, Class

13464-8 with average minimum wall thickness of 0.04 inch.

2.1.10 Heat Shrinkable Sleeve

Radiation crosslinked polyolefin tube internally coated with and adhesive sealant.

2.1.11 Corrosion Inhibiting Compound

The corrosion inhibiting compound must conform to the requirements of

Section 3.2.5 of PTI M10.2.

2.2 MANUFACTURED UNITS

2.2.1 Anchor Head

Anchor head must consist of steel bearing plate with wedge plate and wedges for strand anchors or steel bearing plate with nut for bar anchors, trumpet and corrosion protection. Anchorage devices must be capable of developing

95 percent of the guaranteed ultimate strength of prestressing steel. The anchorage devices must conform to the static strength requirements of

Section 3.1.6 (1) and Section 3.1.8 (1) and (2) of PTI TAB.1. Wedges must be designed to not cause premature failure of the prestressing steel due to notching or pinching. Provide special wedges as required for epoxy coated strand. Removal of epoxy coating to permit use of standard wedges will not be permitted. Threaded anchorage items for epoxy coated bars must be designed to fit over the epoxy coating and maintain the capacity of the prestressing steel. The trumpet used to provide a transition from the anchorage to the unbonded length corrosion protection must be fabricated from steel pipe or steel tube. The minimum wall thickness must be 0.125 inch for diameters up to 4 inches and 0.20 inch for larger diameters. The trumpet must be welded to the bearing plate.

2.2.2 Prestressing Steel Couplers

Prestressing steel couplers for bars must be capable of developing 100 percent of the minimum specified ultimate tensile strength of the prestressing steel. Splicing of strand will not be permitted.

2.2.3 Centralizers and Spacers

Centralizers and spacers must be fabricated from plastic, steel or other

SECTION 31 68 13.00 25 Page 12 approved material which is nondetrimental to the prestressing steel. Wood must not be used. The centralizer must be able to support the tendon in the drill hole and position the tendon so a minimum of 0.5 inch of grout cover is provided. Centralizers and spacers must permit grout to freely flow up the drill hole.

2.2.4 Casing

Casing may be needed in concrete where there is extensive voids that may result in significant circulation loss or grout loss. Casing must be steel pipe or steel tube selected and sized by the Contractor where required.

Casing must be the necessary type and size to permit proper drilling of anchor holes and placing of anchors as specified herein and shown on the drawings. However, if casing is used, anchorage must be designed so that the prestressing force will not be transferred to the casing. Straightening of casings and machining of joints may be necessary in order to meet specified alignment tolerances.

2.2.5 Anchorage Covers

Fabricate anchorage covers from steel. The material used must not be subject to attack by cement, corrosion-inhibiting greases or the environment. Securely attach the cover to the bearing plate. If the cover is to be wax filled, the cover must form a permanent watertight enclosure for the anchorage device.

2.3 EQUIPMENT

2.3.1 Drilling Equipment

Provide drilling equipment suitable for advancing the drill tools to the depths and at the alignment required.

2.3.2 Grouting Equipment

2.3.2.1 Grout Mixer

The grout mixer must be a high-speed, high-shear, colloidal type grout mixer capable of continuous mechanical mixing that will produce uniform and thoroughly mixed grout which is free of lumps and undispersed cement. The mixer must be equipped with a suitable water and admixture measuring devices calibrated to read in cubic feet and tenths and so designed that after each delivery the hands can be conveniently set back to zero.

2.3.2.2 Grout Pump

The grout pump must be of the positive displacement type, and must be capable of pumping at all flow rates below 20 gpm, must be capable of pumping at the pressure of at least 50 psi at zero flow rate. For neat cement grout, the pump must have a screen with 0.125 inch maximum clearance to sieve the grout before being introduced into the pump. Screens are not required for shear type mixers. Make available a pump which is capable of pumping both neat cement grout mixes and sanded grout mixes. The pumping equipment must have a pressure gage capable of measuring pressures of at least 150 psi or twice the required grout pressure, whichever is greater.

2.3.3 Stressing Equipment

Stressing equipment must be hydraulically operated and must have a capacity

SECTION 31 68 13.00 25 Page 13 sufficient to stress the anchors to the required Test Loads within the rated capacity in one stroke. Pumps must be capable of applying each load increment in less than 60 seconds and must be capable of maintaining the hydraulic pressure within 50 psi. The equipment must permit stressing of the tendon in increments and raising or lowering the load in the tendon.

Stressing equipment for strands must be capable of stressing all elements equally and simultaneously. The equipment must be calibrated with an accuracy of +2 percent and the calibration certificate and graphs must be available at the site. The production gage must have graduations of 100 psi or less. A second certified gage must be maintained for periodic verification of the production gage. A dial gage or approved device must be provided to measure total tendon elongation at each load increment to the nearest 0.001 inch. The dial gage must be capable of measuring the entire anchor movement without being reset. Calibration of gages must be verified no more than 30 calendar days prior to commencing work under this contract and at six-month intervals throughout the period of use.

2.3.4 Testing Equipment

Provide testing equipment consisting of a hydraulic jack with calibrated pressure gage for applying the load and a dial gage or vernier scale to measure anchor movement. The ram travel of the stressing equipment must be not less than the theoretical elastic elongation of the total anchor length at the maximum Test Load. The pressure gage must be graduated in 100 psi increments. The stressing equipment and pressure gage must have been calibrated as a unit no more than 30 calendar days prior to commencing work under this contract and at six-month intervals throughout the period of use. The movement measuring device must have a minimum travel equal to the theoretical elastic elongation of the total anchor length at the maximum

Test Load without resetting the device. An approved dial gage or vernier scale and stand must be provided to measure movement of the wall structure.

2.4 GROUT

2.4.1 Cement

ASTM C150/C150M, Type I, II, III or V.

2.4.2 Water

Provide fresh, clean, potable water free from injurious amounts of sewage, oil, acid, alkali, salts, or organic matter.

2.4.3 Aggregates

Fine aggregate for sand-cement grout must conform to ACI 301 and

ASTM C33/C33M for grout for backfilling holes or ASTM C144 for grout for pregrouting. Aggregates must not contain substances which may be deleteriously reactive with alkalis in the cement.

2.4.4 Admixtures.

Admixtures which control bleed, improve flowability, reduce water content and retard set may be used in the grout subject to the approval of the

Contracting Officer. Any admixtures used must be compatible with the prestressing steel and must be mixed in accordance with the manufacturer's recommendations.

SECTION 31 68 13.00 25 Page 14

2.4.5 Grout for Anchors

2.4.5.1 Cement Grout

Cement grout mixture proportions are the responsibility of the Contractor.

Submit the mixture proportions that will produce grout of the quality required, thirty days prior to installation of anchors. Include the mixture proportions in anchor design. Provide applicable test reports to verify that the grout mixture proportions selected will produce grout of the quality specified. Grout for grouting anchors must consist of a homogenous, pumpable, stable mixture of portland cement (Type I/II) and water. Submit the proposed mix design to the Contracting Officer. The water content must be the minimum necessary for proper placement but the water-cement ratio must not exceed 0.45 by weight. Final proportions of materials must be based on results of tests made on sample mixtures of grout. The minimum compressive strength of two-inch cubes, molded, cured, and tested in accordance with ASTM C109/C109M, must be 5,000 psi at the time of stressing. The Contractor is responsible for taking, curing, and breaking of grout test cubes for determining mix design, and all testing must be done by an independent, Engineer Research and Development (ERDC)

Validated laboratory approved by the Contracting Officer. Rock conditions and temperatures must be replicated in the curing process.

2.4.6 Grout for Waterproofing Holes

Grout for waterproofing holes, and grouting holes which fail the watertightness test must consist of neat cement grount. The neat cement grout must consist of a homogeneous, pumpable, stable mixture of portland cement and water. The grout mix proportions must be the responsibility of the Contractor. The grout mix proportions must be the responsibility of the

Contractor. Submit the proposed mix design for approval. The water content must be thecminimum necessary for proper placement but the water-cement ratio must not exceed 0.67 by weight. Final proportions of materials must be based on results of tests made on sample mixtures of grout.

The Contractor is responsible for taking, curing, and breaking of grout test cubes for determining mix design and for quality control testing, and all sampling and testing must be done by an independent, Engineer Research and Development Center (ERDC) Validated laboratory approved by the

Contracting Officer. Rock conditions and temperatures must be replicated in the curing process.

2.4.7 Grout for Anchor Pads

Use nonshrink grout conforming to ASTM C1107/C1107M for leveling bearing plates. The minimum compressive strength must be 5,000 psi.

2.5 TENDON FABRICATION

2.5.1 General

Fabrication of the anchors must be as recommended by the suppliers.

Anchors must be completely assembled with all centralizers, spacers, grout and vent tubes and corrosion protection prior to insertion into the hole.

Fabricated anchors must be protected, transported and stored in a manner to prevent contamination or damage to any components.

2.5.2 Tendon

All spacers for multiple element tendons must be located as indicated on

SECTION 31 68 13.00 25 Page 15 the approved shop drawings. Furnish strands full length with no splicing or coupling permitted. Tendon material must be unblemished and free of pitting, nicks, grease, or injurious defects. When required to maintain the tendon location within the hole, provide centralizers at a maximum of

10 foot intervals center-to-center throughout the bond length. The entire bond length of the tendon must be free of dirt, lubricants, loose rust, corrosion-inhibiting coatings or other contaminants.

2.5.3 Bond Breaker

Bond breaker for free stressing length of unbonded anchors must consist of smooth polyethylene tubing, minimum wall thickness 0.04 inch, or smooth PVC tubing, minimum wall thickness 0.04 inch.

2.5.4 Vent Tubes

Vent tubes used during grouting operations, if necessary, must be any appropriate type for the job, as recommended by the supplier of the anchors.

2.5.5 Grout Tubes

Grout tubes must be polyethylene tubing or as recommended by the anchor manufacturer and approved by the Contracting Officer. Inside diameter of grout tubes must be adequate to fully grout the entire hole.

2.5.6 Corrosion Protection

Corrosion protection must be provided for the entire anchor and must include anchorages covers and trumpets filled with corrosion inhibiting compound or grout and encapsulation of the free stressing length and bond length. Corrosion protection must comply with PTI Class I protection.

2.5.6.1 Anchorage Protection

The trumpet must be sealed to the bearing plate and must overlap the free stressing length encapsulation by at least 4 inches. The trumpet and anchorage cover must be completely filled with corrosion inhibiting compound or grout. Compound filled trumpets must have a permanent seal between the trumpet and the free length corrosion protection.

2.5.6.2 Free Stressing Length Encapsulation

Encapsulation for free stressing length must consist of a sheath of smooth polyethylene tubing, minimum wall thickness 0.06 inch; smooth polypropylene tubing, minimum wall thickness 0.06 inch; smooth PVC tubing, minimum wall thickness 0.04 inch; or corrugated tubing conforming to paragraph Bond

Length Encapsulation. Heat shrinkable sleeve with a minimum thickness of

0.024 inch may only be used for repairs or splicing sheathing in the area of a coupler. Free stressing length encapsulation must extend at least 4 inches into the trumpet, but must not contact the bearing plate during testing and stressing of the tendon.

2.5.6.3 Bond Length Encapsulation

Bond length encapsulation must consist of corrugated polyethylene tubing, minimum wall thickness 0.060 inch or corrugated PVC tubing, minimum wall thickness 0.040 inch.

SECTION 31 68 13.00 25 Page 16

2.6 TESTS, INSPECTIONS, AND VERIFICATIONS

Perform required material tests, on prestressing steel and accessories, by an approved laboratory to demonstrate that the materials are in conformance with the specifications. Test grout in accordance with ASTM C109/C109M.

These tests must be at the Contractor's expense. Furnish to the

Contracting Officer prestressing steel test results prior to beginning fabrication of any anchors and within 24 hours of testing.

PART 3 EXECUTION

3.1 DRILLING HOLES

3.1.1 General

The top of bond zone elevations and other physical conditions indicated on the drawings are the result of 1987 core borings. (See also paragraph

"PROJECT SITE CONDITIONS"). Holes must be drilled at the locations and inclinations shown and to the depths and diameters determined by the

Contractor to provide the design bond length and capacity. The locations of the holes may be changed only as approved by the Contracting Officer.

The Contractor must determine the drilling method to be used except as specified in paragraph 3.1.2. Care must be taken while drilling to avoid damage of any kind to the existing structures. Damages of any nature will be evaluated by the Contracting Officer and repairs or replacements must be made as required. Holes must be drilled a maximum of 3 feet beyond the required anchor bond length. Provide a temporary plug for all holes drilled more than 10 days prior to installation of the anchor. Waste water from drilling operations must be collected and recycled or treated; it must not be discharged directly into the river, lock canal, or on the ground.

See also Section 01 57 19.00 25 TEMPORARY ENVIRONMENTAL CONTROLS.

3.1.2 Drilling Through Existing Structures

Holes through the Canal Wall must be drilled by core drilling equipment to elevation 40 feet to prevent damage to the old concrete and the surrounding structure. Holes through the ashlar masonry in the Guard Lock Wall and the

Monoliths must be drilled by core drilling equipment to prevent damage to the ashlar masonry. The Contractor is advised that foreign material, including metals and other materials remaining from original construction of the existing structure, may be encountered during drilling through existing structures.

3.1.3 Casing

Casing must be utilized for drilling through unstable concrete and voids.

The casing must be advanced by rotary drilling.

3.1.4 Drilling in Rock

Holes in rock may be drilled by rotary drilling, percussion drilling or down-the-hole hammer using equipment suitable for the intended purpose.

Coring in rock may be used but it must not be used in the bond zone. The drilling method must not cause structural damage to existing structures.

If damage is observed, the drilling method must be modified.

3.1.5 Records

Submit driller logs and records as specified in paragraph Driller Logs.

SECTION 31 68 13.00 25 Page 17

The presence of a Government inspector or the keeping of separate drilling records by the Contracting Officer must not relieve the Contractor of the responsibility for the work specified in this paragraph. Payment will not be made for any work for which the required records have not been furnished by the Contractor.

3.1.6 Alignment

3.1.6.1 Tolerances

The anchor hole must be located within one inch of the plan location. The entry angle must be within 1 degree of the vertical. The alignment of the drilled hole must be within 1 degree of the vertical.

3.1.6.2 Alignment Check

Check each drilled hole for alignment as specified herein upon completion of drilling and before commencement of any other work. Check direction and inclination of all anchor holes for each 10-foot intervals throughout the hole. Checking the alignment of each anchor hole must be done by measuring the inclination of the actual drilled anchor hole center line in place with respect to the specified anchor center line. The specified anchor center line must consist of a single, straight, continuous line extending from the top of the hole to the required bottom elevation of the hole. Specified anchor centerlines must slope at the inclinations shown on the drawings.

The Contracting Officer must have access to holes for alignment surveys that may include, but not be limited to, slope indicators or other down-the-hole equipment. Slight adjustments to inclinations indicated on the drawings may be required, as directed by the Contracting Officer. The

Contractor is responsible for all drilled holes until accepted by the

Contracting Officer. All equipment for checking alignment of anchor holes must be operated by personnel experienced in the operation of such equipment.

3.1.7 Watertightness Testing

The rock portion of all drilled holes must be watertightness tested in accordance with the procedures of PTI DC35.1, paragraph 7.5. A packer must be used where necessary to facilitate pressure testing of the bond zone.

Holes which have a water loss in excess of 2.5 gallons in ten minutes must be grouted as specified in paragraph Waterproofing Anchor Holes, and redrilled. Then watertightness testing must be performed again. Grouting, redrilling, and testing must be repeated until the anchor hole passes a watertightness test.

3.1.8 Waterproofing Anchor Holes

The rock portion of anchor holes which fail the watertightness test must be tremie grouted with cement grout as specified in paragraph Grout for

Waterproofing Holes. Grouted holes must be redrilled while the grout strength is considerably less than that of the surrounding rock, but not less than 24 hours after grouting. Assume that anchor holes must be regrouted an average of 2 times per hole.

3.2 INSTALLATION OF ANCHORS

3.2.1 General

The Contractor is responsible for each drilled hole until the anchor has

SECTION 31 68 13.00 25 Page 18 been installed, grouted, stressed and accepted. Holes in rock and casings must be cleaned by pressurized air and/or water to remove drill cuttings and mud.

3.2.2 Placing

All the equipment used in handling and placing the anchors must be such that it does not damage or deteriorate the prestressing steel, corrosion protection, or the anchorages. Each anchor must be inspected prior to insertion into the hole. Any damage to corrosion protection must be repaired prior to insertion or, if determined by the Contracting Officer to be not repairable, the anchor must be replaced. Insertion of anchors must be in accordance with PTI DC35.1.

3.2.3 Cement Grouted Rock Anchors

Grouting equipment must be of type and capacity required for successful installation of the rock anchors. All anchors must use single stage grouting to encase the anchor. Grouting must be performed by a method in accordance with PTI DC35.1, paragraph 7.6. Grouting must commence at the bottom of the grout zone and proceed to the top of the zone. Grouting must be gravity flow.

3.2.4 Anchorage Installation

The bearing plate and anchor head must be installed perpendicular to the tendon, within 3 degrees, and centered on the tendon without bending of the stressing steel. Wedges, wedge holes and tendons must be free of dirt, grout or other contaminants. Corrosion protection must be maintained intact at the anchorage and any damage must be repaired prior to stressing.

3.3 STRESSING

3.3.1 General Requirements

After the anchor grout in the bond zone has reached sufficient strength in accordance with the Contractor's design, as verified by grout cube break, the anchors must be stressed. Prior to stressing, surfaces upon which the stressing equipment is resting must be clean and the stressing equipment must be aligned as nearly with the center of the hole as possible. An

Alignment Load of 10 percent of the Design Load must be applied to the anchor prior to setting dial gauges. Stress the anchor in accordance with the anchor manufacturer's recommendation, subject to the approval of the

Contracting Officer. Design and Lock-off loads are given on the drawings.

Determine the lock-off procedure so that the lift-off results meet the acceptance criteria specified in paragraph Acceptance. The maximum stress must never exceed 80 percent of the guaranteed ultimate strength of anchor steel. The process of stressing the anchors must be so conducted that accurate elongation of the anchor steel can at all times be recorded and compared with the computations submitted to, and accepted by the

Contracting Officer. Stressing elements of strand anchors must be stressed simultaneously. Safety precautions must be taken to prevent workers from being behind or in front of the stressing equipment during stressing.

Stressing of the anchors must be performed in a sequence submitted by the

Contractor for review by the Contracting Officer. All stressing must be done in the presence of a representative of the Contracting Officer. At no time during the stressing and testing of an anchor must the stressing equipment be disconnected from the temporary stressing head or anchor.

SECTION 31 68 13.00 25 Page 19

3.3.2 Lock-off

After completion of the all required tests, the load must be returned to the Alignment Load and the specified Lock-off Load must be applied to the anchor. A lift-off test must be made to verify the load in the anchor tendon before the tendon is locked-off and the stressing equipment is removed. The lift-off reading must be within five percent of the specified lock-off load. If the lift-off reading is not within five percent of the specified lock-off load, the anchorage must be reset and another lift-off reading must be made. This procedure must be repeated until a satisfactory lift-off reading is obtained. After lock-off, the trumpet must be filled with corrosion inhibiting compound and the anchor head protective cap must be installed, or the anchorage recess must be fully grouted flush with the adjacent surfaces.

3.4 FIELD QUALITY CONTROL

The first three anchors and a minimum of 2 percent of the remaining anchors must be designated as demonstration test anchors. Demonstration test anchors must be used to verify top of rock elevation, rock quality and the adequacy of the Contractor's anchor design and installation procedures.

Demonstration test anchors must pass the performance test prior to placing other anchors within the the section represented by the respective demonstration test anchor. All other anchors must be proof tested. During the stressing of each anchor, a record must be kept of gage pressure and of anchor elongation at each stage of stressing to the specified test or

Lock-off Load, as applicable. The Test Load must not be exceeded. Provide a qualified engineer to evaluate the anchor test results and determine the acceptability of the anchors in accordance with the criteria indicated hereunder. Final acceptance of each anchor will be made by the Contracting

Officer. All tests must be run in the presence of the Contracting Officer or his representative.

3.4.1 Performance Test

Performance test must consist of cyclically and incrementally loading and unloading the anchor, and must be conducted in accordance with PTI DC35.1, Paragraph 8.3.2. During the testing of each anchor, a record must be kept of gage pressure and of anchor elongation at each stage of stressing to each Test Load required by PTI DC35.1. Measurements of the elongation of prestressing steel must be made in accordance with PTI DC35.1. If the total movement between 1 - 10 minutes at the Test Load exceeds 0.040 inch, the Test Load must be held an additional 50 minutes and the movement readings must be taken at the interval specified in PTI DC35.1, Paragraph

8.3.2. Test records, including plots and graphical analysis of test data, must be furnished upon acceptance of each performance tested anchor in accordance with paragraph SUBMITTALS. If epoxy strand is used, follow PTI

DC35.1-14, page 95, Supplement A.

3.4.2 Proof Test

Proof test must consist of incrementally loading the anchor and must be conducted in accordance with PTI DC35.1, Paragraph 8.3.3. During the testing of each anchor, a record must be kept of gage pressure and of anchor elongation at each stage of stressing to the Test Load required by

PTI DC35.1. Measurements of the elongation of prestressing steel must be made in accordance with PTI DC35.1. If the total movement at the end of 10 minutes at the Test Load exceeds 0.040 inch, the Test Load must be held an additional 50 minutes and the movement readings must be taken at the

SECTION 31 68 13.00 25 Page 20 interval specified in PTI DC35.1, Paragraph 8.3.3. Test records, including plots and graphical analysis of test data, must be furnished upon acceptance of each proof tested anchor in accordance with paragraph

SUBMITTALS. The proof test results must be compared with similar anchors in which performance tests have been performed. If any significant variation from the proof tests occurs, the Contracting Officer may require additional performance tests. If epoxy strand is used, follow PTI

DC35.1-14, page 95, Supplement A.

3.4.3 Driller Logs

Submit the original handwritten log and three (3) copies in typed format within two days of the completion of each hole. Keep accurate driller logs and records of all work accomplished under this contract and deliver complete, legible copies of these logs and records to the Contracting

Officer upon completion of the work or at such other time or times as he may be directed. All such records must be preserved in good condition and order by the Contractor until they are delivered and accepted, and the

Contracting Officer must have the right to examine such records at any time prior to their delivery. Separate logs must be made for each hole. Use

DRILLING LOG, ENG FORM 1836 and 1836A or other approved form which provides the required information for his logs. The following information must be included on the logs or in the records for each hole:

a. Hole number or designation and elevation of top of hole.

b. Inclination of the hole.

c. Make and manufacturer's model designation of drilling equipment.

d. Dates and time when drilling operations were performed.

e. Time required for drilling each run.

f. Elevation of top of rock.

g. Steel casing seat elevation.

h. Depths and elevations at which core was recovered or attempts made to core including top and bottom depth of each run.

i. Geologic classification or description by depths of each stratigraphic unit cored. This classification or description must be made immediately following the taking of the core.

j. Percentage of core recovered and rock quality designation per run.

k. Depth and elevation of rod drops and other unusual occurrences.

l. Depth and elevation at which groundwater is encountered.

m. Depths and elevations at which drill water is lost and regained and amounts.

n. Depth and elevation of bottom of hole, determined by measuring the drill steel length.

SECTION 31 68 13.00 25 Page 21

3.4.4 Anchor Records

Upon completion of installation of each anchor, the anchor records must be furnished to the Contracting Officer with watertightness test results and report of remedial action taken, top of bond zone elevation, bond length, free stressing length of anchor, grout mix, grouting pressure, bags of cement injected, and a report of performance test or proof test and extended creep test results, and hole alignment surveys. The performance test, proof test results must include measured lengths of drill holes and anchors, the loads and elongations recorded during testing, monitoring and stressing of the anchors, and graphs of test results.as specified in paragraph SUBMITTALS. In addition as-built drawings showing the completed installation of the anchors must be furnished upon completion of installation of all anchors.

3.5 ACCEPTANCE

3.5.1 General

Acceptance of anchors must be determined by the Contracting Officer. The following criteria will be used in determination of the acceptability of each anchor:

3.5.1.1 Creep

Creep movement must not exceed 0.040 inch at maximum Test Load between the

1-10 minutes of the performance or proof test. If the creep movement exceeds this limit, it must not exceed 0.080 inch at the maximum Test Load between 6-60 minutes. If the creep movement exceeds 0.080 inch at the maximum Test Load between 6-60 minutes, the anchor must be rejected.

3.5.1.2 Movement

Apparent free length must be calculated from the observed elastic movement in accordance with PTI DC35.1, Section 8.3.2.

3.5.1.2.1 Minimum Apparent Free Length

The calculated free length must be not less than 80 percent of the designed free tendon length plus the jack length. If the anchor does not meet this criteria, the anchor must be restressed from the Alignment Load to the Test

Load and the apparent free length must be recalculated. If the anchor does not meet this criteria after 3 attempts (original plus 2 restresses), the anchor must be rejected.

3.5.1.2.2 Maximum Apparent Free Length

The calculated free length must be not more than 100 percent of the designed free tendon length plus 50 percent of the bond length plus the jack length. If the anchor does not meet this criteria, and the cause of the behavior is not investigated and explained to the satisfaction of the

Contracting Officer, the anchor must be rejected.

3.5.1.3 Initial Lift-Off Reading

The initial lift-off reading must be within 5 percent of the Lock-off

Load. If the anchor does not meet this criteria, the anchor must be adjusted as necessary and the lift-off reading must be repeated.

SECTION 31 68 13.00 25 Page 22

3.5.2 Replacement of Rejected Anchors

Any anchor that fails the performance or proof test or is rejected by the

Contracting Officer must be replaced. A replacement anchor, including a new anchor hole, must be provided by the Contractor at no expense to the

Government. The location of the replacement anchor must be as directed by the Contracting Officer. Provide all materials, supplies, equipment, and labor necessary to provide a new anchor assembly to the satisfaction of the

Contracting Officer. No drilling must be performed for a replacement anchor until the grouting of all rock anchors within 50 feet of the replacement anchor location has been allowed to set for at least 24 hours.

Payment will not be made for rejected or failed anchors. Either remove failed anchors and thoroughly ream and clear the anchor hole or remove the load and cut the anchor and casing flush.

-- End of Section --

SECTION 31 68 13.00 25 Page 23