11B0026-SPECS-AM8.PDF

US ARMY ENGINEER DISTRICT, PHILADELPHIA

POC: MICHAEL TOTH

WANAMAKER BUILDING

100 PENN SQUARE EAST

PHILADELPHIA PA 19107-3390

AMENDMENT OF SOLICITATION/MODIFICATION OF CONTRACT

Except as provided herein, all terms and conditions of the document referenced in Item 9A or 10A, as heretofore changed, remains unchanged and in full force and effect.

15A. NAME AND TITLE OF SIGNER (Type or print)

30-105-04EXCEPTION TO SF 30

APPROVED BY OIRM 11-84

STANDARD FORM 30 (Rev. 10-83) Prescribed by GSA

FAR (48 CFR) 53.243

THE BID OPENING OF 28 MARCH 2012 AT 11:00 AM EST STANDARD TIME REMAINS THE SAME

CONTINUED ON NEXT PAGE

1. CONTRACT ID CODE PAGE OF PAGES

16A. NAME AND TITLE OF CONTRACTING OFFICER (Type or print)

16C. DATE SIGNED

BY

16B. UNITED STATES OF AMERICA15C. DATE SIGNED15B. CONTRACTOR/OFFEROR

(Signature of Contracting Officer)(Signature of person authorized to sign)

8. NAME AND ADDRESS OF CONTRACTOR (No., Street, County, State and Zip Code) X W912BU-11-B-0025

X 9B. DATED (SEE ITEM 11)

29-Sep-2011

10B. DATED (SEE ITEM 13)

9A. AMENDMENT OF SOLICITATION NO.

11. THIS ITEM ONLY APPLIES TO AMENDMENTS OF SOLICITATIONS

X The above numbered solicitation is amended as set forth in Item 14. The hour and date specified for receipt of Offer X is extended, is not extended.

Offer must acknowledge receipt of this amendment prior to the hour and date specified in the solicitation or as amended by one of the following methods:

(a) By completing Items 8 and 15, and returning copies of the amendment; (b) By acknowledging receipt of this amendment on each copy of the offer submitted;

or (c) By separate letter or telegram which includes a reference to the solicitation and amendment numbers. FAILURE OF YOUR ACKNOWLEDGMENT TO BE RECEIVED AT THE PLACE DESIGNATED FOR THE RECEIPT OF OFFERS PRIOR TO THE HOUR AND DATE SPECIFIED MAY RESULT IN

REJECTION OF YOUR OFFER. If by virtue of this amendment you desire to change an offer already submitted, such change may be made by telegram or letter, provided each telegram or letter makes reference to the solicitation and this amendment, and is received prior to the opening hour and date specified.

12. ACCOUNTING AND APPROPRIATION DATA (If required) Construction of 350 feet of gabions for erosion protection a roadway along the Delaware Bay in East Point, New Jersey.

13. THIS ITEM APPLIES ONLY TO MODIFICATIONS OF CONTRACTS/ORDERS.

IT MODIFIES THE CONTRACT/ORDER NO. AS DESCRIBED IN ITEM 14.

A. THIS CHANGE ORDER IS ISSUED PURSUANT TO: (Specify authority) THE CHANGES SET FORTH IN ITEM 14 ARE MADE IN THE

CONTRACT ORDER NO. IN ITEM 10A.

B. THE ABOVE NUMBERED CONTRACT/ORDER IS MODIFIED TO REFLECT THE ADMINISTRATIVE CHANGES (such as changes in paying office, appropriation date, etc.) SET FORTH IN ITEM 14, PURSUANT TO THE AUTHORITY OF FAR 43.103(B).

C. THIS SUPPLEMENTAL AGREEMENT IS ENTERED INTO PURSUANT TO AUTHORITY OF:

D. OTHER (Specify type of modification and authority)

E. IMPORTANT: Contractor is not, is required to sign this document and return copies to the issuing office.

14. DESCRIPTION OF AMENDMENT/MODIFICATION (Organized by UCF section headings, including solicitation/contract subject matter where feasible.)

10A. MOD. OF CONTRACT/ORDER NO.

2. AMENDMENT/MODIFICATION NO. 5. PROJECT NO.(If applicable)

6. ISSUED BY

3. EFFECTIVE DATE

15-Mar-2012

CODE

CONTR DIV-CONTRACTS BR

USAED, PHILA DISTRICT

WANAMAKER BUILDING

100 PENN SQUARE EAST

PHILADELPHIA PA 19107-3390

W912BU 7. ADMINISTERED BY (If other than item 6)

4. REQUISITION/PURCHASE REQ. NO.

CODE W912BU

FACILITY CODECODE

EMAIL:TEL:

THIS PAGE WAS INTENTIONALLY LEFT BLANK FOR DUPLEXING PURPOSES

Amendment No. 0008

IFB W912BU-11-B-0025

14. DESCRIPTION OF AMENDMENT (continued)

a. SPECIFICATIONS:

(1) Section 02371 – WIRE MESH GABIONS AND MARINE MATTRESSES: Please delete section 02371 in its entirety and substitute revised section 02371, annotated Amendment No. 0008, attached hereto.

b. Please indicate receipt of this amendment on Standard Form 1442 (SOLICITATION, OFFER, AND AWARD) as Amendment No. 0008. Failure to acknowledge all amendments may be cause for rejection of the offer.

This page was intentionally left blank for duplex printing.

SECTION 02371

WIRE MESH GABIONS AND MARINE MATTRESSES

PART 1 GENERAL

1.1 SUMMARY

The work covered by this section consists of furnishing all labor, materials, plant and equipment and performing all operations required to construct and install marine mattresses and wire mesh gabions.

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.

ASTM INTERNATIONAL (ASTM)

ASTM A 313/A 313M (2010e1) Stainless Steel Spring Wire

ASTM A 370 (20011) Test Methods and Definitions for Mechanical Testing of Steel Products

ASTM A 641/A 641M (2009a) Zinc-Coated (Galvanized) Carbon Steel Wire

ASTM A853 (2004; R 2010) Standard Specification for Steel Wire, Carbon, for General Use

ASTM A 90/A 90M (2009) Weight [Mass] of Coating on Iron and Steel Articles with Zinc or Zinc-Alloy Coatings

ASTM A974 (1997; R 2011) Standard Specification for Welded Wire Fabric Gabion and Gabion Mattresses (Metallic Coated or Polyvinyl Chloride (PVC) Coated)

ASTM A 975 (1997; R 2003) Double-Twisted Hexagonal Mesh Gabions and Revet Mattresses (Metallic-Coated Steel Wire or Metallic-Coated Steel Wire With Poly(Vinyl Chloride) (PVC) Coating)

ASTM B 117 (2009) Standing Practice for Operating Salt Spray (Fog) Apparatus

ASTM C 127 (2007) Standard Test Method for Density, Relative Density (Specific Gravity), and Absorption of Coarse Aggregate

ASTM C 131 (2006) Standard Test Method for Resistance to Degradation of Small-Size Coarse

Section 02371 Page 1

Aggregate by Abrasion and Impact in the Los Angeles Machine

ASTM C 136 (2006) Sieve Analysis of Fine and Coarse Aggregates

ASTM C 295 (2008) Petrographic Examination of Aggregates for Concrete

ASTM C 33/C 33M (2011a) Concrete Aggregates

ASTM D 1388 (2008) Stiffness of Fabrics

ASTM D 1499 (2005) Filtered Open-Flame Carbon-Arc Exposures of Plastics

ASTM D 2240 (2005; R 2010) Rubber Property - Durometer Hardness

ASTM D 412 (2006ae1e2) Vulcanized Rubber and Thermoplastic Elastomers - Tension

ASTM D 4355 (2007) Deterioration of Geotextiles by Exposure to Light, Moisture and Heat in a Xenon Arc Type Apparatus

ASTM D 4759 (2011) Determining the Specification Conformance of Geosynthetics

ASTM D 5312 (2004) Evaluation of Durability of Rock for Erosion Control Under Freezing and Thawing Conditions

ASTM D 5818 (2011) Exposure and Retrieval of Samples to Evaluate Installation Damage of Geosynthetics

ASTM D 638 (2010) Standard Test Method for Tensile Properties of Plastics

ASTM D 746 (2007) Brittleness Temperature of Plastics and Elastomers by Impact

ASTM D 792 (2008) Density and Specific Gravity (Relative Density) of Plastics by Displacement

ASTM D6637 (2011) Standard Test Method for Determining Tensile Properties of Geogrids by the Single or Multi-Rib Tensile Method

ASTM G 152 (2006) Operating Open Flame Carbon Arc Light Apparatus for Exposure of Nonmetallic Materials

GEOSYNTHETIC INSTITUTE (GSI)

GSI GRI GG1 Geogrid Rib Tensile Strength

Section 02371 Page 2

GSI GRI GG2 Geogrid Junction Strength

U.S. ENVIRONMENTAL PROTECTION AGENCY (EPA)

EPA Method 9090 Compatibility Tests for Wastes and Membrane Liners

1.3 DEFINITIONS

1.3.1 Double Twisted Wire Mesh Gabions

Gabions are classified according to the wire coating, which is applied prior to manufacturing the mesh. The coating styles relative to this project are as follows:

1.3.1.1 Style 1

Wire mesh made from wire which is zinc coated prior to being double twisted into mesh. Fasteners, lacing wire, and stiffeners are produced from zinc-coated wire.

1.3.1.2 Style 3

Wire mesh, lacing wire, and stiffeners as defined in Style 1 and overcoated with PVC. Contractor shall choose type of fasteners from the following two options: stainless steel hog rings as used for gabions manufactured by Maccaferri or approved equal; or zinc- and PVC-coated hand lacing wire made of the same material as the basket components.

1.3.2 Welded Wire Fabric Gabions

Classified according to wire coating styles as follows:

1.3.2.1 Style 2

Welded wire fabric which is made from uncoated wire and the fabric is subsequently zinc-coated after fabrication. Spiral binders, lacing wire, and stiffeners are produced from zinc-coated wire. Style 2 for the wire coating is normally recommended for permanent gabion structures, for works installed in non-aggressive or non-polluted environments, and this condition remains unchanged over time.

1.3.2.2 Style 5

Welded wire fabric, spiral binders, lacing wire, and stiffeners as Style 2, and overcoated with PVC. Style 5 for the wire coating is normally recommended for permanent gabion structures, for works installed in aggressive or polluted environments, or when the aggressiveness of the site is moderately unpredictable or variable from low to high.

1.4 SYSTEM DESCRIPTION

a. The work under this specification includes furnishing, assembling, filling and tying marine mattresses and open wire mesh rectangular compartmented gabions placed on a prepared surface of geotextile, as specified, and in accordance with the lines, grades, and dimensions shown on the drawings or otherwise established in the field.

b. Gabions are wire mesh containers of variable sizes, uniformly

Section 02371 Page 3 partitioned into internal cells, interconnected with other similar units, and filled with stone at the project site to form flexible, permeable, monolithic structures. Gabions shall be manufactured with all components mechanically connected at the production facility. The supply to the jobsite of unassembled individual wire mesh components (panels) forming gabions will not be permitted.

c. Marine mattresses are compartmental rectangular mattresses, made of structural geogrid and filled with stone. The required width and depth of the mattress units shall be as shown on the drawings. The mattress units shall be fabricated and filled off-site, for lifting into place.

d. Definitions of terms specific to this specification and to all materials furnished on the jobsite, with the exception of the stone to fill the baskets and the filter material, shall refer and be in compliance with ASTM A 975 for double twisted wire mesh gabions or with ASTM A974 for welded wire fabric Gabions.

1.5 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.

NOTE: Any submittals classified as "SD-01 Preconstruction Submittals" require approval prior to mobilization to the contract work site. All other submittals, classified as "SD-02" through "SD-11," require approval prior to commencing the particular task to which the submittal is associated.

Submit the following in accordance with Section 01330 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Marine Mattress; G, DO

Contractor shall provide shop drawings, developed specifically for this contract, depicting the fabrication of the marine mattresses including all connections.

SD-03 Product Data

Waybills and Delivery Tickets

Certified waybills and delivery tickets for all stone fill materials actually used.

SD-04 Samples

Mattress Material; G, DO. Connectors; G, DO. Stone Fill; GC DO.

The Contractor shall furnish physical examples of the mattress geogrid and braid materials, the mechanical connection elements for the mattress and the stone fill for both the mattresses and gabions, that are physically identical to the materials to be used in the contract work.

Alternative Wire Fasteners

Section 02371 Page 4

If the Contractor elects to use this fastener option, samples of the alternative fasteners (stainless steel hog rings), used to fabricate the gabions, shall be furnished to the Contracting Officer 60 days prior to assembly of units onsite.

SD-06 Test Reports

Alternative Wire Fasteners; G, DO

For each shipment of alternative wire fasteners delivered to the site, furnish the Contracting Officer, in duplicate, test reports or records that have been performed during the last year on the fasteners contained within the shipment, showing that the product meets the composition, physical, and manufacturing requirements stated in this specification.

SD-07 Certificates

Work Plan; G, DO

The Contractor shall submit for approval his proposed plan for fabricating, filling and placing the marine mattresses and wire mesh gabions and for placing and effectively maintaining the location of the geotextile. Equipment, labor, materials and methods shall be detailed for all tasks.

Gabions; G, DO

For each shipment of wire gabions delivered to the site, the Contractor shall furnish the Contracting Officer, in duplicate and at least 60 days prior to assembly of units on site, a manufacturer's certificate or affidavit signed by a legally authorized official from the company manufacturing the gabion units, wire ties and fasteners, that all material contained within the shipment meets the composition, physical, and manufacturing requirements stated in this specification.

Mattresses; G, DO

For each shipment of marine mattresses delivered to the site, the Contractor shall furnish the Contracting Officer, in duplicate and at least 60 days prior to delivery of units on site, a manufacturer's certificate or affidavit signed by a legally authorized official from the company manufacturing the mattress units, braids and connectors, that all material contained within the shipment meets the composition, physical, and manufacturing requirements stated in this specification.

Stone Fill; G, DO

A certificate or affidavit signed by a legally authorized official of the supplier(s) of the stone fill, for each the mattresses and the gabions, that it meets the quality required and gradation limits specified.

Sieve Curve; G, DO.

The Contractor shall submit a sieve curve for the stone proposed for filling the gabions and the marine mattresses.

Section 02371 Page 5

SD-08 Manufacturer's Instructions

Gabions; G, DO. Marine Mattresses; G, DO.

Contractor shall provide manufacturer's recommendations for fabrication, filling, installation and repair of the marine mattresses and gabions.

1.6 DELIVERY, STORAGE, AND HANDLING

1.6.1 Gabions

Prevent excessive mud, wet concrete, epoxy, or other deleterious materials from coming in contact with and affixing to gabion materials. Gabion units shall be delivered with all components mechanically connected at the production facility and ready for stone filling and assembly onsite. All gabions shall be supplied in the collapsed form, either folded or bundled or rolled, for shipping. Bundles shall be banded together at the factory for ease of shipping and handling. Gabions shall be delivered to the jobsite labeled in bundles. Labels shall show the dimensions of the gabions included, the number of pieces and the color code. Lacing wire shall be shipped in coils with a diameter of the coil approximately 2 feet.

Fasteners shall be shipped in boxes. Preformed stiffeners shall be shipped in bundles.

1.6.2 Mattresses

Prevent excessive mud, wet concrete, epoxy, or other deleterious materials from coming in contact with and affixing to mattress materials. Store at temperatures above -20 degrees F (-29 degrees C). Mattress units, including stone fill, shall be constructed offsite and delivered ready for placement and connection to adjacent mattresses. Mattresses shall be delivered to the jobsite labeled in bundles. Labels shall show the dimensions of the mattresses included and the number of units. Braided lacing shall be shipped in coils with a diameter of the coil approximately 2 feet. Fasteners shall be shipped in boxes.

1.6.3 On-Site Technical Assistance

The Contractor shall have a qualified representative of the stone-filled marine mattress supplier present at the job site during the entire first week of installation to provide technical assistance to the Contractor as needed. The Contractor shall remain solely responsible for the quality of installation.

1.6.4 Waybills and Delivery Tickets

Submit copies of waybills and delivery tickets during the progress of the work. Before the final payment is allowed, file certified waybills and certified delivery tickets for all stone fill materials actually used, as specified in the Submittals paragraph.

PART 2 PRODUCTS

2.1 MARINE MATTRESSES

The marine mattresses shall be fabricated using structural geogrid, Section 02371 Page 6 mechanical connectors, braided lacing and stone fill.

2.1.1 Structural Geogrid

The structural geogrid shall be an integrally formed grid structure manufactured of a stress resistant high density polyethylene (HDPE) or polypropylene (PP) material with molecular weight and molecular characteristics which impart high resistance to loss of load capacity or structural integrity when the geogrid is subjected to mechanical stress in installation, to long-term environmental stress, and to deformation when the geogrid is subjected to applied force in use. Nominal roll size shall be 13.1 feet wide by 164 feet in length.

The structural geogrid type shall be:

a) Type 1 for the internal diaphragms of the units; and

b) Type 2 for the top, bottom and sides of the units, as well as the lifting loops.

The structural geogrid shall have the following characteristics:

PROPERTY UNITS TYPE 1 TYPE 2

True In-Use Tensile Modulus at

1% Strain1 lb/ft 50,000 112,000

Junction Strength2 lb/ft 3,000 6,500

Flexural Stiffness3 mg-cm 650,000 6,500,000

Torsion Stiffness4 kg-cm/deg 4.8 4.8

Resistance to Installation

Damage5

%GP 85 85

Resistance to Long Term

Degradation6 % 100 100

Ultraviolet Stability7 % 98 98

Aperture Size (maximum) in. 6.0 6.0

Percent Open Area (maximum) % 70 70 Deleted

NOTE: Unless indicated otherwise, values shown are determined in accordance with ASTM D 4759. Brief descriptions of test procedures are given in the following notes.

1 True resistance to elongation when subjected to a load measured via GSI GRI GG1 and ASTM D 1388.

Section 02371 Page 7

2 Load transfer capability measured via GSI GRI GG2.

3 Resistance to bending force measured via ASTM D 1388 or ASTM D6637.

4 Resistance to in-plane rotational movement measured by applying a 20 cm-kg moment to the central junction of a 9" x 9" specimen restrained at its perimeter (U.S. Army Corps of Engineers Methodology).

5 Resistance to loss of load capacity or structural integrity when subjected to mechanical stress in installation measured via ASTM D 5818 in a poorly graded gravel with a maximum 2 inch particle size (GP).

6 Resistance to loss of load capacity or structural integrity when subjected to chemically aggressive environments measured via EPA Method 9090 immersion testing.

7 Retained strength after 500 hours of exposure per ASTM D 4355.

2.1.2 Braid

The braid material used for tying and lacing in the fabrication of the mattress units shall be 8-strand hollow-core braid composed of high density polyethylene (HDPE). Each strand shall consist of a bundle of monofilament HDPE. The braid shall have a nominal diameter of not less than 3/16-inch and a breaking strength of not less than 400 pounds on a test specimen 36 inches in length. For UV stability, the braid material shall have a minimum carbon black content of 2.0%, by weight, throughout.

2.1.3 Mechanical Connectors

The mechanical connectors used shall be bodkin type, 3/8-inch diameter round rods, composed of HDPE and/or polypropylene (PP).

2.2 WIRE MESH GABIONS

The gabions shall be fabricated using double twisted or welded wire mesh, wire fasteners, lacing wire, stiffeners and stone fill.

2.2.1 Double Twisted Wire Mesh Gabions

Double twisted wire mesh gabions shall be Style 3 manufactured with a non-raveling mesh made by twisting continuous pairs of wires through three half turns (commonly called double twisted) to form a hexagonal-shaped opening. Gabion sizes, wire diameters, mesh opening sizes, and tolerances shall comply with the requirements of ASTM A 975 (Tables 1, 3, 4, 5, 6, and Sections 9). Gabions shall meet the following test requirements:

a. Metallic coating - The coating weights shall conform to the requirements of ASTM A 641/A 641M, Class 3 (Style 1) and ASTM A 90/A 90M.

b. PVC for Coating - The PVC coating shall show no cracks or breaks after the wires are twisted in the fabrication of the mesh. The initial properties of PVC coating material shall have a demonstrated ability to conform to the following requirements:

1). Specific Gravity - In the range from 1.30 to 1.35 dN/dm3, when tested in accordance with test method ASTM D 792;

2). Tensile Strength - Not less than 2985 psi when tested in accordance with test method ASTM D 412;

3). Modulus of Elasticity - Not less than 2700 psi when tested in

Section 02371 Page 8 accordance with test method ASTM D 412;

4). Hardness - Shore "D" between 50 and 60, when tested in accordance with test method ASTM D 2240;

5). Brittleness Temperature - Not higher than 15 degrees F, or lower temperature when specified by the purchaser, when tested in accordance with test method ASTM D 746.

6). Resistance to Abrasion - The percentage of the weight loss shall be less than 12%;

7). Salt Spray Exposure and Ultra Violet Light Exposure - The PVC shall show no effect after 3,000 h of salt spray exposure in accordance with ASTM B 117. The PVC shall show no effect of exposure to ultra violet light with test exposure of 3,000 h, using apparatus Spectral Irradiance of Open Flame Carbon Arc with Daylight Filters and 145 degrees F, when tested in accordance with practice ASTM D 1499 and ASTM G 152;

8). Evaluation of Coating After Salt Spray and Ultraviolet Exposure Test - After the salt spray test and exposure to ultraviolet light, the PVC coating shall not show cracks nor noticeable change of color, or blisters or splits. In addition, the specific gravity, tensile strength, hardness and resistance to abrasion shall not change more than 6%, 25%, and 10% respectively, from their initial values.

c. Wire Tensile Strength - The tensile strength of the wire used for the double twisted mesh, lacing wire, and stiffener, when tested in accordance with Test Methods and definitions ASTM A 370, shall be in accordance with the requirements of ASTM A 641/A 641M (Style 1), for soft temper wire.

d. Mesh strength and panel to panel joint strength - The minimum strength requirements of the mesh, selvedge wire to mesh connection, panel to panel connection, and punch test, when tested in accordance with ASTM A 975 Section 13.1, shall be as shown in Table 1. The strength values reported in lb/ft are referred to the unitary width of the specimen. The panel to panel test shall demonstrate the ability of the fastening system to achieve the required strength, and indicate the number of wire revolutions for the lacing wire or the ring spacing for ring fasteners used. The same number of wire revolutions or ring spacing shall be used in the field installation. Pleating the based panel to obtain internal panels is prohibited.

TABLE 1

Minimum Strength Requirements of Mesh and Connections

Test description Gabions, PVC coated lb/ft

Tensile strength 2900 parallel to twist Tensile strength 1400

Section 02371 Page 9

TABLE 1

Minimum Strength Requirements of Mesh and Connections

Test description Gabions, PVC coated lb/ft perpendicular to twist Connection to selvedges 1200 Panel to panel (using 1200 lacing wire or ring fasteners)

Test description Gabions, PVC coated lb

Punch Test 5300

2.2.2 Welded Wire Fabric Gabions

Welded wire fabric gabions shall be Style 2, and Style 5 manufactured with a welded wire mesh composed of a series of longitudinal and transverse steel wires arranged substantially at right angles to each other, and welded together at the points of intersection by electrical resistance welding to form fabricated sheets. Gabion sizes, wire diameters, mesh opening sizes, physical properties of the PVC for coating, and tolerances shall comply with the requirements of ASTM A 974 (Tables 1, 2, 3, and Sections 9). Gabions shall meet the following test requirements:

a. Metallic coating - The coating weights shall conform to the requirements of ASTM A 856/A 856M.

b. PVC for Coating - PVC adhesion test shall be PVC coating shall show no cracks or breaks after the wires are twisted in the fabrication of the mesh. The initial properties of the PVC coating on the wire and welded wire fabric shall have a demonstrated ability to conform to the following requirements:

1). Adhesion - The PVC coating shall adhere to the wire such that the coating breaks rather than separates from the wire, in accordance with test method ASTM A 974 Section 13.3;

2). Mandrel bend - The PVC-coated wire when subjected to a single 360 bend at 0 degrees F around a mandrel ten times the diameter of the wire, shall not exhibit breaks or cracks in the PVC coating;

3). Specific Gravity - In the range from 1.20 to 1.40 dN/dm3, when tested in accordance with test method ASTM D 792;

4). Tensile Strength - Not less than 2275 psi when tested in accordance with test method ASTM D 638;

5). Modulus of Elasticity - Not less than 1980 psi at 100% strain, when tested in accordance with test method ASTM D 638;

6). Hardness - Shore "A" not less than 75, when tested in accordance with test method ASTM D 2240;

Section 02371 Page 10

7). Brittleness Temperature - Not higher than 15 degrees F, or lower temperature when specified by the purchaser, when tested in accordance with test method ASTM D 746.

8). Resistance to Abrasion - The percentage of the weight loss shall be less than 12%;

9). Salt Spray Exposure and Ultra Violet Light Exposure - The PVC shall show no effect after 3,000 h of salt spray exposure in accordance with ASTM B 117. The PVC shall show no effect of exposure to ultra violet light with test exposure of 3,000 h, using apparatus Spectral Irradiance of Open Flame Carbon Arc with Daylight Filters and 145 degrees F, when tested in accordance with practice ASTM D 1499 and ASTM G 152;

10). Evaluation of Coating After Salt Spray and Ultraviolet Exposure Test - After the salt spray test and exposure to ultraviolet light, the PVC coating shall not show cracks nor noticeable change of color, or blisters or splits. In addition, the specific gravity, tensile strength, hardness and resistance to abrasion shall not change more than 6%, 25%, and 10% respectively, from their initial values.

c. Wire Tensile strength - The tensile strength of the wire used for the welded wire fabric, spiral binders, lacing wire and stiffeners shall be soft medium in accordance with hand drawn in accordance with ASTM A853. The cross-sectional area of the test specimen shall be based on the diameter of the metallic coated wire. All the wires used in the fabrication of gabions must use the same temper wire in accordance with given order.

d. Weld Shear Strength - The minimum average shear value in pounds-force shall be 70% of the breaking strength of the wire or as indicated in the table as follows, whichever is greater, when tested in accordance with ASTM A 974 Section 13.4. Typical minimum average shear strengths as specified are as follows:

TABLE 2

Minimum average shear strength values for the welded mesh

Wire Diameter Min. Av. Shear Strength Min. Shear Strength inch lbs lbs

0.087 292 225

0.106 472 360

0.120 584 450

The material shall be deemed to conform with the requirements for weld shear strength if the average of the test results of the first four specimens or if the average of the test results for all welds tested comply with TABLE 2.

Panel to Panel Joint Strength - The minimum strength of the joined panels, when tested as described in ASTM A 974 Section 13.5, shall be as follows:

Section 02371 Page 11

TABLE 3

Panel to panel joint strength for welded gabions

Test Description Gabions lb/ft

Connection to selvedges 1400 Panel to panel (using lacing wire or ring 1400 fasteners)

The strength values reported in lb/ft are referred to the unitary width of the specimen. The panel to panel test shall demonstrate the ability of the fastening system to achieve the required strength, and indicate the number of wire revolutions for the lacing wire used. The same number of wire revolutions shall be used in the field installation.

2.2.3 Alternative Wire Fasteners for Gabions

At the Contractor's option and subject to the approval of the Contracting Officer, alternative fastening systems may be used for the gabions in lieu of lacing wire. Alternative fasteners to lacing wire recommended for woven wire gabions, according to ASTM A 975, are stainless steel rings for PVC coated gabions. Ring fasteners for woven wire gabions shall comply with the minimum requirements indicated in paragaph Ring Fasteners below, and they shall develop a minimum panel to panel joint strength as indicated in TABLE 1. Contractor shall provide a complete description of the fastener system and a description of a properly installed fastener, including drawings or photographs if necessary. Provide test results that demonstrate that the alternative-fastening system meets the requirements of the specifications, according to the following criteria:

a. That the proposed fastener system can consistently produce a panel to panel joint strength as indicated in the TABLE 1 for double twisted wire mesh gabions;

b. That the proposed fastener system does not cause damage to the protective coating on the wire;

c. That the Contractor has the proper equipment and trained employees to correctly install the fasteners;

d. That proper installation can be readily verified by visual inspection.

Samples of wire fasteners with their certified test records shall be submitted at least 60 days in advance to the Contracting Officer for approval. The Government reserves the right to test additional samples to verify the submitted test records at the Government's expense. When the first test results indicate that the fasteners do not meet the specified requirements, the additional test will be at the Contractor's expense. The fasteners will be rejected after two tests failing to meet the requirements.

Section 02371 Page 12

2.2.3.1 Ring Fasteners

The tensile strength of stainless steel wire used for fasteners shall be in accordance with the requirements of ASTM A 313/A 313M, Type 302, Table 2.

The fastener system shall give the number of fasteners required to comply with TABLE 1, in accordance with ASTM A 975 (Section 13.1.2) for woven wire gabions. Ring fasteners shall not be installed more than 4 inches apart.

Each fastener type shall be closed and the free ends of the fastener shall overlap a minimum of 1 inch. The manufacturer or supplier shall state the number of fasteners required for all vertical and horizontal connections for single and multiple basket joining. Approved ring fasteners including fasteners made of stainless steel shall be subject to the salt spray test and pull-apart resistance test and shall be documented by actual testing of panel to panel connections within the last year by validated laboratories.

a. Salt Spray Test - A set of two identical rectangular gabion panels, each with a width about 10-1/2 mesh openings along a selvedge wire, shall be joined by properly installed wire fasteners along the two selvedge wires so that each fastener confines two selvedge and two mesh wires. If the fasteners are also to be used to joint two individual empty gabion baskets, two additional selvedge wires which are each mechanically wrapped with mesh wires shall be included so that each fastener confines four selvedge and four mesh wires. The set of the jointed panels shall be subject to salt spray test, ASTM B 117, for a period of not less than 48 hours. At the end of the test, the fasteners, the selvedge, or mesh wires confined by the fasteners shall show no rusty spots on any part of the surface excluding the cut ends.

A properly installed fastener shall meet the following requirements:

1). Each interlocking fastener shall be in a locked and closed position.

2). Each ring fastener shall be closed, and the free ends of the fastener shall overlap a minimum of 1 inch.

b. Pull-Apart Resistance Test - A new set of the jointed panels, which are prepared by the same method as specified in the salt spray test but without being subject to the 48-hour salt spray test, shall be mounted on a loading machine with grips or clamps such that the panels are uniformly secured along the full width. The grips or clamps shall be designed to transmit only tension forces. The load will then be applied at a uniform rate of 50 lbs/sec until failure occurs. The failure is defined as when the maximum load is reached and a drop of strength is observed with subsequent loading or the opening between any two closest selvedge wires, applicable to a fastener confining either two or four selvedge wires, becomes greater than 2 inches at any place along the panel width. The strength of the jointed panels at failure shall have a minimum as indicated in TABLE 1 or TABLE 3.

2.2.4 Testing

Test records made within one year by certified laboratories and Government agencies will be used to determine the acceptability of the fastening system. Samples of wire fasteners with their certified test records, and manufacturer's certificates for the gabions shall be submitted at least 60 days in advance to the Contracting Officer for approval. The Government reserves the right to test the assembled baskets and additional samples of the alternative fasteners to verify the submitted test records at the Government's expense. When the first test results indicate that the

Section 02371 Page 13 fasteners do not meet the specified requirements, the additional test will be at the Contractor's expense. The fasteners will be rejected after two tests failing to meet the requirements.

2.3 STONE FILL FOR GABIONS AND MATTRESSES

2.3.1 General

For gabions and mattresses, the ability to function properly depends upon their stability, which is partly depending upon the stones filling them.

Stone sizes shall be chosen to prevent them from falling through the mesh of the mattresses and gabions. The stone has also to withstand natural weathering processes during the life of the project that would cause it to breakdown to sizes smaller than the wire mesh and geogrid opening dimensions. Stone to fill gabions and mattresses shall be sound and durable, free of cracks, soft seams and other structural defects, and of suitable quality to ensure permanence in the structure and climate in which it is to be used.

a. Delivery. Stone shall be delivered to the work site (in the case of gabions) and to the fabrication site (in the case of marine mattresses) in a manner to minimize its reduction in sizes (breakdown) during the handling of the stone, and be placed and secured within the mattresses and within the assembled and interconnected gabions.

b. Sources. The sources from which the Contractor proposes to obtain the material shall be selected well in advance of the time when the material will be required in the work. The inclusion of more than 5% by weight of dirt, sand, clay, and stone fines will not be permitted.

Stone may be of a natural deposit of the required sizes, or may be crushed stone produced by any suitable method and by the use of any device that yields the required size limits chosen in TABLE 5.

c. Properties. Stones shall be hard, angular to round, durable and of such quality that they shall not disintegrate on exposure to water or weathering during the life of the structure.

d. Source Approval. The Government may make such investigations and tests as necessary to determine whether acceptable stone can be produced from the proposed source. Suitable samples of stone fill material shall be collected in the presence of a Government representative and submitted to the Contracting Officer for approval prior to delivery of any such material to the work site. Unless otherwise specified, all test samples shall be obtained and delivered at the Contractor's expense to the COR at least 60 days in advance of the time when placing of the stone-filled gabions is expected to begin. Suitable tests and/or service records will be used to determine the acceptability of the stone. In the event suitable test reports and service records are not available, as in the case of newly operated sources, the material may be subjected to petrography analysis, specific gravity, absorption, wetting and drying, freezing and thawing, and such other tests as may be considered necessary to demonstrate to the satisfaction of the Contracting Officer that the materials are acceptable for use in the work. All tests shall be made under the supervision of the Government and at the Contractor's expense.

2.3.2 Stone Quality

Stone fill, crushed stone, shall meet the quality requirements of

Section 02371 Page 14

ASTM C 33/C 33M, and freezing and thawing requirements of ASTM D 5312 for the region of the United States in which the structure will be constructed.

2.3.3 Testing

The contractor shall perform, at their own expense, the following tests, the results of which will be used by the Government to determine the acceptability of the stone sources selected by the Contractor. The testing shall be performed by a USACE-validated laboratory and shall be submitted to the Government at least 6 weeks prior to delivery of the stone fill (for the gabions) or the pre-filled mattress units to the site.

TABLE 4

Tests

PROPERTY TEST METHOD ACCEPTABLE TEST RESULTS

Petrographic ASTM C 295 Fresh, interlocking, crystalline, with few vugs, no clay minerals and no soluble minerals.

Specific Gravity and Absorption ASTM C 127 Minimum Unit Weight (dry) of 160 pounds per cubic foot for both gabions and mattresses. Absorption less than 1%.

Abrasion Resistance ASTM C 131 Less than 20% loss for 500 revolutions.

Freezing/ Thawing CRD-C 144 Less than 10% loss for 12 cycles.

2.3.4 Gradation

Gradation testing of stone for gabions shall be performed once for every 1000 tons placed under this contract in accordance with ASTM C 136.

Gradation testing of stone for marine mattresses shall be performed once for every 100 tons placed under this contract in accordance with ASTM C 136.

Sizes of stone to fill gabions and mattresses shall be chosen on the basis of the mesh sizes, the structure's thickness, and within the limits shown in TABLE 5. Within each range of sizes, the stone shall be large enough to prevent individual pieces from passing through the mesh openings. Each range of sizes may allow for a variation of 5% oversize stone by weight, or 5% undersize stone by weight, or both.

a. Oversize Stone. In all cases, the sizes of any oversize stone shall allow for the placement of three or more layers of stone within each gabion compartment and two or more layers of rock within each mattress compartment dependent upon the height of the mattress.

b. Undersize Stone. In all cases, undersize stone shall be placed within the interior of the gabion or mattress compartment and shall not

Section 02371 Page 15 be placed on the exposed surface of the structure. There shall be a maximum limit of 5% undersize or 5% oversize stone, or both, within each gabion or mattress compartment. The required stone gradation is reported in Table 4.

TABLE 5

Required Stone Gradations

Type of structure Thickness (height), inches Stone diameters, inches

Gabions 12 4 - 8 Gabions 18 or higher 4 - 8 Marine mattresses 12 2 - 6 (Average 4)*

(* For mattresses, minimum stone size shall be 2 inches over the shortest dimension. The average stone diameter shall be 4 inches.)

2.4 GEOTEXTILE

The geotextile to be used shall be in accordance with Section 02373 GEOTEXTILE, of these specifications

PART 3 EXECUTION

3.1 SUBGRADE PREPARATION

Foundation preparation shall not take place on frozen or snow-covered ground. After excavation or stripping, to the extent indicated on the drawings or as directed by the Contracting Officer, all remaining loose or otherwise unsuitable materials shall be removed. All depressions shall be carefully backfilled to grade. If pervious materials are encountered in the foundation depressions, the areas shall be backfilled with free-draining materials. Otherwise, the depressions shall be backfilled with suitable materials from adjacent required excavation, or other approved source, and compacted to a density at least equal to that of the adjacent foundation. Any debris that will impede the proper installation and final appearance of the gabion layer shall also be removed, and the voids carefully backfilled and compacted as specified above. Immediately prior to placing the material, the Contracting Officer shall inspect the prepared foundation surface, and no material shall be placed thereon until that area has been approved.

3.2 GEOTEXTILE PLACEMENT

Geotextile material shall be spread uniformly on the prepared foundation surface in a manner satisfactory to the Contracting Officer, and to the slopes, lines, and grades as indicated on the drawings or as directed. See Section 02373 GEOTEXTILE for other placement requirements for the geotextile.

Any damage to the foundation surface during the geotextile placement shall be repaired before proceeding with the work.

3.3 ASSEMBLY OF MARINE MATTRESSES

3.3.1 Test Mattresses

The Contractor shall assemble a test mattress. The COR and/or his designated representative shall be present during the assembly of the test mattress. The test mattress shall be assembled at the facility where all

Section 02371 Page 16 the mattresses are to be assembled. The Contractor shall utilize and demonstrate the personnel, equipment, materials, and methods proposed in the approved work plan for assembling the mattresses. The Contractor shall not assemble any other mattresses until the test mattress is approved.

3.3.2 Coordination

The Contractor shall provide 10 days advance notification to the COR prior to commencing the construction of the test mattress. This advance notification to the COR will serve to facilitate coordination of the site visit with the Government's various technical and project personnel who will conduct the inspection.

3.3.3 Assembling Mattresses - General

Empty mattress units shall be assembled as recommended by the manufacturer and as indicated on the contract drawings. The joints where the ends and baffles of each unit join the top or bottom of the unit shall be made with a mechanical connection. During stone filling operations, the Contractor shall take care to protect the mattresses from all damage such as crushing, breaking, excessive bulging, tearing, etc.

3.3.4 Braid Material

All cut ends of braid material shall be knotted within 1 inch to 2 inch of the end to prevent raveling of the braid material. The braid material shall be securely knotted to the geogrid at all ends of all stitched seams, and at a spacing not to exceed 6 feet along any stitched seam. Pieces of braid material may be spliced end to end by securely knotting. The stitches along each seam shall be sufficiently tight to close the gap between the adjacent pieces of geogrid. The braid material shall be stitched through each pair of apertures along each seam at least once. The spacing of stitches shall be reasonably uniform at approximately 6 (minimum) stitches per foot along the entire length of each seam.

3.3.5 Deleted

3.3.6 Lifting Hoops

Lifting hoops shall be formed by joining the top and bottom layers of grid from each unit by means of approved mechanical connections.

3.3.7 Extensions

The 2-foot extensions on the marine mattresses shall be attached to the

Section 02371 Page 17 marine mattresses in the same manner as specified herein for connecting one marine mattress to another.

3.3.8 Filling with Stone

The mattresses shall be pre-filled with stone prior to delivery as specified below. Stone filling operations shall carefully proceed with placement by hand or machine, along with compaction, so as not to damage the geogrid or seams, to assure a minimum of voids between the stones, and to avoid deformation throughout the filling process. Undue bulging of the mattress material shall be avoided, however finished height of stone fill shall match the full height of the mattress. The maximum height from which the stone may be dropped into the basket units shall be 1 foot. The stone shall be overfilled to allow for raking the stone level with the top of the mattress.

3.3.9 Closing Mattresses

The mattresses shall be closed over the stone as recommended by the manufacturer. Mattress lids shall be attached to the perimeter and diaphragms of the mattresses using lacing wire or braid with half hitches and a knot spaced 6 to 9 inches apart.

3.4 INSTALLATION OF MATTRESSES

Mattresses shall be set to the required lines and grades as shown on the contract drawings. Vertical placement tolerances shall be +/- 0.25 feet and lateral placement tolerances shall be +/- 0.0 feet. Adjacent mattresses shall be placed on the extension of grid attached to each mattress and shall abut each other along their entire perimeters, in order to obtain a monolithic structure.

The space between adjacent mattresses shall be no greater than 4 inches.

The long dimension of a unit (created by connecting individual mattresses together for installation) shall be placed perpendicular to the direction of flow.

The procedure used in placement of the units shall be in accordance with the recommendations of the system supplier and as approved by the Contracting Officer. For lifting of each unit, a spreader beam and / or spreader bars shall be used in a manner that the unit is not subjected to severe bending or distortion and that the top and bottom layers of the mattress material are tensioned uniformly across their width. Units should generally be lifted from a horizontal position. Personnel shall stay clear of the area beneath units and rigging during lifting.

3.5 REPAIRS OF MARINE MATTRESSES

Damaged geogrid shall be repaired by placing a geogrid patch over the damaged area such that it overlaps onto the acceptable geogrid material by at least one foot in all directions; the perimeter edges of the patch shall be attached to the mattress in accordance with the seaming requirements, above. Damaged braid shall be repaired by installing a new braided seam in accordance with above, and extending at least one foot in either direction beyond the location of the damaged braid.

Section 02371 Page 18

3.6 WIRE MESH GABIONS

3.6.1 ASSEMBLY

3.6.1.1 Double Twisted Wire Mesh Gabions

The gabions shall be opened and unfolded one by one on a flat, hard surface. Gabion units over 6 foot in length usually have an extra shipping fold, which must be removed. The sides, ends and diaphragms shall be lifted up into a vertical position to form an open box shape. The back and the front panels of the gabion shall be connected to the end panels and center diaphragms. The top corner of the end panels and center diaphragms have a selvedge wire extending approximately 4 inches out from the corner edge. The end panels and the diaphragms shall be raised to a vertical position and the selvedge wire shall be wrapped around the edge wire of the top and back panels.

3.6.1.2 Welded Wire Fabric Gabions

The gabions shall be opened and unfolded on a flat, hard surface. The units shall be rotated into position and the edges joined with fasteners for assembly. Where spiral fasteners are used, the ends shall be crimped to secure them in place. Where lacing wire is used, the wire shall be wrapped with alternating double and single loops with spacings not to exceed 6 inches. Ends shall be secured with two complete revolutions and finished with a one-half hitch. The same fastening procedures shall be used to secure interior diaphragms and end panels. When two gabions are placed side by side, the two end panels may be connected along the vertical edges with a single spiral fastener.

3.6.2 LACING OPERATIONS

3.6.2.1 Double Twisted Wire Mesh Gabions

Either lacing wire or ring fasteners are permitted to lace double twisted wire mesh gabions.

a. When using lacing wire, a piece of wire 1.2 to 1.5 times the length of the edge to be laced shall be cut off. If the edge of the basket is 3 foot long, no more than 4 to 5 feet of wire shoul be uses at a time to lace. For vertical joints, starting at the bottom end of the panel, the lacing wire shall be twisted and wrapped two times around the bottom selvedge and double and single loops shall be alternated through at intervals not bigger than 4 to 6 inches. The operation shall be finished by looping around the top selvedge wire. The use of pliers to assemble the units with lacing wire is normally recommended.

b. When steel wire ring fasteners are used, the rings shall be installed at the top and bottom connections of the end and center diaphragms. The ring spacing shall be based on the minimum pull apart strength as specified in TABLE 1. In any case, the maximum ring spacing along the edges shall not exceed 6 inches. The use of either a mechanical or a pneumatic fastening tool for steel wire ring fasteners is required. Ring fasteners shall be stainless steel.

3.6.2.2 Welded Wire Mesh Gabions

Either lacing wire or spiral binders are permitted to lace welded wire mesh gabions. The empty units shall be placed on the foundation and

Section 02371 Page 19 interconnected with the adjacent unit along the top, bottom and vertical edges using spiral fasteners. Lacing wire may be used in lieu of spiral binders for the interconnection of gabions as specified above. The connection with lacing wire or spiral binders shall be based on the minimum panel to panel joint strength as specified in TABLE 3. Spiral binders shall be screwed along the connecting edges, and then each end crimped to secure the spiral in place. Each layer of gabions shall be interconnected to the underlying layer along the front, back and sides.

3.6.3 INSTALLATION AND FILLING

Empty gabion units shall be assembled individually and placed on the approved surface to the lines and grades as shown or as directed, with the sides, ends, and diaphragms erected in such a manner to ensure the correct position of all creases and that the tops of all sides are level.