Amendment0001.pdf

AMENDMENT NO. 0001 Rehabilitation and Painting Tainter Gates W912BV-09-R-1010 Fall River Dam, Kansas

AMENDMENT OF SOLICITATION

1. CONTRACTOR ID CODE

NOT APPLICABLE (NA) PAGE 1 OF 2

2. AMENDMENT/MODIFICATION NO. 3. EFFECTIVE DATE 4. REQUISITION/PURCHASE REQ. NO. 5. PROJECT NO. (If Applicable)

0001 10 April 2009 NA NA

6. ISSUED BY

CODE

7. ADMINISTERED BY (If other than Item 6)

CODE

DISTRICT ENGINEER

TULSA DISTRICT, CORPS OF ENGINEERS

1645 SOUTH 101ST EAST AVENUE

TULSA, OK 74128-4609

NA

8. NAME AND ADDRESS OF CONTRACTOR (No., street, county, State and ZIP Code) (%) 9A. AMENDMENT OF SOLICITATION NO.

W912BV-09-R-1010

% 9B. DATED (SEE ITEM 11)

23 March 2009

10A. MODIFICATION OF CONTRACT/ORDER NO.

NA

10B. DATED (SEE ITEM 13)

CODE FACILITY CODE NA

11. THIS ITEM APPLIES ONLY 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 Offers is extended, X is not extended.

Offers 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 1 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 ACKNOWLEDGEMENT 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)

NA

NA 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.)

SEE ATTACHED CONTINUATION SHEET.

NOTE: IN THIS AMENDMENT “SOLICITATION NO.”, “OFFER”, AND “OFFEROR” MEAN “INVITATION NO.”, “BID”, AND “BIDDER”, RESPECTIVELY Except as provided herein, all terms and conditions of the document referenced in Item 9A or 10A, as hertofore changed, remains unchanged and in full force and effect.

15A. NAME AND TITLE OF SIGNER (Type or print) 16A. NAME AND TITLE OF CONTRACTING OFFICER (Type or print)

NA

15B. CONTRACTOR/OFFEROR 15C. DATE SIGNED 16B. UNITED STATES OF AMERICA 16C. DATE SIGNED

NA NA

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

NSN 7540-01-162-8070 30-105-02 STANDARD FORM 30 (REV. 10-8)

PREVIOUS EDITION UNUSABLE Prescribed by GSA

AMENDMENT 0001

RFP NO. W912BV-09-R-1010

REHABILITATION AND PAINTING TAINTER GATES

FALL RIVER DAM, KANSAS

The proposal documents shall be revised as follows:

INITIAL TASK ORDER

Remove in its entirety Initial Task Order, Rehabilitation and Painting Tainter Gates, dated March 2009 and replace with new Initial Task Order, Paint Tainter Gate #1, dated April 2009 attached hereto.

SPECIFICATIONS

Section 09 97 02 – Delete paragraphs 1.4.3 and 1.4.4.

INFORMATION

Minutes of the Site Visit held on 31 March 2009 are provided herewith.

Meeting Minutes

Paint MATOC Initial Task Order Site Visit

Subject Meeting minutes for organized site visit for Solicitation W912BV-09-R-1010 Sheet 1 Of 4

Project Title Reference:

Initial Task Order – Rehabilitation and Painting Tainter Gates, Fall River Dam, Kansas.

Meeting Date

31 March 2009 Meeting Location

Fall River Dam Project Office

Notes by Bob Goranson REV 000

Topics Discussed Agenda for Plans & Specifications and Site Specific Issues

Fall River Dam Project Office 10:00 am.

Attendees: See attached sign-in sheet.

Items for Discussion

1. Robert Goranson to lead with introductions:

2. This is a MULTIPLE AWARD TASK ORDER CONTRACT (MATOC) INDEFINITE

DELIVERY, INDEFINITE QUANTITY (IDIQ) FOR PREPARATION, REHABILITATION,

AND PAINTING LARGE INDUSTRIAL AND HYDRAULIC STATIONARY AND FLOATING

STRUCTURES.

a. THIS SOLICITATION IS UNRESTRICTED.

b. Efforts include but are not limited to the following: Preparation and painting of large industrial structures and hydraulic stationary and floating structures; welding; minor structural work; and general repair work on hydraulic structures. Typical structures could include bridges, catwalks, sluice gates, tainter gates, floating bulkheads, tainter gate superstructures and control equipment, and stoplogs.

c. Estimated cost range is $25M to $49.5M for ALL contracts awarded under this solicitation, over the base year and four option year period.

3. Initial Task Order. Rehabilitation and Painting Tainter Gates, Fall

River Dam, Kansas.

a. Project Description:

TYPE OF WORK: Surface Preparation, Painting, Metal Repair, and General Labor.

DESCRIPTION OF WORK: The Contractor shall provide all plant, materials, equipment, labor, instruments, tools, subcontractors, supervision, and management to complete all work in accordance with the base MATOC contract and this task order. In general, the work consists of the following:

• Surface preparation;

• Paint tainter gates, catwalks, and hoist machinery;

• Replace side seals;

• Rehabilitate babbitt;

• Replace hoist chains;

• Replace gear.

b. Contractor shall work between the hours of 7:00 a.m. and 6:00 p.m.

Monday through Friday unless otherwise directed by the Contracting Officer.

c. There are flood releases and low flow releases at Fall River Lake.

These releases are described within this Task Order scope of work.

d. Fall River Lake reservoir information may be viewed at http://www.swt-wc.usace.army.mil/FALL.lakepage.html. Keystone Lake monthly charts of reservoir data since November 1994 may be viewed at http://www.swt-wc.usace.army.mil/FALLcharts.html.

e. Any conclusions drawn by the Contractor related to item “d” above are done so at the Contractor's risk.

f. Only one tainter gate can be out of service at a time. If flood releases are made for flood damage reduction, all tainter gates must be in service. The Contractor shall constantly monitor weather conditions and forecasts and be prepared for potential emergency conditions. The Contractor shall develop a plan to remove all construction scaffolding and equipment in less than 24 hours in order for the Government to operate the tainter gates for flood damage reduction purposes.

g. Liquidated damages for this Task Order are $242/day.

h. Contract Duration for this Task Order is 290 days.

i. Weather delays are noted in the scope of work.

z. All work shall be in accordance with the safety guidelines of

EM385-1-1.

Issues raised for discussion by those in attendance.

• There is no bulkhead or stoplog available.

• The entire side seal assemblies will be replaced (including seals, nuts, bolts, spacers, clamping bars, etc).

• Concrete spall repair at Gate 8 is not included.

• A staging area for a small office trailer with 220V/50A service is available in the camping area on the East side of the dam.

• The Contractor is responsible for removing all material and debris offsite, including the hoist chains.

• Work will start at Tainter Gate #1 and progress across the dam.

• The Contractor shall replace the lettering on Gates #2 and #6.

• The Contractor shall prepare and paint accessible, lower portions of the hoist platform beams. Do not remove bolts and the beams from the hoist platform.

• Should a bridge closure be necessary, 7 days public notice and adequate signage will be required. A traffic control plan shall be required. Coordinate the bridge closure through the Contracting Officer.

• Hatch cover sealant is a One Part, Semi-Self Leveling Joint Sealant (Revere X JTtm Joint Sealant or approved equal).

General Information.

1. Contractors may visit Fall River Dam for an additional site visit per Operations Division convenience.

Contact one of the following to coordinate an additional site visit:

Gale Puckett - (620) 658-4445 Susan Couch - (620) 336-2741 Ken Reznicek – (918) 669-8501 or (620) 364-8613

2. Questions to be submitted in writing to Susie Mall:

Susie.Mall@usace.army.mil

Fax: 918.669.7495.

3. Any changes to the RFP will be issued by amendment.

4. Sealed offers in original and 4 copies to perform the work required are due by 4:00 p.m. local time, 22 April 2009.

PAINT MATOC

INITIAL TASK ORDER

PAINT TAINTER GATE #1

Fall River Dam, Kansas

April 2009

Fall River, Kansas

TABLE OF CONTENTS

Fall River Dam, Kansas

SECTION TITLE

00100 SOLICITATION, OFFER AND AWARD (PROPOSAL SCHEDULE)

00800 SPECIAL CONTRACT REQUIREMENTS

01 00 00 SCOPE OF WORK

01 27 00 MEASUREMENT AND PAYMENT

OTHER DOCUMENTS

1. Sections of latest District Inspection Report, including TAINTER GATE

CRITICAL LOCATIONS, PICTURES AND RECOMMENDATIONS.

2. FALL RIVER 2009 SEASONAL POOL PLAN

3. EVALUATION, LINK-BELT CRANE (JUNE 2002)

4. PLAN - RECOMMENDED CRANE PLACEMENT

5. Rubber Seal Shop Drawing

SECTION 00100

PROPOSAL SCHEDULE

Item Unit

No. Description Quantity Unit Price Amount

1. Sandblast and paint upstream Sum Job xxxx _______ side of tainter gate #1

2. Sandblast and paint downstream Sum Job xxxx _______ side of tainter gate #1

TOTAL BASE BID _______

OPTION 1

3. Remove and replace side seal Sum Job xxxx _______ assemblies on tainter gate #1

OPTION 2

4. Repair babbitt on tainter gate #1 Sum Job xxxx _______

TOTAL FOR OPTIONS 1 AND 2 (BID ITEMS 3 AND 4) $________

TOTAL FOR BASE BID AND OPTIONS 1 AND 2 $________

NOTES

1. All costs for items of work not listed separately in the Bidding Schedule or specifically mentioned to be included in a particular item price shall be included in the listed item price most closely associated with the work involved.

2. This solicitation requires submission of a proposal on all items. Failure to do so will result in the proposal being rejected without further consideration.

3. Options shall be evaluated in accordance with the clause EVALUATION OF

OPTIONS (JULY 1990) (FAR 52.217-5) in SECTION 00100.

THE FOLLOWING PARAGRAPHS TO BE INCLUDED IN SECTION 00800 AS A PART OF THIS

TASK ORDER

52.0000-4020 TIME EXTENSIONS FOR UNUSUALLY SEVERE WEATHER (OCT 1989)

(ER 415-1-15)

1. This provision specifies the procedure for determination of time extensions for unusually severe weather in accordance with the contract clause entitled "Default: (Fixed Price Construction)". In order for the Contracting Officer to award a time extension under this clause, the following conditions must be satisfied:

a. The weather experienced at the project site during the contract period must be found to be unusually severe, that is, more severe than the adverse weather anticipated for the project location during any given month.

b. The unusually severe weather must actually cause a delay to the completion of the project. The delay must be beyond the control and without the fault or negligence of the contractor.

2. The following schedule of monthly anticipated adverse weather delays is based on National Oceanic and Atmospheric Administration (NOAA) or similar data for the project location and will constitute the base line for monthly weather time evaluations. The contractor's progress schedule must reflect these anticipated adverse weather delays in all weather dependent activities.

MONTHLY ANTICIPATED ADVERSE WEATHER DELAY

WORK DAYS BASED ON (5) DAY WORK WEEK

JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC

5 4 4 5 6 5 4 3 4 4 3 3

3. Upon acknowledgment of the Notice to Proceed (NTP) and continuing throughout the contract, the contractor will record on the daily CQC report, the occurrence of adverse weather and resultant impact to normally scheduled work. Actual adverse weather delay days must prevent work on critical activities for 50 percent or more of the contractor's scheduled work day.

The number of actual adverse weather delay days shall include days impacted by actual adverse weather (even if adverse weather occurred in previous month), be calculated chronologically from the first to the last day of each month, and be recorded as full days. If the number of actual adverse weather delay days exceeds the number of days anticipated in paragraph 2, above, the contracting officer will convert any qualifying delays to calendar days, giving full consideration for equivalent fair weather work days, and issue a modification in accordance with the contract clause entitled "Default (Fixed Price Construction)".

52.211-10 COMMENCEMENT, EXECUTION, AND COMPLETION OF WORK (APR 1984)

The Contractor shall be required to (a) commence work under this contract within 10 calendar days after the date the Contractor receives the notice to proceed, (b) prosecute the work diligently, and (c) complete the work:

Base bid - 90 calendar days.

52.211-12 LIQUIDATED DAMAGES--CONSTRUCTION (SEP 2000)

(a) If the Contractor fails to complete the work within the time specified in the contract, the Contractor shall pay liquidated damages to the Government in the amount of $242 for each calendar day of delay until the work is completed or accepted.

(b) If the Government terminates the Contractor's right to proceed, liquidated damages will continue to accrue until the work is completed. These liquidated damages are in addition to excess costs of repurchase under the Termination clause.

(End of clause)

(END OF SECTION 00100)

SECTION 00800

SPECIAL CONTRACT REQUIREMENTS

PART 1 GENERAL

1.1 SUMMARY

Specification Section 00800 – SPECIAL CONTRACT REQUIREMENTS in the base MATOC contract shall be revised by replacing the same numbered base MATOC contract clauses with the contract clauses included or revised herein.

252.236-7001 CONTRACT DRAWINGS, MAPS, AND SPECIFICATIONS (AUG 2000)

Delete paragraph (e) and replace with the following:

(e) The work shall conform to the specifications and the following contract drawings. Except when identified as a new drawing, the following drawings are as-built drawings from previous construction contracts, are intended only to show the original construction, and are furnished for information only.

DRAWING NUMBER TITLE

COVER SHEET (NEW DRAWING)

C1 VICINITY/LOCATION MAPS AND DRAWING INDEX (NEW DRAWING)

C22 SPILLWAY AND NON-OVERFLOW SECTIONS, GENERAL PLAN

C23 SPILLWAY AND NON-OVERFLOW SECTIONS, GALLERIES

C40 TAINTER GATES GENERAL ARRANGEMENT

C41 TAINTER GATES SECTIONS & DETAILS

C42 TAINTER GATES SIDE SEAL & SILL BEAM

C43 TAINTER GATES TRUNNION ANCHORAGE

PART 2 PRODUCTS (NOT USED)

PART 3 EXECUTION (NOT USED)

(END OF SECTION 00800)

SECTION 01 00 00

SCOPE OF WORK

1.1 GENERAL PROJECT DESCRIPTION

The contractor shall provide all materials, equipment, labor, instruments, tools, subcontractors, supervision, and management to paint tainter gate #1 at Fall River Dam. Work shall include, but is not limited to: sandblast and paint tainter gate #1, rehabilitate babbitt on tainter gate #1, and replace the existing side seal assemblies on tainter gate #1. The tainter gates are approximately 50 feet wide and 25 feet high. The entire gate including beams, girders and strut arms shall be cleaned of all debris, including but not limited to: debris, sludge, water and biological formations. All drain holes shall be located and opened.

a. Upstream Surface of Tainter Gate #1: Clean all surfaces to SSPC SP5

(White Metal) and apply paint system 5-E-Z.

b. Downstream Surface of Tainter Gate #1: Clean all surfaces to SSPC SP5

(White Metal) and apply paint system 5-E-Z. Either pre-sandblast the corroded areas or sandblast to white metal and apply up to the first coat of paint in the 5-E-Z paint system on the gate. A combined inspection shall then be done with Corps and Contractor to verify areas that get epoxy. Inspect the gate for corrosion damage 1/8 inch or deeper. Document the number and size of corrosion damage pits or grooves and take photographs with a scale in the picture of corrosion damage areas. Repair all corrosion damage 1/8 inch or greater with weld build-up as specified. Fill all corrosion damage less than 1/8 inch deep with epoxy coating Thortex. Re-sandblast to white metal, prime with VZ 108d an area covering a minimum 1’ wider than the weld, and apply up to the first coat of paint the areas repaired with weld.

Sand smooth, clean with solvent, apply primer and apply up to the first coat of paint the areas filled with epoxy. Either pre-sandblasting or the re-sandblasting and applying up to the first coat in the repaired areas are to be included in the bid item for sandblasting and painting the downstream surface of Tainter Gate #1.

Areas that require weld build-up opposite the side that has been painted by the contractor shall be jointly inspected on the painted side after the weld is completed. If the paint has been damaged due to welding operations, the area on the painted side shall be repaired by a method to be approved by the Contracting Officer at no additional cost to the Government.

c. Trunnion Girders and Assemblies - Work shall include, but not necessarily be limited to, removing residual sealant, debris, laminated rust, and pack rust, unclogging drain holes, cleaning drain holes and pans of debris, blasting, painting, and greasing the trunnion assemblies. Painting work consists of blasting to white metal, priming, and painting each trunnion anchorage and assembly in its entirety with System No. 5-E-Z.

d. Tie Back Beams and Anchorages - Work shall include, but not necessarily be limited to, removing residual sealant, debris, laminated rust, and pack rust. Painting work consists of blasting to white metal, priming, and painting each tie back beam and anchorage in its entirety with System No. 5-E-Z.

e. Provide and replace the side seal assemblies, including but not limited to seals, bolts, nuts, washers, screws, retainer and spacer bars, and appurtenant items, of the gates with new seals and adjust for proper fit to minimize water leaks when the gates are shut.

f. Rehabilitate babbitt on the gate sill to provide a smooth and level surface per the Babbitt Repair Procedure described in Section 05 50 03 of the base MATOC specifications. Ensure the gate bottom is straight and even to provide a flush watertight seal between babbitt and the gate.

g. Clean all Government property including the gates, weirs, and bridge of all blast media and debris resulting from the Contractor’s construction activities.

1.2 PROTECTION OF TRUNNION ASSEMBLY

Due to the enormous cost of possible repair, the importance of protecting the trunnion assemblies (bronze bushings, steel castings, trunnion pins, keys, keeper plates, etc.) during blasting and painting cannot be over-emphasized.

Proper protection shall rest solely on the Contractor. Any damage to the trunnion assemblies, as with all damage to Government property, shall be repaired by the Contractor entirely at the Contractor’s expense. Trunnion assembly protection methods shall be submitted to the Contracting Officer for approval before any work begins.

1.3 LEAD PAINT

The existing paint contains lead. Lead level is shown to be 12,800 mg/Kg.

Data was analyzed on February 5, 2009.

1.4 SITE VISIT

A site visit was conducted on 31 March 2009.

1.5 PRICE PROPOSAL

The price proposal for the task order shall follow the guidance in paragraph 1.1.3, Section 00050 of the basic MATOC contract. Proposals shall be submitted in accordance with the Bidding Schedule in Section 00100. The contractor shall use the information in this Scope of Work in conjunction with information obtained at the site visit as the basis of his proposal.

1.6 PRE-WORK CONFERENCE

The Contractor shall attend a pre-work conference with the Contracting Officer’s Representative prior to commencing work on the project.

1.7 WORK HOURS

Work hours shall be Monday through Friday, 7 a.m. to 6 p.m. unless otherwise requested in writing by the Contractor and approved in writing by the Contracting Officer. The Contractor shall not work on Federal holidays unless prior approval is granted in writing by the Contracting Officer.

Request and approval for working outside the designated work hours shall be on a case-by-case basis.

1.8 GOVERNMENT FURNISHED UTILITIES

480V/3 phase/30 amp electric service is available at each tainter gate operating machinery platform (Elevation 991.5). 120V/15 amp single-phase service is available at each pier. Non-potable (raw lake) water is available at the spillway. Electricity and non-potable water are available at no additional cost to the Contractor if proper energy conservation methods are implemented. The Contractor shall be responsible for conditioning the power as necessary and providing conductors, hoses, etc. from existing service locations.

1.9 RESERVOIR INFORMATION AND HISTORICAL DATA

The conservation pool elevation is 948.5 feet, and the top of the weir is at elevation 962.5 feet. The tainter gates are usually above lake level, so bulkhead placement will not be required. Fall River Lake monthly charts of reservoir data since November 1994 may be viewed at http://www.swt-wc.usace.army.mil/FALL.lakepage.html. Any conclusions drawn by the Contractor from this data are done so at the Contractor’s risk.

1.10 WATER RELEASES THROUGH TAINTER AND SLUICE GATES

Water releases may affect the Contractor’s operations. Two types of water releases may occur: low flow releases and flood releases.

Low flow releases to maintain water quality for fish and wildlife habitat will be made from the outlet works year around as necessary to meet regulatory requirements. The Government will give 24 hours advance notice to the Contractor when water releases and/or gate changes are made for water quality purposes. Wind direction, gates currently being rehabilitated, and the volume of water to be released will be taken into consideration in an attempt to minimize impact on the Contractor’s work.

Flood releases will be made as required for flood damage reduction. In flood release emergencies, every effort will be made to give the Contractor 24 hours notification of gate changes. The Contractor shall constantly monitor weather conditions and forecasts and be prepared for potential emergency conditions. The Contractor shall be prepared to secure and protect current working areas and personnel from flood releases. The Contractor’s on-site superintendent will be notified of gate changes by the Government. Phone and/or voice mail notification will be made when Government personnel are unable to contact the superintendent in person.

PART 3 EXECUTION

3.1 TRUNNION ANCHORAGE AND TRUNNION ASSEMBLY WORK

3.1.1 Removal of Rust and Debris between Anchor Beams and Concrete Piers

Before blasting, all loose laminated rust, pack rust, scaled rust, debris, and sealant shall be removed from the anchor beams. Removal shall extend 24” inside the face of the concrete piers. The Contractor’s method and equipment for removal shall be submitted to the Contracting Officer for approval. The Contractor shall provide 24 hours notice before any painting begins to allow the Government to inspect the anchor beams after blasting and before painting.

3.1.2 Blasting and Painting

The Contractor shall blast and paint each trunnion anchorage and assembly in accordance with the base MATOC specification Section 09 97 02 Painting of Hydraulic Steel and Cast Iron Structures, Including Removal of Lead Paint.

Paint for all structures shall be System No. 5-E-Z. Each subsequent coat of paint shall completely hide previous coat. Blasting and painting of the trunnion assemblies shall extend from the extreme downstream end of the trunnion assembly, along the tainter gate strut arms to a point 3 feet past the centerline of the trunnion pin. Using specialized equipment and/or nozzles, the Contractor shall blast and paint the anchor beams 24” inside the face of the concrete piers. Where the openings are too narrow to reach the full 24”, a lesser depth will be allowed upon approval of the Contracting Officer.

3.2 GREASING TRUNNION ASSEMBLIES

The Contractor shall grease the trunnion assemblies. Grease shall be Texaco Starplex 2 or equal. The assembly shall be greased before Contractor is allowed to start work on the other trunnion anchorage. Trunnion assemblies should be greased during a full cycle of gate operation to ensure that the grease is evenly distributed.

3.3 PROTECTION OF GOVERNMENT PROPERTY

In addition to all requirements to protect Government property in the base MATOC specifications, Contract Clauses, and Special Contract Requirements, the Contractor shall take particular care to protect the tainter gate hoist operating machinery assemblies and trunnion assemblies, which are highly susceptible to damage by dust, blast media, and debris. The contractor shall not drill holes or otherwise alter or deface any existing structure including the bridge, trunnion anchorages, trunnion assemblies, tainter gates, piers, bullnoses, weirs, catwalks, or equipment decks unless requested in writing with proposed repair methods and approved in writing by the Contracting Officer. Scaffolding, work platforms, hoists, chain falls, or other equipment shall not be attached to catwalks or equipment decks unless requested in writing with attachment details and calculations showing the catwalks or equipment decks are capable of supporting the proposed loads and approved in writing by the Contracting Officer.

3.4 CRANE PLACEMENT AND BRIDGE LOADING

The Contractor shall furnish the crane necessary to perform the work. The bridge has been analyzed for the use of a Link-Belt HTC-8670LB crane. The results of the analysis are in the “Fall River Lake, Fall River, Kansas;

Spillway Bridge Evaluation, Link-Belt Crane” report dated June 2002. A copy of the report will be provided to the Contractor. The analysis specifies crane placement and load limits to safely set the bulkhead and for other operations. The HTC-8670LB can only be used in accordance with the directions specified in the report. If the contractor plans on using any other crane on the bridge, he must first analyze the bridge for that crane’s planned operation. The Contractor must submit to the Contracting Officer for approval, the analysis and an operation plan showing the size and type of crane, where and how it will be operated and how the outriggers will be placed. Depending upon the weight, boom, and placement of the outriggers, the bridge may not support some heavy crane operations. In addition, if the contractor plans on using a crane near the training walls of the spillway he must first analyze if the walls can withstand the crane loads and submit his analysis and operation plan for approval.

3.5 BULKHEAD

There is no bulkhead or stoplog available.

3.6 BRIDGE CLOSURE

If bridge closure is necessary, 7 days’ public notice and adequate signage will be required. Coordinate the bridge closure through the Contracting Officer.

3.7 HATCH COVER SEALANT

Hatch cover sealant is a One Part, Semi-Self Leveling Joint Sealant (Revere X JTtm Joint Sealant or approved equal).

3.8 CLEAN UP

After completion of construction, the Contractor shall clean all Contractor-generated blast media and construction debris from all gates, weirs, bridge, catwalk, machinery, decks, and assemblies, and all other Government property.

The Contractor shall properly dispose of all construction debris and waste materials off-site.

3.9 SUBMITTALS

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

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

SD-01 Preconstruction Submittals

Detailed Work Plan; G

A detailed work plan shall be submitted. The plan shall include details for the following:

a. Sandblast, prepare for painting, and painting,

b. Methods for removal, containment, and disposal of blast media and paint containing lead,

c. Babbitt repair

All submittals shall be in accordance with specification Section 01 33 00 SUBMITTAL PROCEDURES and Section 01 45 02 Quality Control System (QCS).

Items shall be submitted and numbered under the technical specification section to which the materials and equipment apply and these numbers shall properly interface with WinRMS and QCS.

(END OF SECTION 01 00 00)

SECTION 01 27 00

MEASUREMENT AND PAYMENT FOR INITIAL TASK ORDER

PAINT TAINTER GATE #1 AT

Work referenced in the bid items is covered under the general MATOC technical provisions.

All costs for items of work, which are not specifically mentioned to be included in a particular unit price shall be included in the listed unit price item most closely associated with the work involved.

Payment for the items listed below shall constitute full compensation for furnishing all plant, labor, materials, and equipment, and performing any associated Contractor quality control, environmental protection, meeting safety requirements, tests and reports, and for performing all work required for which separate payment is not otherwise provided.

BID ITEM 1 SANDBLAST AND PAINT UPSTREAM SIDE OF TAINTER GATE #1

MEASUREMENT

No separate measurement will be made for the cleaning or painting of the upstream side of the tainter gate.

PAYMENT

Payment for removal of existing paint system, sandblasting and applying 4 coats of vinyl paint to the upstream surface of tainter gate #1 including repairing any corroded areas on the surfaces, will be made at the contract price for bid item, "Sandblast and paint upstream side of tainter gate #1".

Price and payment shall constitute full compensation for materials, labor, plant, equipment and incidentals required for blasting, cleaning and painting the surfaces as specified.

BID ITEM 2 SANDBLAST AND PAINT DOWNSTREAM SIDE OF TAINTER GATE #1

MEASUREMENT

No separate measurement will be made for the cleaning or painting of the downstream side of tainter gate #1.

PAYMENT

Payment for removal of existing paint system, blast-cleaning and applying 4 coats of vinyl paint to the downstream surface of tainter gate #1 including gate ribs, girders, bracing, trunnion girders, tie-back beams, strut arms and thrust girders; and repairing any corroded areas on the surfaces and either pre-sandblasting or re-sandblasting and applying up to the first coat in the repaired areas will be made at the contract price for bid item, "Sandblast and paint downstream side of tainter gate #1". Price and payment shall constitute full compensation for materials, labor, plant, equipment and incidentals required for blasting, cleaning and painting the surfaces as specified.

Either pre-sandblasting or the re-sandblasting and applying up to the first coat in the repaired areas are to be included in the bid item for sandblasting and painting the downstream surface of Tainter Gate #1

BID ITEM 3 REMOVE AND REPLACE SIDE SEAL ASSEMBLIES ON TAINTER GATE #1

MEASUREMENT

No separate measurement will be made for removing and replacing side seal assemblies on tainter gate #1.

PAYMENT

Removing, preparing, furnishing, installing and adjusting of side seal assemblies and filler material, if required, will be made at the contract lump sum price for bid item "Remove and replace side seal assemblies on tainter gate #1". This work shall include removing and installing new rubber seals, neoprene gaskets, stainless steel bolts, nuts and washers, with plastic sleeves or other suitable material to isolate the bolting assembly from the gate metal, and replacing seals, bolts, nuts, washers, screws, retainer and spacer bars, and appurtenant items. Seal holes in the bottom corners of the gates with rubber wedges, Devcon’s Plastic Steel Liquid B, and roof cement or approved equal. This item shall include all material and hardware required for complete installation of side seal assemblies. Price and payment shall constitute full compensation for materials, labor, equipment and incidentals required to complete the work as specified and shown on the drawings.

BID ITEM 4 REPAIR BABBITT ON TAINTER GATE #1

MEASUREMENT

No separate measurement will be made for repairing babbitt on tainter gate #1.

PAYMENT

Repairing the babbitt on tainter gate #1 will be made at the contract lump sum price for bid item "Repair babbitt on tainter gate #1". This shall include all work necessary to repair babbitt on the gate sill, and repair of the gate bottom to ensure the gate bottom is straight and even to provide a flush watertight seal between babbitt and the gate. Price and payment shall constitute full compensation for materials, labor, equipment and incidentals required to complete the work as specified and shown on the drawings.

PART 3 EXECUTION (NOT USED)

October 2008October 2008

FALL RIVERFALL RIVER

TAINTER GATETAINTER GATE

STRUCTURAL STRUCTURAL

INSPECTION REPORTINSPECTION REPORT

TABLE OF CONTENTS

1. Introduction

2. Tainter Gates

3. Methods of Inspection

4. Findings

5. Conclusions

6. Recommendations

Inclusions

Appendix 1.......................................................................................................................................................... Photographs Appendix 2......................................................Table of Significant Findings and Recommended Actions Appendix 3........................................................................................................................................................ As-built Plans

FALL RIVER TAINTER GATE STRUCTURAL INSPECTION REPORT

1. Introduction. The tainter gates at Fall River Dam, Kansas were inspected on 7-8 Oc-tober 2008. The inspections were done in accordance with EM 1110-2-6054 Structural Inspection, Evaluation and Repair of Hydraulic Steel Structures, December 2001. This EM requires that all critical members of the spillway gates be inspected close enough to be able touch them. The critical areas that would receive the most attention during the inspection were determined before the inspection. General and specific recommendations for properly maintaining these gates are included in Appendix 2 of this report. The inspectors were Mark McVay and Chuck Miles from Dam Safety / Geotechnical Engineering Section, Engineering and Construction Division. Messrs Gale Puckett, James Keath and Terry Harrell from Fall River Lake Office assisted the inspectors by providing access to the gates, operating the gates and manning the safety ropes.

2. Tainter Gates. The Fall River Dam has eight tainter gates each 50 feet wide by 25 feet tall, see Photos 1 and 2 in Appendix 1. Plates 1 and 5 in Appendix 3 are as-built plans of the tainter gates. They consist of a skin plate supported by 23 T- ribs, two horizontal girders, and two strut arms on each side of the gate. The strut arms come together at the trunnions that bear against the steel trunnion girders that are anchored into the piers with steel tie-back beams. The girders and strut arms are braced with intermediate members.

The gates are raised and lowered with hoist driven chains.

3. Methods of Inspection. The lake level was below the weir at the time of the inspec-tion so the upstream sides of the gates could be inspected without de-watering them, see Photo 2. The upstream sides of the gates were accessed by climbing down to the weirs on the downstream sides, raising the gates 3 feet, and crawling under them. The downstream sides of the gates were inspected by climbing on the downstream members with fall protection gear, see Photo 3. The fall protection gear consisted of a body har-ness, lanyard, rope grab, 5/8-inch nylon rope 100’ long, carabiners, cinchers, and 5/16-inch steel cable 60’ long. The steel cable was attached to the hoist machinery at each pier with chokers and suspended above the top of each gate. The nylon rope was attached to the steel cable by a carabineer which slid along the cable. The rope grab attached around the nylon safety rope and only allowed upward motion unless over ridden. The lanyard connected the body harness to the rope grab. The other end of the nylon rope was held secure by lake personnel sitting on a trunnion girder. This method allowed the inspector to visually inspect and photograph all of the critical parts of the downstream sides. Figures 1 to 3 were used during the inspection to note findings and identify the location of photo-graphs taken during the inspection. Critical areas were identified and noted on these fig-ures with a “C” on the drawings. For this report the struts and girders will be referred to as top and bottom. Reference to the right and left sides of the gate are as if you were fac-ing downstream. A grid of general location names related to the member type and a num-ber counting from one end to the other is shown on the figures for reference. For exam-ple, TG1 is at the top girder’s right end and LB9 is at the left bottom strut arm’s end at the girder. All portions of the gates were inspected for corrosion, deformation, and cracks; the critical areas were examined with the greatest care.

4. Findings. In general, the tainter gates themselves are in good overall condition.

However, there are rust stains coming out of cracks at the tie-back beam level of the piers and out of the tie-back beam cavities where the beams exit the piers. It is hard to tell what the extent of the corrosion has been inside of the piers. In addition, it appears that pack rust has formed between gate members with open joints and some significant rust spots were found in critical locations on the gates that could lead to serious metal loss if left to continue rusting. All of the significant findings and specific recommended actions for each gate are listed in Appendix 2.

The upstream sides of the gates are in good overall condition, see Photo 4. The areas near the chains and along the bottom 3 feet have a few small rust spots and paint blisters, see Photo 5. The hitches are a little rusty and but the chains are still in good condition and well greased, see Photo 6. Recommend continuing to apply lubricant on the chains a least once a year.

FIGURE 1. Critical locations on the downstream sides of tainter gates at Fall River Dam.

FIGURE 2. Critical locations on a tainter gates’ right strut arms at Fall River Dam.

FIGURE 3. Critical locations on a tainter gates’ left strut arms at Fall River Dam.

The downstream sides of the tainter gates are in fair to good overall condition, Photo 7.

Typical conditions of various parts of the downstream sides of the gates are shown in Pho-tos 7 to 34. The paint is getting old and rust is showing through the paint in places (Photos 9, 11, 14, 16-17), but the gates have been spot painted off and on to keep them in good overall condition. The last spot painting on the gates was done in 2004. It ap-pears that pack rust has formed between gate members with open joints and some signifi-cant rust spots were found in critical locations on the gates that could lead to serious metal loss if left to continue rusting. The pack rust between strut arm members is the most wor-risome, see Photos 22-23, 33, 39, 44, 47, and 51. Many of the strut arm braces are at-tached on just two sides leaving open joints to suck in water. A stiffener plate on the brace at RB5 on Gate 7 has a cracked weld due to the pack rust expansion, Photo 47.

Recommend sealing the open sides of the connections within the next year. A few signifi-cant rust spots are in critical places where drains were clogged or dirt held moisture on members. Some of those locations are the girder brace attachments at locations BG3 (Photo 12), BG5, and BG7. Originally the drain holes in the tips of the braces were too small and easily clogged when debris got trapped in the pockets like in Photo 13. The tips of the braces were cutoff several years ago to widen the drain holes but the torch cut a few gouges in the flanges of some girders, see Photos 35-36, 42, and 48. Some of the pockets behind the braces held water too long and formed scaled rust in them like in Pho-tos 40 and 41. Some of these locations have suffered significant metal loss. These are critical locations that should be kept free of debris and the rusty ones spot painted within the next 5 years. Other locations of concern are at RT1, LT1, RB8-9 and LB8-9 that are low points on the strut arms. Debris washes down to these locations, clogs the drains, holds water there that causes rust, see Photos 20, 24, 39, and 51. These are critical loca-tions that should be kept free of debris and spot painted within the next 5 years. At loca-tions BG1 and BG9 on top of many x-brace junctures and next to the end ribs in the corner where birds like to nest and it causes these spots to rust, see Photos 14-15 and 38. The members near most bottom corners of the gates have worn paint and some rust. In addi-tion the undersides of the bottom beams on every gate are rusty, see Photo 16. The bab-bitt sills in the weirs have dents in them from the gates closing on debris. Whenever the gates are rehabilitated the babbitt seals should also be rehabilitated.

Rust stains coming out of cracks in the piers at the same level as the tie-back beams (Photos 16 and 29) and laminated rust on the tie-back beams where they exit the piers were reported several inspections ago. The first 12” of the tie-back beams just inside of the piers were cleaned and spot painted in 2000 to stop the laminated rust. However, some of the tie-back beams had already lost significant metal (Photos 26, 31, and 43).

The Tulsa District hired ERDC in 2005 to develop a method to determine if the tie-back beams have lost significant cross section inside of the piers due to rust. On 18 June 2005, inspectors on 24-hour flood watch first noticed water flowing out of some of the tie-back beam cavities on the back the piers. This raised concerns that the flood waters could be causing the tie-back beams to rust inside the piers. Possible points of entry into the tie-back beam cavities for the flood waters is the cold joints along the rub plates in the sides of the piers. ERDC installed gages on the tie-back beams for Gate 4 in September 2005 to measure strains and elongations during high pools (Photo 30). ERDC has been collecting data over the past three years. The lake levels did not raise up against the gates in 2006, there were equipment problems during part of 2007, but there were several high pools during the rest of 2007 and in 2008. ERDC is currently analyzing the data to determine if the tie-back beams are still in good condition and plan on submitting a report later this fis-cal year. In addition, pack rust may have formed between the left tie-back beams and the gage mounts on top of them, see Photos 25 and 27-28. Recommend sealing around these mounts to prevent any additional moisture from being drawn underneath them within the next 5 years.

The trunnion girder webs are starting to get rusty again, see Photos 24, 28, and 34. Rec-ommend tool cleaning and spot painting with funds are available.

5. Conclusions. Fall River’s tainter gates themselves are in fair to good overall condition.

However, there are rust stains coming out of cracks at the tie-back beam level of the piers and out of the tie-back beam cavities where the beams exit the piers. It is hard to tell what the extent of the corrosion has been inside of the piers. In addition, it appears that pack rust has formed between gate members with open joints and some significant rust spots were found in critical locations on the gates that could lead to serious metal loss if left to continue rusting. Sealing of open joints and continued spot painting of the gates will prevent the significant rust spots from becoming serious.

6. Recommendations. Recommend the following actions:

a. Accomplish the items in the Appendix 2 tables with priority (1) as soon as possi-ble. These include sealing all open joints, cleaning out the pockets behind all of the bot-tom girder brace points, and frequently lubricating the trunnion pins and chains.

b. Accomplish within the next 5 years the items in the Appendix 2 tables with pri-ority (2). Most of these items are to seal around the gage mounts on the left tie-back beams; seal all possible entry points for water to seep into the tie-back beam cavities;

clean, wire brush and spot clean light rust spots at critical locations or moderate rust spots at non-critical locations.

c. Accomplish the items in the Appendix 2 tables with priority (3) with a contract as soon money is available. These are the items that should be done while the gate is be-ing completely rehabilitated and re-painted. They include replacing the chains and side seals, rehabilitating the babbitt sill in the weirs, and painting the trunnion girders.

APPENDIX 1

PHOTOGRAPHS

Photo 1. Downstream view of Fall River Dam’s spillway with 8 tainter gates.

Photo 3. Chuck Miles with safety equipment climbing on the down-stream side of a tainter gate.

Photo 2. Upstream of Fall River Dam’s spillway and tainter gates.

Appendix 1

Photo 4. The upstream side of Gate 5 is in good overall condition with just a few small rust spots near the bottom and is typical of most of the gates.

Appendix 1

Photo 5. Rust showing thru paint on skin plate of Gate 6, similar to some rust showing on other gates.

Photo 6. Left chain & hitch on Gate 7 is rusty & is typical of most gates chains.

Photo 7. The downstream side of Gate 7 is in fair to good overall condition with a some pack rust behind brace stiffeners, pits in bottom girder behind brace attachments, & rusty areas near the bottom corners.

Photo 8. Top Girder of Gate 1 in overall good condition is typical of all of the gates.

Photo 9. Light rust showing thru paint in the middle of the top girder of Gate 4, typical of most gates.

Photo 12. The tips of the braces connecting to the bottom girders (like these on Gate 8) were cut off & spot painted to improve drainage.

Photo 11. Rusty welds on upstream ends of bottom girder stiffeners on Gate 4, similar on all of the gates.

Photo 10. Bottom girder of Gate 8 in overall good condition with some dirt typical of most gates.

Photo 13. Pocket between brace & girder at BG5 on Gate 1 has been spot painted but is full debris.

Photo 16. Bottom of Gate 5 is rusty & the knife edge is un-even. Typical of most gates.

Photo 15. Juncture of X-brace between right ends of girders on Gate 7 with nest dirt & rust similar to all.

Photo 14. Left end of bottom girder on Gate 2 is full dirt & rusty in pockets, rusty on roller, & rusty end stiffener - typical corner.

Photo 17. Right bottom corner of Gate 1 has surface rust & debris & is similar to other corners.

Photo 18. Right strut arm of Gate 8 is typical of most strut arms.

Photo 20. Dirt accumulates at the lower ends of many strut arms, clogs the drain holes & moist con-ditions accelerate rust like this at RB8-9 on Gate 1.

Photo 19. Rust show thru paint on left strut arm of Gate 3, similar to many locations on other gates strut arms.

Photo 23. Pack rust bending stiffener plate on brace at LB5 on Gate 3. Similar to many brace plates.

Photo 22. Open joint between braces & bottom strut at location RB2-4 on Gate 7.

Photo 21. RB1 on Gate 6 dirty from nests & rusty is similar to other RB1 & LB1 spots.

Photo 24. Location RT1 on Gate 2 has surface rust & is similar to others.

Photo 25. Spot paint around the right tie-back beam exit at Pier 3, similar to most tie-back beams.

Photo 27. Pack rust between gage mount & tie-back beam at Pier 5.

Photo 26. Metal loss in side of tie-back beam at Pier 8 from past corrosion.

Photo 28. Rusty trunnion girder web on Pier 6 where rain water has stood.

Photo 30. ERDC instrumentation on Gate 4 to measure stretching of tie-back beam relative to lake loads on the gate.

Photo 29. Rust stains coming out a crack in Pier 5 at the same level as the bottom of the tie-back beam.

Photo 35. Gouge in the bottom girder flange at BG3 on Gate 3 where brace end was cut off to drain.

Photo 36. Gouge in the bottom girder flange at BG5 on Gate 3 where brace end was cut off to drain.

Photo 34. Rusty left trunnion girder top of Gate 2. Photo 33. Open joint that could allow pack rust be-tween brace and strut at LB8 on Gate 2.

Photo 31. Pits in the web of the tie-back beam in Pier 1 caused by rust before spot painting.

Photo 32. Rust stains coming out a crack at same level as tie-back beam in Pier 1.

Photo 41. Scaled rust between the brace & bottom girder flange at BG4.9 on Gate 5 where pocket re-mained clogged.

Photo 42. Gouge in bottom girder flange at BG3 on Gate 5 where tip of brace was cut off.

Photo 40. Scaled rust between the brace & bottom girder flange at BG5.1 on Gate 5 where pocket re-mained clogged.

Photo 39. Standing water at RB8-9 on Gate 4 where drain holes are clogged.

Photo 37. Scaled rust at RB1 of Gate 3. Photo 38. Rusty at BG9 on Gate 4 where debris hin-dered drainage.

Photo 47. Pack rust caused cracked weld connecting stiffener plate to brace at RB5 on Gate 7.

Photo 48. Gouge in the bottom girder flange at BG5.1 on Gate 7 where brace end was cut off to drain.

Photo 46. Spot paint over scaled rust in the tie-back beam in Pier 7.

Photo 45. Pack rust under the gage mount for Gate 7.

Photo 43. Pits in the web of the tie-back beam in Pier 6 caused by rust before spot painting.

Photo 44. Open joints that could be allowing pack rust to form between the braces & strut arm at RB5-7 on Gate 6.

Photo 49. Pits in the web of the tie-back beam in Pier 8 caused by rust before spot painting.

Photo 50. Rusty at RB7-8 on Gate 8 where paint has pealed off.

Photo 51. Dirt clogging drain hole at RB8-9 on Gate 8.

APPENDIX 2

TABLE OF SIGNIFICANT FINDINGS

AND RECOMMENDED ACTIONS

Appendix 2

FALL RIVER TAINTER GATE NO. 1

TABLE OF SIGNIFICANT FINDINGS & RECOMMENDED ACTIONS

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