W912BV18R0038_Amendment_01.pdf

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

Birch Lake Rehabilitate and Repair Service and Emergency Gates, Barnsdall, OK.

See attached summary of changes for revisions located in Amendment 01. Amendment 01 includes site visit information. Proposal due date and time shall remain unchanged.

All other terms and conditions shall remain unchanged.

1. CONTRACT ID CODE PAGE OF PAGES

J 1 2

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 W912BV18R0038

X 9B. DATED (SEE ITEM 11)

17-Jul-2018

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 is extended, X 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 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 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)

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

25-Jul-2018

CODE

CONTRACTING DIV

US ARMY CORPS OF ENGINEERS, TULSA DISTRICT

2488 E. 81ST STREET

TULSA OK 74137-4290

W912BV 7. ADMINISTERED BY (If other than item 6)

4. REQUISITION/PURCHASE REQ. NO.

CODE

See Item 6

FACILITY CODECODE

EMAIL:TEL:

W912BV18R0038

SECTION SF 30 BLOCK 14 CONTINUATION PAGE

SUMMARY OF CHANGES

BIRCH LAKE REHABILITATE AND REPAIR SERVICE GATES, BARNSDALL, OK.

AMENDMENT 0001

DELETE CLAUSE 52.236-27 SITE VISIT (CONSTRUCTION) (FEB 1995) – ALTERNATE 1 (FEB 1995) and REPLACE with the following:

52.236-27 SITE VISIT (CONSTRUCTION) (FEB 1995) – ALTERNATE I (FEB 1995)

(a) The clauses at 52.236-2, Differing Site Conditions, and 52.236-3, Site Investigations and Conditions Affecting the Work, will be included in any contract awarded as a result of this solicitation. Accordingly, offerors or quoters are urged and expected to inspect the site where the work will be performed.

(b) An organized site visit has been scheduled for-- Thursday August 2, 2018 at 10:00 a.m. CST.

(c) Participants will meet at the Birch Project Office. The Birch Project Office is just south of Barnsdall, Oklahoma. Take Highway 11 into Barnsdall and turn West on W. Chestnut Ave. Then turn left on 8th street and the office will be on your left prior to the dam. Should you have any questions concerning directions to the Birch Project Office, contact Mr. Lee Perry 918-396-3170. All interested offerors are urged to attend. During this site visit, the requirements set forth in the solicitation will be reviewed and discussed, with part of the site visit to include a question and answer period.

(End of provision)

Those offerors wishing to attend MUST submit in writing, via email, the firm’s name, address, point of contact, telephone number, email address and number of personnel planning to attend no later than July 31, 2018 at 2:00 p.m CST to:

Daniel Foyil Email: daniel.a.foyil@usace.army.mil

DELETE SECTION 02 83 13 Lead Paint of the RFP in its entirety and replace with the attached SECTION 02 83 13 Lead Paint.

(End of Summary of Changes)

Birch Dam Rehab and Repair Service and Emergency Gates

W912BV18R0038

SECTION 02 83 13

LEAD PAINT

PART 1 GENERAL

1.1 EXISTING ITEMS CONTAINING LEAD PAINT

Paint samples were collected from various items by Government personnel in February 2018 and tested for lead. See the following memorandum attached to the end of this section for lead paint test results:

21 February 2018, Subject: Sampling Results (Lead Paint), Birch Lake

PART 2 PRODUCTS (NOT USED)

PART 3 EXECUTION

3.1 REMOVAL AND DISPOSAL OF ITEMS CONTAINING LEAD PAINT

Submit lead containment and waste disposal plans in accordance with Section 09 97 02 - Painting: Hydraulic Structures. Do not begin removal or disposal of items containing lead paint until the plans have been approved by the Contracting Officer. Remove, contain, and dispose of lead containing items and lead paint residue in accordance with all Federal, State, and local laws and regulations and the approved plans.

-- End of Section --

SECTION 02 83 13 Page 1

CESWT-SO 21 February 2018

MEMORANDUM FOR LAKE MANAGER, BIRCH LAKE

SUBJECT: Sampling Results (Lead Paint), Birch Lake

1. Lead paint samples were collected at Birch Lake on 13 February 2018 by Greg Snider and

David Ford from the Safety and Occupational Health Office. Samples were sent via Federal

Express to QuanTEM Laboratories for analysis using standard chain of custody protocol.

Samples were analyzed using P EPA 7000B method.

2. Sampling results are summarized below. Detailed laboratory analytical results are included in

Enclosure 1.

ID Sample Location / Description Results

LEG-OS Left Emergency Gate, Operator Stand 17,100 ppm

1.71 %

REG-OS Right Emergency Gate, Operator Stand 2,690 ppm

0.269 %

LSG-OS Left Service Gate, Operator Stand 17,600 ppm

1.76 %

RSG-OS Right Service Gate, Operator Stand 6,470 ppm

0.647 %

LEG-SB Left Emergency Gate, Support Beam 124,000 ppm

12.4 %

REG-SB Right Emergency Gate, Support Beam 121,000 ppm

12.1 %

LSG-SB Left Service Gate, Support Beam 72,800 ppm

7.28 %

RSG-SB Right Service Gate, Support Beam 144,000 ppm

14.4 %

LINERLEFT Left Conduit Liner 234 ppm

0.0234 %

LINERRIGHT Right Conduit Liner <49.9 ppm below detection limit

LEG Left Emergency Gate <49.3 ppm below detection limit

REG Right Emergency Gate <49.6 ppm below detection limit

LSG Left Service Gate <49.8 ppm below detection limit

RSG Right Service Gate <48.9 ppm below detection limit

BULKHEAD Bulkhead <49.9 ppm below detection limit

LIFTBEAM Lifting Beam 133 ppm

0.0133 %

LF LINER Low Flow Conduit Liner Could not be sampled. Excessive leakage prevented access to collect sample.

CESWT-SO

SUBJECT: Sampling Results (Lead Paint), Birch Lake

3. Please add these results to your project files and incorporate these results into future work planning and contract actions. Please post the attached lead warning sign within the gate tower and inform all personnel to the presence of lead based paint within the facility.

4. If you have any questions or need additional information or assistance, please contact Greg

Snider at (918) 669-4969, greg.snider@usace.army.mil.

2 Encls MIKE KERR

Chief, Safety and Occupational

Health Office

CF:

Northern Area OPM

Robert Goranson

Acct. No.:

Project: Birch Outlet Works

Location:

Project No.:

QuanTEM Set ID: 290881

Date Received: 02/15/18

Received By: Katie Davis

Date Sampled:

Time Sampled:

Date of Report: 02/20/18

B603

N/A

N/A

Matrix Parameter Results Units MethodClient ID

QuanTEM

ID

Reporting

Limits

Date/Time

Analyzed

Environmental Chemistry Analysis Report

Client: U.S. Army Corp of Engineers-Tulsa

1645 S. 101 E. Ave.

Tulsa, OK 74128-4629

Analyst: CR

AIHA ID: 101352

Lead 17,100 48.8 ppm 02/20/18 15:02 P EPA 7000B (1)PaintLEG-OS001

Lead 2,690 50 ppm 02/20/18 15:02 P EPA 7000B (1)PaintREG-OS002

Lead 17,600 48.8 ppm 02/20/18 15:02 P EPA 7000B (1)PaintLSG-OS003

Lead 6,470 49.3 ppm 02/20/18 15:02 P EPA 7000B (1)PaintRSG-OS004

Lead 124,000 49.8 ppm 02/20/18 15:02 P EPA 7000B (1)PaintLEG-SB005

Lead 121,000 50 ppm 02/20/18 15:02 P EPA 7000B (1)PaintREG-SB006

Lead 72,800 49.2 ppm 02/20/18 15:02 P EPA 7000B (1)PaintLSG-SB007

Lead 144,000 49 ppm 02/20/18 15:02 P EPA 7000B (1)PaintRSG-SB008

Lead 234 49.9 ppm 02/20/18 15:02 P EPA 7000B (1)PaintLINERLEFT009

Lead <49.9 49.9 ppm 02/20/18 15:02 P EPA 7000B (1)PaintLINERRIGH

T

Lead <49.3 49.3 ppm 02/20/18 15:02 P EPA 7000B (1)PaintLEG011

Lead <49.6 49.6 ppm 02/20/18 15:02 P EPA 7000B (1)PaintREG012

Lead <49.8 49.8 ppm 02/20/18 15:02 P EPA 7000B (1)PaintLSG013

Lead <48.9 48.9 ppm 02/20/18 15:02 P EPA 7000B (1)PaintRSG014

Lead <49.9 49.9 ppm 02/20/18 15:02 P EPA 7000B (1)PaintBULKHEAD015

Lead 133 49.3 ppm 02/20/18 15:02 P EPA 7000B (1)PaintLIFTBEAM016

Note: Sample results have not been corrected for blank values.

This report applies only to the standards or procedures indicated and to the specific samples tested. It is not indicative of the qualities of apparently identical or similar products or procedures, nor does it represent an ongoing assurance program unless so noted. These reports are for the exclusive use of the client and are not to be reproduced without specific written permission. QuanTEM is not responsible for user-supplied data used in calculations.

Unless otherwise noted, upon receipt the condition of the sample was acceptable for analysis.

Wipe materials must meet ASTM E1792 criteria. Method detection limits and resultant reporting limits may not be valid for non-ASTM E1792 wipe material.

EPA Method 7000B (1) = EPA 600/R-93/200 Preparation Modified. EPA 7000B Analysis Modified

EPA Method 7082 (2) = EPA 600/R-93/200 Preparation Modified. EPA 7082 Analysis Modified

Acct. No.:

Project: Birch Outlet Works

Location:

Project No.:

QuanTEM Set ID: 290881

Date Received: 02/15/18

Received By: Katie Davis

Date Sampled:

Time Sampled:

Date of Report: 02/20/18

B603

N/A

N/A

Matrix Parameter Results Units MethodClient ID

QuanTEM

ID

Reporting

Limits

Date/Time

Analyzed

Environmental Chemistry Analysis Report

Client: U.S. Army Corp of Engineers-Tulsa

1645 S. 101 E. Ave.

Tulsa, OK 74128-4629

Analyst: CR

AIHA ID: 101352

Authorized Signature:_______________________________________________

Cherry Rossen, Technical Manager

Note: Sample results have not been corrected for blank values.

This report applies only to the standards or procedures indicated and to the specific samples tested. It is not indicative of the qualities of apparently identical or similar products or procedures, nor does it represent an ongoing assurance program unless so noted. These reports are for the exclusive use of the client and are not to be reproduced without specific written permission. QuanTEM is not responsible for user-supplied data used in calculations.

Unless otherwise noted, upon receipt the condition of the sample was acceptable for analysis.

Wipe materials must meet ASTM E1792 criteria. Method detection limits and resultant reporting limits may not be valid for non-ASTM E1792 wipe material.

EPA Method 7000B (1) = EPA 600/R-93/200 Preparation Modified. EPA 7000B Analysis Modified

EPA Method 7082 (2) = EPA 600/R-93/200 Preparation Modified. EPA 7082 Analysis Modified

Supplemental Report

QAQC Results

QA ID: 16042 Date: 2/20/2018

Test: Lead

Notes:

Matrix: Paint Approved By: Cherry Rossen

Date Approved: 2/20/2018

Blank Data:

Duplicate Data:

Recovery Data:

Standards Data:

Lab Number: 290881

Type of Blank Blank Value

0FCB

0ICB

0Matrix Blank

0Matrix Blank

Sample Number Result Duplicate % RPD

0.0160.015 6.6290942-001

Sample Number Result Spike Level Result +

Spike

Dup. Result +

Spike

% Spike RPD% Recovery % Dup.

Recovery

2.002 2.0030.000 2.191100.0 109.4 9.0LCS-P1

1.962 2.1240.000 2.082108.3 106.1 2.0LCS-P2

2.000 1.9100.015 94.8290942-001

Standard Low Limit Obtained High Limit

4.5 5.54.7CCV

4.5 5.54.8FCV

0.9 1.11.1ICV

0.05 0.150.11RLVS

Authorized Signature:_______________________________________________

Cherry Rossen, Technical Manager

WARNING

LEAD BASED PAINT AND DUST PRESENT

DO NOT EAT, DRINK, OR SMOKE IN THIS AREA

Maintain diligent personal hygiene practices. Thoroughly wash hands and exposed skin, with soap and water or wet wipes when leaving the work area or prior to hand to mouth activities.

Emergency Gate Repairs 2010 Page 1 Birch Lake

REPORT OF EMERGENCY AND SERVICE GATE REPAIRS

Birch Lake, Oklahoma

28 June – 21 October 2010

1. References.

a. Report of Gate Operational Capability Inspection, Birch Service Gates & Low Flow Gate, Birch Lake, Oklahoma, November 9, 10, & 17, 2009.

b. Repair Service & Emergency Gates and Perform Miscellaneous Gate Tower Repairs, FY10 Scope of Work.

2. Personnel Involved in Repairs.

Dennis Duke Project Manager (Chloride Control) CEWST-OD-TT Weldon Smith Civil Engineering Tech CEWST-OD-TT Chad Rainwater Civil Engineering Tech CEWST-OD-TT Anthony Burson Mechanical Engineer CEWST-OD-T Richard McCanlies Civil Engineering Tech CEWST-OD-TT Preston Hunter Lake Manager CEWST-OD-NS Jim Riley Facility Maintenance Worker CEWST-OD-NS Malcolm Hendricks Facility Maintenance Worker CEWST-OD-NS Mike Kerr Industrial Hygienist CESWT-SO Greg Snider Industrial Hygienist CESWT-SO Lance Perdue Supervisory Electronics Technician CESWT-OD-TH David Ford District Electrician CESWT-OD-TH Jeff Waldie Field Engineer CEWST-OD-T Stephen Chapman Civil Engineer CESWT-OD-T Mark McVay Structural Engineer CEWST-EC-DD

3. History. On 9 & 10 November 2009 a gate operability and capability inspection was held that revealed a gate deficiency. During operation of service gate 1 through its full range of travel the District electricians noted very high motor amperage readings. Despite the deficiency, service gate 1 successfully traveled from full close to full open position.

However during closure, service gate 1 seized up and would only operate for brief travels and then seize once again. Investigation into the problem revealed the stem guides were displaced and not in proper alignment with the 79 ft long gate stem. As a result, the gate stem was rubbing against the guides and developing a high level of friction. Additional investigation revealed all four gates at the project (two service, two emergency) were all in similar condition. An inoperable gate on a flood control structure quickly became an emergency situation and required immediate attention. A scope of work for contract was created, but due to budget restraints and high cost estimates, contracting this project was not an option. The decision was made to use an in-house project delivery team, the Truscott Team, led by Dennis Duke. They were chosen for their experience and expertise in piping and construction.

Emergency Gate Repairs 2010 Page 2 Birch Lake

4. Description. The gate tower at Birch Lake consists of one overhead crane, one bulkhead, four (3.75 ft by 8.5 ft) slide gates, and one low-flow slide gate. As indicated in the previous paragraph, two of the four gates serve as primary (service) gates, the other two are emergency gates. Each gate has its own EIM Operator, including an electric motor that spins a drive nut raising or lowering the attached gate stem power screw. Below the operator is the stem that attaches to the gate. The stem is made up of five sections. The first section is the power screw section that feeds through the operator. This is connected to the next section by a 6” 400 lb. flange. The second section is 17’ 2” schedule 80 pipe and connected on both ends with a 6” 400 lb slip-on flange. The same flange is used to connect the next two stem sections, both are 18’ 6” schedule 80 pipe. The fifth stem section is 10’ 8” long and is connected to the gate. When the gate operator is activated, the gate slides vertically across soft metal seals, allowing for smooth gate operation. To insure proper stem alignment during operation, each stem section is held against the wall by two stem guides. Each stem guide is made up of two pieces, front plate and back bracket. These two pieces are clamped around the stem by four 5/8” bolts. The guides are attached to the wall by four ¾” x 6” concrete wall anchors. As the gate is raised and lowered, the stem slides up and down through the guides, keeping the load purely vertical.

5. Repair Recommendations. The scope of work created for this repair stated:

“The contractor shall procure or manufacture a minimum of 4 each new stem guides (marked MK-H8 on attached shop drawings), 24 each new stem guides (MK-J8), an assortment of 50 shims ranging from No. 3 to No. 16 gauge in size (use MK-K8 as general template), 120 fluorocarbon coated (factory applied coating) bolts (and associated nuts and washers) to tighten the stem guide tubing together, 120 new fluorocarbon coated stainless steel anchor bolts (adhesive anchor type) for concrete attachment (MK-T8), and 200 fluorocarbon coated (factory applied coating) bolts and associated nuts and washers for connecting gate stem flanges together (MK-C8, MK-F8, and MK-G8) per the attached plans, shop drawings, and specifications. The contractor shall disassemble all four existing gate stem systems, clean each gate stem, re-verify tolerances per the attached shop drawings and re-assemble. The contractor is not required to remove the operator system (MK-G4) from the controller. If there is a deformation or tolerance not met with the gate stems, the contractor shall notify the Contracting Officer immediately before re-installation begins and receive guidance from the Contracting Officer. New stem guides, shims, connecting bolts, and anchor bolts shall be installed. The new anchor bolts must meet the strength requirements of the old anchor bolts as shown on the enclosed shop drawings. The number of metal shims installed per stem guide shall be kept to a minimum. No more than three shims per stem guide will be allowed.

Thicker shims to meet alignment needs are desired. The stem guides, shims, and gate stems marked MK-F8 and MK-G8 shall be painted at an offsite location as agreed upon by the Corps of Engineers and the contractor. All components shall be sand blasted to Near White Metal (SSPC-SP-10) and coat with Unified Facilities Guide Specification, System No. 5-E-Z (Primer, Vinyl Zinc Rich VZ-108D, 2nd coat Gray Vinyl V-766e, 3rd coat White Vinyl V- 766e, and 3rd coat Gray Vinyl 766e). Reference the attached specification 09 97 02, PAINTING: HYDRAULIC STRUCTURES. All paint will be applied using double spray coat application. No dry film thickness (DFT) reading will be less than 5.5 mils with a DFT surface average of 6 mils. The anchor bolts will also need a protective coating. The

Emergency Gate Repairs 2010 Page 3 Birch Lake contractor shall propose the coating method to the contracting officer for review and approval. Items that will not be painted or sandblasted include: a) Gate Stems MK-G4 and MK-A8 (cleaned and lubricated). b) Service and Emergency Gates. c) Manual/Electric Operators. d) Floor Grates / Covers at top of gate tower.”

6. Repair Procedures. After performing initial site visits, reviewing applicable documentation, and interviewing project personnel, the repair process was initiated. A list of equipment used for this repair is included in Enclosure 1. Repair photos are located in Enclosure 2.

a. Step 1 - Remove existing stems and guides.

1). Man Basket Entry Man baskets were lowered into the service and emergency gate slots (chambers) to disassemble and remove existing stems and guides. The cover to the gate slots had to be removed which created a safety hazard. This hazard was minimized by fabricating a guard rail around the exposed gate slot, with approval of safety office. The man baskets were attached to the overhead crane beam using beam clamps supplied by the basket rental company. Safety life lines were also attached to the beam using beam clamps, supplied by safety office. One basket was used on each side of the operator. The operator control box limited the space needed to drop a basket into that side, and therefore both baskets had to be dropped into the gate slot through the same side. One basket was moved over to the other side.

2). Gate Stem & Guide Removal.

The front plates on all the guides were then removed. Some bolts were corroded severely, preventing removal and reuse of bolts. These frozen bolts had to be cut using a cutting torch. The shims behind the back bracket of the guide were removed. The 7/8” stainless steel bolts used to hold the bottom flanges together were found to be very loose, and removed. One man basket was removed from the slot and the overhead crane was lowered and attached to the choker straps on the top section. All 7/8” bolts were removed and the crane was used to raise the entire stem out of the slot. Once the crane reached its upper limit switch, the bottom flange of the first stem section was blocked using 3” square tubing and then the crane was lowered allowing the stem to be supported by the blocks. All twelve 7/8” bolts were removed from the bottom flange of the first gate stem section and the crane was used to remove first section from the tower. Once close to the door, a small crane mounted on the back of a truck was used to support the other end. The truck slowly moved across the tower bridge pulling the stem to the trailer. The second gate stem section was longer but removed in a similar fashion.

However, the overhead crane’s upper limit switch did not allow the entire stem to clear the finished floor height. As a result, the flange had to be supported with drop blocks that extended into the slot by 8 inches and hung on the finished floor of the tower. The second and third stem sections were removed and loaded onto the trailer.

Emergency Gate Repairs 2010 Page 4 Birch Lake

3). Condition Assessment.

Original locations of all items removed were marked and noted. Back brackets were then removed either by unbolting from ¾” anchor bolts, or by cutting anchors flush with wall. A final assessment of anchor bolts was made to determine possibility of re-use. Structural engineers from the district office inspected the stems on the trailer and concluded that some of the stems needed to be completely replaced, and some were still in a good enough condition to be refurbished.

b. Step 2 - Rehabilitation of existing equipment.

All stems and guides were transported back to the Truscott Project for repairs. New Schedule 80 pipe, 6 inch 400 lb flanges, and two new guides were ordered. Hardware was inventoried and cleaned for re-use. Old stems were dropped off at Arrowhead Coating in Wichita Falls for sand blasting and coating. The coating used was a thermo-set epoxy, widely used in oilfield applications to coat the interior of pipe as a protective barrier against corrosion. The same coating was used on the guides and stems, coated inside and out. Some hardware was re-used and new hardware was ordered. Fluorocarbon coated hardware with a factory applied coating was too expensive, so a coating facility in Houston, TX applied a fluorocarbon coating to the existing hardware. This coating did not adhere to the bolts sufficiently and also caused problems when tightening stainless steel hardware. This coating was only used once; afterwards the hardware was coated with green rebar epoxy after installation. Shims were cut and painted at Truscott using ½”, ¼”, 1/8” and 1/16” x 6” steel strap. The shims were also coated with green rebar epoxy. The flanges were welded onto the pipe with a 7018 welding rod, inside and out, 4 passes each.

c. Step 3 - Installation of new and refurbished stems and guides.

1). Initial Installation.

Installation began with hanging guides 6 through 3 on the wall reusing the anchor bolts. Stem guides 1 and 2 were attached to the bottom stem before dropping the stem into the slot. The guides were kept in place by custom clamps built by the Truscott Team. The bottom stem was then lowered into the slot by the overhead crane and suspended on blocks. The second stem was dollied down the service bridge. One end was connected to the overhead crane, the other end connected to the crane mounted on the nearby service truck. This allowed the stem to be suspended in mid-air and backed into gate tower, then lowered into the slot.

Flange to flange assembly required twelve 7/8” stainless bolts and nuts coated with anti-seize copper compound. Two 1-5/16” wrenches and a ½” impact with a 1-5/16” socket were used to tighten connections. These bolts were only tightened enough to leave a ¼” gap between flanges. Both stems were then lowered into the gate slot and suspended on the blocks. The top stem was brought in the tower the same way as the other two and set down on the flange. Flange assembly was the same. The entire stem assembly was then lowered into the slot by the overhead crane until the top flange was in line with the bottom flange of the operator stem.

Emergency Gate Repairs 2010 Page 5 Birch Lake

2). Gate Stem Alignment.

To get everything in proper position, one man basket was lowered into the slot, personnel pulled the hanging assembly over into the proper location, and a flange bar was used to ‘stab’ the bottom flange bolt holes of the assembly into proper alignment with the gate assembly bolt holes. The overhead crane was lowered at very small increments until the remaining bolts could be inserted and loosely tightened. The man basket was then brought up to the top flange of the hanging assembly. The flange bar was again used to ‘stab’ the top flange assembly holes together with the operator stem holes. At the same time the overhead crane released tension allowing the stem to line up. The remaining bolts were inserted and loosely tightened. Stem alignment was crucial to reducing the friction between the stem and the guides.

However, when re-using old stems and anchors, the tolerance control is pre-determined and fixed. The best solution for overcoming this problem was to rotate the individual stem pieces until the shaft was in alignment vertically, not necessarily horizontally. The flanges were then tightened using a 3/32” feeler gauge inserted between the flange faces. The bolts were tightened until the feeler gauge was ‘stuck’, and then backed off until the gauge could be removed. The anchor bolts for stem guides 1 and 2 had to be cut off during removal and therefore new anchors needed to be set. A ¾” masonry bit and hammer drill were used to drill holes in the concrete wall. The holes were drilled after the operator applied some tension to the stem and gate assembly allowing the weight of the gate to plumb the stem. The new holes had to be drilled lower than the previous holes, provided there was enough clearance between the gate and the guide. The holes were then cleaned using compressed air and a nozzle. The guide was inserted, then raised up the stem into position and held in place by a custom-made clamp. Rezi-weld two part epoxy was applied to the drilled hole; anchors were installed and set mechanically before epoxy dried. Front plates were then installed on the remaining guides (6-3). Shims were used to bring the guides away from the wall to achieve a uniform clearance between the stem and the guide. See the Shim Alignment Diagram located in Enclosure 3. The flange bolts were marked using a punch and hammer to prevent nuts from falling off. All exposed metal was coated using green rebar epoxy. Stem and guides were coated with a generous amount of Lubriplate 105 grease.

d. Step 4 – Test and verify operations. Tests were conducted by raising and lowering the gate three feet while monitoring the guides and operation. The electrical motor was used for the majority of the lowering. While conducting the first test, during the lowering operation the limit switch did not stop motion prior to contact with the gate seal and the operator pushed itself up off the concrete floor causing a very loud noise. The I-beam that supports the operator is bolted to the concrete floor using four 1-½” bolts. One of the bolts was very loose and allowed the beam to be popped off the concrete without damage to the beam, concrete, or bolts. Lowering operations were restricted to manual lowering with the wheel for the last few inches. Visual inspection was made to verify the gate was

Emergency Gate Repairs 2010 Page 6 Birch Lake closed. Electricians were onsite to reset both upper and lower limit switches. After limit switches were reset, they were then retested to verify repeatability. Surprisingly, the motor amperage is nearly the same as to what was previously recorded during the 2009 GOCI Inspection (see Enclosure 4).

7. Repair Results. Before and After Photos are located in Enclosure 2 and the Shim Alignment Diagram in Enclosure 3.

a. Service Gate 1. Bottom gate stem section is new; the other stem sections are refurbished.

The anchors bolts for guides #1, #2, #3, and #4 are new along with stem guide #4. Stem guide #6 was mounted upside down due to fitting issues.

b. Emergency Gate 1. Bottom two gate stem sections are new and stem guide #4 is new. All other materials are refurbished. The hardware used on this gate was fluorocarbon coated.

Stem was installed plumb and true. No issues with keeping the stem plumb. No concrete leaks in this shaft and stem was well greased.

c. Service Gate 2. Bottom gate stem section is new and top two stem sections are refurbished. No new guides were used. Overall stem is not plumb and it makes slight contact with guides #2 and #3. Extensive shimming behind guides #1 and #2. All hardware was coated with green bar epoxy after installation. Epoxy was used in a caulking application on top of the shims to prevent standing water from corroding shims.

All guides were machined for a ¼” of material removed from the overall inner diameter.

This allowed for more clearance between the guide and stem.

d. Emergency Gate 2. Bottom two gate stem sections are new, the top section is refurbished. No new guides were used. All hardware was coated with green rebar epoxy after installation. All guides were machined for a ¼” of material removed from the overall inner diameter. This allowed for more clearance between the guide and stem.

8. Recommendations for Future Inspections. Inspector shall open floor hatch and visually inspect operation of gates. Look for scraping between stem and stem guides on all surfaces, front, back and sides. Determine if the guides are ‘sagging’ (not perpendicular to the wall);

caused by the shims swelling due to laminated rust and corrosion. Notice any unusual noises caused by friction or binding of stem inside guides. Periodically operate gates between the upper and lower limit switches to verify switches are repeatable and to visually inspect gate functions normally through its operating range. Inspect gates from outlet conduit to verify no restrictions exist that would keep gate from closing completely.

9. Cost Analysis. Expenditure costs were noted as the project was completed by in-house staff.

A listing of all expenditures is in Enclosure 5. As a result of the good records kept by Truscott personnel, a ‘rough’ comparison can be made between the costs incurred by performing this type of work in-house versus contract services. Some allowances for deviations in the scope of work have been incorporated into the analysis. Findings are also located in Enclosure 5.

Emergency Gate Repairs 2010 Page 7 Birch Lake

10. Lessons Learned.

a. Fluorocarbon Coating. The contract specified the use of factory applied fluorocarbon coated hardware. The cost estimate for this was extremely high and the option of applying the coating to the re-usable hardware was more cost efficient. This was a bad choice because the quality of fluorocarbon coating not factory applied is very poor. The coating flaked off and clogged the threads on most hardware.

b. Crane Limits. The upper limit of the overhead crane inside the gate tower was not set high enough to allow complete extraction of the stem from the stem slot. This caused improper lifting and leaning of the stem in order to remove it from the tower. This problem was easily fixed by resetting the limit on the crane and could have been avoided if the limit was reset before the project began.

c. Stem Assembly. Before the project began there were differing opinions about how the stem should be assembled in order to reduce potential safety risks. The method used during construction was to assemble the stem as it is lowered into shaft and position the entire assembly with one man in the gate slot. This was by far the best method possible and achieved both goals by reducing risk and keeping the work environment safe.

d. Wall Anchors. The use of wall anchors to tie off the stem once inside the shaft was not necessary because the stem was easily manageable by one man and could be positioned safely. Although the anchors seemed necessary, they were not.

e. Man Basket Accessories. The man baskets used had accessories offered as an option with the rental. Wall riding wheels and connecting members used to Siamese the baskets together were not used on this project. However, using these accessories is strongly recommended and would keep the baskets from swinging inside the slot.

f. Budget. If this project had not been an emergency gate outage, and had been scheduled and budgeted accordingly, the re-use of existing pieces would have been prevented.

Many problems were encountered by reusing pieces of the existing system. Stem alignment could have been kept to closer tolerances by using new anchors and stems. All hardware would have had factory applied fluorocarbon coating. Overall the life of the product would have been extended.

g. Safety Office. The willingness and availability of the district safety office was paramount on this project. The equipment and knowledge they shared during demolition and construction provided all workers with a safe work environment. The project did not encounter any accidents and all workers were taught more about why and how to work safely.

h. Coordination. This repair was required due to an emergency gate outage. The Birch service and emergency gates themselves currently need to be repaired as well. If the work on the gate stems and stem guides could have been scheduled, it should have been performed at the same time as the gate repair work. Overall, this would have avoided redundant disassembly and wasted time on the gate repair project.

i. Water Issue Prevention. During installation of Emergency Gate 1 the shaft began filling with water while workers were bolting together the bottom flange. This rushed the construction and caused panic until the water level subsided. This could have been avoided by first putting 4x4 wooden blocks under the gate before lowering and

Emergency Gate Repairs 2010 Page 8 Birch Lake disconnecting the gate from the stem. The blocks would allow the water to run out the outlet conduit and prevent the filling of the tower.

j. Supplier Communication. Some contracted services conflicted with travel and installation schedules due to lack of communication between contractor and customer.

This could have been avoided by communicating better and more often.

k. PPE. Personal protective equipment was vital to creating a safe work environment.

Hearing protection was necessary for use around the power tools and man baskets. Hard hats were required in every facet of this project. Safety glasses were necessary mostly for in-slot operations such as: clear glasses for blowing out the anchor holes, shaded glasses for cutting torch use, clear glasses for general protection. Gloves were used and worn out due to the greasy, muddy, and wet conditions. Steel-toed boots were necessary during all phases of this project and rubber boots were necessary for going up the outlet conduit.

Coveralls are strongly suggested for workers going down into the slots to prevent ruining personal clothes.

l. Safety Equipment. The safety office supplied most of the safety equipment used during this project such as: air monitoring device, fresh air supply for confined spaces, beam mounted life-lines, PPE, and tie off points. The climbing harnesses were manufactured by DBI and the tethers were manufactured by Miller. This would have caused a liability issue since both pieces of equipment were not made by the same manufacturer.

m. Water Leak Solution. Many different products were used to stop the water leak from the lake to Service Gate 2 shaft. None of the fast curing concrete, hydraulic cement, type products worked. The best solution for this would have been some foam that expands when in contact with water. It is recommended that research be performed to find an expanding foam material that can withstand the head pressures caused by the depth of water.

n. Machining Guides. The ¼” removal off the stem guide inner diameter on Emergency and Service Gates 2 proved to be beneficial and necessary. In some instances, clearances were still tight due to the reuse of misplaced anchor bolts. The stem would not have had the clearance required for smooth operation without machining the guides.

11. Conclusions.

a. The gate stems and guides should be initially checked every five years, with a minimum frequency thereafter of every 10 years. With the bulkhead installed, obtain a man basket and physically inspect the condition of all installed equipment per Section 8 above. Most damage will likely occur at the equipment routinely inundated with water. At the time of inspection, apply more lubrication to the gate stem. Insure that all gate stem guides are lubricated. Coordinate with the Safety Office on all aspects of the inspection.

b. The electrical amperage motor readings are still too high for the installed motors at the operators. Follow-up investigation needs to occur to find out why this is occurring.

Determine if the motors are undersized for the loads experienced. If the motors are undersized, develop recommendations on when to replace the motors and/or operator systems.

Emergency Gate Repairs 2010 Page 9 Birch Lake

c. Pieces of metal were found just below the operators when cleaning the gate stem flanges.

It is presumed the metal fragments are from the internal portions of the operators themselves. Most likely cause is internal damage due to over travel past the limit switches. Further investigation is recommended.

d. If damage is noted after the initial inspection, consider manufacturing and installing new guides that will reduce friction. Possible new systems could include gate stem collars that have internal bearings, bushings, or polyethylene pipe coatings fused to the surrounding metal. Insure the new system does not promote galvanic corrosion.

e. Tulsa District should purchase and maintain one or two pneumatic operated man-baskets (Spider or equivalent). The service gate lifting mechanism used at Birch Lake is similar to systems used at other Tulsa District lakes and several levee systems. In addition to Birch Lake, these other systems should be inspected as well. The rental fees encountered on this project were very expensive compared to the man-basket ownership costs. It is recommended that Safety Office evaluate the size man-basket needed to access most slots/wet wells of concern and procure the needed equipment. One man-basket should be sufficient for inspections, but two man-baskets will be necessary for repairs.

f. In-house personnel did an excellent job on this emergency repair. Not only did they provide the highest quality workmanship, the crew performed the work in a timely manner and saved the District approximately $56,000. In-house crews should continue to be used within their specialty areas whenever possible.

JEFFREY L. WALDIE ANTHONY BURSON

Field Engineer Mechanical Engineer

CESWT-OD-T CESWT-OD-T

Enclosures:

1 – Equipment List 2 - Inspection Photos 3 – Shim Alignment Diagram 4 – Electrical Limit Switch & Motor Readings 5 – Cost Analysis

Emergency Gate Repairs 2010 Page 1-1 Birch Lake

EQUIPMENT & SUPPLIES USED

DURING EMERGENCY & SERVICE GATE REPAIRS

Birch Lake, Oklahoma

Quantity Equipment & Supplies Source 2 each Pneumatic Man-Baskets (SPIDER) Rental, See Contact Info 4 each 48 inch adjustable wall rollers Spider Rental 8 each Rail Clamps Spider Rental 2 each 200 ft wire rope, 5/16 FC, Drum Hook Spider Rental 2 each 5/8” Shackle; Bolt Spider Rental 2 each I-Beam Clamp; 1-1/2 x 8” Spider Rental 2 each Stem Guides Barnsdall Machinist, Ed Watts 110 each 7/8” Stainless Steel Bolts Abilene Sales 110 each 7/8” Stainless Steel Nuts Abilene Sales 25 each ¾” Stainless Steel Anchors Abilene Sales 60 each ¾” Stainless Steel Nuts Abilene Sales 30 each ¾” Flat Washers (Small Outside Diameter) Abilene Sales 30 each ¾” Flat Washers (Large Outside Diameter) Abilene Sales 60 each 5/8” Clamp Bolts Abilene Sales 60 each 5/8” Nuts Abilene Sales 80 each 5/8” Flat Washers (Small Outside Diameter) Abilene Sales 80 each 5/8” Flat Washers (Large Outside Diameter) Abilene Sales 10 each ½” Full Shims Truscott 15 each ¼” Full Shims Truscott 15 each 1/8” Full Shims Truscott 10 each 1/16” Full Shims Truscott 5 each ½” Partial Shims Truscott 5 each ¼” Partial Shims Truscott 10 each 1/8” Partial Shims Truscott 20 each 1/16” Partial Shims Truscott 1 Roll Shim Stock Precision Brand, Grainger

1 Gallon (6 lbs) Lubriplate #105 Grease Lubriplate 1 12 oz Can Aervoe Rebar Green Epoxy Coating Aervoe

1 each Air Compressor RSC, Bartlesville 10 each 50 ft Pneumatic Hoses with Connectors RSC, Bartlesville 1 each Pneumatic Wye with Valve Controls (to operate two man baskets) Truscott

1 each Portable Ventilation Blower w/100 ft air hose Safety Office 1 each Service Truck with Mounted Crane Truscott 1 each Plumber’s Truck with Welding Equipment Truscott 1 each Backhoe Skiatook 2 each Pipe Dolly (Custom Built) Truscott 1 each Oxygen Meter Safety Office

Emergency Gate Repairs 2010 Page 1-2 Birch Lake

Contact Information Spider, A Division of SafeWorks, LLC 10460 Shady Trail, Suite 104 Dallas, TX 75220-2535

(214) 352-8400

Abilene Sales Inc.

1649 S. Treadway Abilene, TX 79602

(325) 673-7962

Precision Brand 2250 Curtiss Street Downers Grove, IL 60515

(630) 969-7200

RSC Equipment Rental 3801 Nowata Road Bartlesville, OK 74006-5114

(918) 333-9580

Ed Watts

<<INSERT CONTACT INFORMATION>>

Products Used & Manufacturers Lubriplate Division Fiske Brothers Refining Company Newark, NJ 07105 and Toledo, OH 43605

Rebar Green Epoxy Coating Aervoe Industries, Inc.

Gardnerville, NV 89410

Rezi-Weld Gel Paste (2 Part Epoxy) W.R. Meadows SealTight

Garonite - Pourable Hydraulic Cement (5 Gal Bucket)

UGL - Drylok Fast Plug Hydraulic Cement (10 lbs)

Emergency Gate Repairs 2010 Page 2-1 Birch Lake

Photo 1. Personnel are moving the SPIDER man-baskets off the delivery truck.

Photo 2. Skiatook, Truscott, and Safety Office personnel are preparing the man-basket for slot entry. Pneumatic lines from the rented air compressor allow the man-basket to travel and power pneumatic tools when working in the basket.

Photo 3. Typical setup used around an open slot. Guard rail was fabricated to reduce safety hazards around the open gate slot.

Emergency Gate Repairs 2010 Page 2-2 Birch Lake

Photo 4. Mr. Dennis Duke is getting ready to access the work area. Each person had a safety line secured to the overhead crane via beam clamp.

Photo 5. The gate stems and guides at the higher elevations did not have significant wear.

Photo 6. Typical guide/shim example at the lower elevations. Pack rust has forced the guide away from the wall and caused binding.

The anchor bolts are bent and the front plate around the gate stem has nearly fallen off.

Emergency Gate Repairs 2010 Page 2-3 Birch Lake

Photo 7. Another view of Photo 6 above. Note that the front plate is only being held on by one bolt.

Photo 8. Typical example of the flange connections between gate stems at lower elevations.

Photo 9. Typical example of the bottom flange connection.

The bottom stem is connected to the gate.

Emergency Gate Repairs 2010 Page 2-4 Birch Lake

Photo 10. Personnel are removing the stems.

Photo 11. Six stems were removed at a time. Stems for Service Gate 1 and Emergency Gate 1 shown.

The corrosion varies based upon water elevation.

Photo 12. The corrosion is both on the inside and the outside of the gate stem. It can generally be assumed that loss of material on the outside equates to nearly the same metal loss on the inside of the gate stem pipe.

Emergency Gate Repairs 2010 Page 2-5 Birch Lake

Photo 13. Typical example of the metal loss encountered on half of the stems removed.

Six of the twelve stems were replaced.

Photo 14. The guides and front collar assemblies were organized, inventoried and evaluated.

Photo 15. Typical condition of a guide.

Emergency Gate Repairs 2010 Page 2-6 Birch Lake

Photo 16. This front collar displays the apparent rubbing from the gate stem. Future guide system modifications may need to include some form of reduced friction (bearings, fused polyethylene pipe, etc).

Photo 17. A 400 lb flange is being welded onto a new gate stem at the Truscott Chloride Control Office.

Photo 18. Two new flanges and gate stems are ready to go to the paint shop.

Emergency Gate Repairs 2010 Page 2-7 Birch Lake

Photo 19. New and reused gate stems arriving on site for installation.

Photo 20. The interior of the gate stems have been coated and protected as well.

Photo 21. A typical rehabilitated guide.

Emergency Gate Repairs 2010 Page 2-8 Birch Lake

Photo 22. Another view of the rehabilitated guide.

Photo 23. Stem guides (red) and shims (green) are organized and ready for installation.

Photo 24. Many of the stainless steel bolts were reused. A fluorocarbon coating was applied, but did not perform well. A manufacturer-applied fluorocarbon coating during bolt manufacture would have performed much better.

Emergency Gate Repairs 2010 Page 2-9 Birch Lake

Photo 25. A Truscott-original pipe dolly makes it easier to move gate stems into position.

Photo 26. A cover was bolted onto one end of the gate stem. This end was connected to the overhead crane inside the gate tower.

Photo 27. Initially the other end of the gate stem just rolls along the pipe dolly as the stem is being lifted in the air.

Emergency Gate Repairs 2010 Page 2-10 Birch Lake

Photo 28. To insure the gate stem paint integrity is not compromised, the pipe dolly is removed and the truck-mounted crane holds the gate stem in mid-air.

Photo 29. The overhead crane has the gate stem at maximum height. Note the beam clamp configuration for the life lines and man-basket support.

Photo 30. The upper limit switch on the overhead crane is set too low. Personnel cannot make the needed bolt connections.

Emergency Gate Repairs 2010 Page 2-11 Birch Lake

Photo 31. The Truscott team quickly welds together two cradles for the gate stem already in the slot. This will provide the additional height needed the crane cannot provide.

Photo 32. Success. With the cradles in place, personnel can now connect the two pieces of gate stem.

Photo 33. Typical working conditions in the gate slot.

Emergency Gate Repairs 2010 Page 2-12 Birch Lake

Photo 34. Looking up at the new Service Gate 2 system.

Photo 35. Typical example of a completed guide and pipe flange. This is the condition prior to applying Lubriplate grease. Project personnel added washers to move out the front collar and allow some space between the collar and the stem.

Photo 36. Original drawings called for 16 gauge metal shims. Due to wall variances, several shims were used. This caused the pack rust failure.

The shims have been replaced with much thicker and fewer shims. Between this change, and coating of all components, pack rust should be significantly minimized if not eliminated.

Emergency Gate Repairs 2010 Page 2-13 Birch Lake

Photo 37. Typical top view of assemblies at higher water elevations.

Photo 38. In locations where water may try to pool on the shims, a coating was added to shed the water off as much as possible.

Photo 39. Typical example of a flange connection.

Emergency Gate Repairs 2010 Page 2-14 Birch Lake

Photo 40. Good comparison of rehabilitated vs. not rehabilitated. The top flange is the stem that goes through the operator above.

Photo 41. The flange in Photo 40 is receiving some green epoxy rust inhibitor.

Photo 42. Typical flange connection example at the bottom of the gate slot (Image Taken: Service Gate 2). The stem connected to the gate itself is on the bottom, the new gate stem is on the top.

Emergency Gate Repairs 2010 Page 2-15 Birch Lake

Photo 43. Typical image of a gate (Image Taken: Service Gate 2). The guide and stem closest to the gate was not rehabilitated.

Photo 44. Lake water has found a pathway through the gate tower concrete into the Service Gate 2 slot.

Personnel attempted to seal the void. The board was wedged into place as pressure to allow additional curing time for the repair.

Photo 45. Regrettably the repair was not successful.

Emergency Gate Repairs 2010 Page 2-16 Birch Lake

Photo 46. Pieces of metal were found just below the operators. It is believed that these pieces came from the internal portions of the operators. Most likely cause is damage caused by over travel of limit switches.

Further investigation is needed.

DATE 11-09-2009 GATE OPERATIONAL

CAPABILITY INSPECTION

PROJECT BIRCH

Inspectors: Joe Thouvenel,…