Specification-_35_31_19_-_Rev20191022.pdf

2018 Federal North Kansas City Levee Unit W912DQ19B1019 Kansas City, Missouri

SECTION 35 31 19

STONE PROTECTION

01/08

PART 1 GENERAL

Processing, hauling, stockpiling, and placing stone, including but not limited to quarry run rockfill and riprap listed herein, shall meet the requirements of the contract documents.

1.1 UNIT PRICES

1.1.1 STONE

1.1.1.1 Payment

Payment for stone satisfactorily placed will be included in the lump sum contract price. Price(s) and payment(s) shall constitute full compensation for furnishing, hauling, handling, placing, and maintaining the stone until final acceptance by the Government. No separate payment will be made for the stockpiling of stone, and all cost in connection with stockpiling shall be included in the contract lump sum price.

1.1.1.2 Measurement

Stone will not be measured for payment.

1.2 REFERENCES

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

ASTM INTERNATIONAL (ASTM)

ASTM C127 (2015) Standard Test Method for Density, Relative Density (Specific Gravity), and Absorption of Coarse Aggregate

ASTM D4791 (2010) Flat Particles, Elongated Particles, or Flat and Elongated Particles in Coarse Aggregate

ASTM D5519 (2015) Particle Size Analysis of Natural and Man-Made Riprap Materials

U.S. ARMY CORPS OF ENGINEERS (USACE)

EM 1110-2-1601 (1991; 1994 Change 1) Engineering and Design -- Hydraulic Design of Flood Control Channels

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1.3 DEFINITIONS

1.3.1 Bank Stabilization

This paragraph explains certain terminology which is common to construction of bank stabilization work on the Levee Rehabilitation Flood Protection Project and which may not be self explanatory in the subsequent applicable provisions of the technical specifications and on the drawings.

1.3.2 Standard Drawings

Details of the Levee Rehabilitation Flood Protection Project are shown on standard drawings forming a part of these specifications.

1.3.3 Stone Protection

Stone Protection is defined as a system which includes a layer of bedding material or layers of filter material beneath a layer or layers of riprap.

Stone protection is placed around structures in slack water or within a dewatered site. Stone protection may also be used to protect channel banks when it is placed in the dry or in slack water.

1.3.4 Riprap

Riprap is defined as a material having a gradation band similar to those specified in EM 1110-2-1601, Chapter 3, uniform graded material. Riprap is normally produced by mechanical methods, with a jaw crusher and grizzly after the stone has been mined by blasting in a quarry. Riprap gradations have a maximum top size of 3.5 tons.

1.3.5 Graded Stone

Graded Stone is defined as material with gradations that are produced by the mining technique and minimal additional processing other than the use of a skeleton bucket or a bar grizzly. The gradation band may have more fines than riprap and may have gradations with a top size up to 3.5 tons and could be classified as being well graded.

1.3.6 Channel Protection

Channel protection is stone placed in a current as revetment, dikes, or slope paving without the use of a separate layer of bedding or filter material. In this type of environment, materials with gradation bands with a top size of 150 mm (6 inches) will not stay where placed.

1.4 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 "RO" designation identifies the resident engineer. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Proposed Source Quarry; G, RO

Proposed source quarry name and the geological rock unit (ledge)

35 31 19 - 4 for each gradation of stone to be provided.

SD-03 Product Data

Riprap; G, RO

Conveying and Placing

SD-06 Test Reports

Bulk Specific Gravity

Bulk Specific Gravity documentation (historical or recent test results).

Gradation Test; G, RO

SD-07 Certificates

Written Certificates; G, RO

Written (signed) certification from the quarry and the Contractor that the proposed stone and stone source meets all requirements stated herein.

1.5 QUALITY ASSURANCE

1.5.1 Stone

1.5.1.1 General

All stone (the terms "stone-fill", "rock", and "rockfill", may be used interchangeably with "stone") shall be durable limestone or calcareous cemented sandstone meeting the criteria and gradation requirements specified herein. The acceptability of all stone delivered to the site is subject to final approval by the Contracting Officer.

Stone shall be of a suitable quality to ensure permanence in the structure and in the climate in which it is to be used. It shall be free from cracks, blast fractures, bedding, seams and other defects that would tend to increase its deterioration from natural causes. Stone shall be resistant to rapid degradation under the repeated freeze-thaw conditions occurring in a streambank environment. Stone shall be angular and blocky in shape with sharp corners. Stones with rounded corners are unacceptable.

Stone shall be relatively free from thin slabby pieces.

Inspections for cracks, fractures, seams and defects shall be made by visual examination. If, by visual examination, it is determined that 20 percent or more of the stone produced contains hairline cracks, then all stone produced by the means and measures which caused the fractures shall be rejected. A hairline crack that is defined as being detrimental shall have a minimum width of 4 mil and shall be continuous for one-third the dimension of at least two sides of the stone. The stone shall be clean and reasonably free from soil, quarry fines, and shall contain no refuse. The stone shall be clean and adequately free from all foreign matter. Any foreign material adhering to or combined with the stone as a result of stockpiling shall be removed prior to placement.

Bulk specific gravity as measured by Standard Test Method for Density, 35 31 19 - 5

Relative Density (Specific Gravity), and Absorption of Coarse Aggregate ASTM C127, shall not be less than 2.4.

Stone shall be free from environmental contaminants such as petroleum (and associated products), man-made chemicals, and any other substance which is considered unacceptable for the use in a riverine habitat as generally determined by governmental agencies overseeing environmental compliance issues. Any foreign material adhering to or combined with the stone as a result of stockpiling shall be removed prior to placement.

1.5.1.2 Sources

Stone shall be furnished from any of the Government Approved Sources listed at the end of this section. The approved source listing is not to be construed as approval of all material from such source.

The Government reserves the right to reject materials from certain localized areas, zones, strata, or channels when such materials are unsuitable as determined by the Contracting Officer. The Contractor is responsible for all materials produced from a source and shall ensure that the materials meet all contract requirements.

1.5.1.3 Proposed Stone Submittals

Not later than 5 calendar days after contract award, and prior to the full-scale production of any stone, the Contractor shall submit in writing the following:

a. Proposed source quarry name and the geological rock unit (ledge) for each gradation of stone to be provided.

b. Written (signed) certification from the quarry and the Contractor that the proposed stone and stone source meets all the requirements stated herein.

c. Bulk specific gravity documentation (historical or recent test results).

Government review and approval of the proposed source information and certifications will be considered tentative and contingent on field review and approval of the 24-ton Pre-Production Sample as described in Section

3.5 TEST AND INSPECTIONS.

PART 2 PRODUCTS

2.1 STONE

2.1.1 General

2.1.1.1 Quarry Operations

Conduct quarry operations in a manner to produce stone conforming to the requirements specified, which may involve selective quarrying, handling, processing, blending, and loading as necessary, all of which shall be as specified in Section 01 45 00.00 10 Quality Control. Control blasting and handling of rock to produce rock of the size ranges and quality specified.

Techniques such as the use of proper hole diameter, hole depth, hole angle, burden and spacing distances, types and distribution of explosives, delay intervals and sequence, removal of muck piles between each shot, and special handling techniques are required as necessary to produce the

35 31 19 - 6 specified materials. All aspects of blasting operations shall be specifically designed so that the end product is not damaged from the blasting technique and that the stone is suitable for the intended purpose.

a. Curing Stone

Conduct curing operations on freshly quarried stone to allow it to release stored energy and moisture and to allow the stone to demonstrate that it will not fracture during the energy release and drying-out phase. Quarry run rock materials shall be temporarily stockpiled at the quarry site a minimum of 30 calendar days before being shipped to the project site, unless this requirement is waived by the Contracting Officer. Such waiver will be granted only if the stone has characteristics that make curing unnecessary.

b. Stone Quarrying Exclusion Period

Stone quarried between the 15th of October and the 15th of April will not be approved for use in the project. If the stone is not affected by freeze-thaw cycles, and the durability history of the stone demonstrates that quarrying during the exclusion period has no adverse effect on the durability of the stone and the Contracting Officer approves the use of stone quarried during the exclusion period, the stone quarrying period exclusion may be waived by the Contracting Officer. Stone quarried before the the exclusion period at a time which will not permit sufficient curing time before being subjected to freezing conditions, and which is subject to fracturing as a result of freeze-thaw cycles, will not be approved for use.

2.1.1.2 Stone Gradation

Graded stone shall be obtained from a Corps of Engineers approved source, and shall contain a combined total of not more than 5 percent of clay, silt, sand, shale, and non-durable rock. The stone gradations should allow for a dense in-place mass with few voids.

The Contractor shall select a quarry and a geological rock unit (in accordance with the approved source list) that can and will consistently produce a gradation that shall contain no more than 10 percent less than 2-inch size, and the maximum stone shall be 36 inches. Further gradation requirements are provided in tables below.

Riprap Gradation (48-inch layer thickness)

STONE WEIGHT (Pounds) CUMULATIVE PERCENT (Finer by Weight)

2100 100

1500 85-95

600 30-50

135 15

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2.1.1.3 Proportional Dimension Limitations

The maximum aspect ratio (greatest dimension:least dimension) of any piece of stone for size ranges which are not graded with a screen or grizzly, shall not be greater than 3:1 when measured across mutually perpendicular axis. ASTM D4791 shall be used as a guide to perform the test.

PART 3 EXECUTION

3.1 EXCAVATION OF MATERIAL

The excavation into suitable material should begin at the top of the slide mass and continue downwards at a 1:1 slope. The failed slope mass, all loose material and debris from the slope repair area should be removed until a firm surface is encountered. The firm surface should be clean and intact for placement of rock fill. Compaction of the base soil is not required. Excavated material and debris shall be removed from the site.

3.2 EQUIPMENT OPERATIONS

Equipment shall not be permitted on the rock except as identified within these contract documents. Equipment operation will be permitted on the rock placed to construct ramps and the rock placed within the channel flowline.

3.3 PLACEMENT OF Rock

3.3.1 General

Rock will be placed to construct the riprap blanket and bendway weirs as shown on the contract drawings. Water may be present at the project site during construction. Rock may be placed at any water level if the water is caused by backwater from the Missouri River. If major contributing flows from Rock Creek occur, extension for unusually severe weather pay apply (specification 01 30 00 paragraph 1.10).

Determination wether Contracting Officer

3.3.2 Placement

Rock shall be placed in a manner which will produce a well-graded mass of rock with the minimum practicable percentage of voids, and shall be constructed, within the specified tolerances, to the lines and grades shown on the contract drawings or staked in the field. A tolerance of plus 5 inches and minus 2 inches from the slope lines and grades shown on the contract drawings will be allowed in the finished surface of the riprap.

Rock shall be placed by means of truck, crane operated skip-pan (box), dragline bucket, clamshell, rock-bucket, hydraulic excavator, trackhoe, or other approved equipment. The use of tractor loaders or other equipment

35 31 19 - 8 commonly referred to as front end loaders shall not be permitted. Rock shall be placed to its full course thickness in one operation and in such amanner as to avoid displacing formed base material. The large stones shall be well distributed and the entire mass of stones in their final position shall be graded to conform to the gradation specified. Placement shall begin at the bottom of the area to be covered and continue up slope.

Subsequent loads of material shall be placed against previously placed material in such a manner as to ensure a relatively homogenous mass. The finished rock shall be free from objectionable pockets of small stones and clusters of larger stones. Placing riprap in layers will not be permitted. Placing rock by dumping it into chutes, or by similar methods likely to cause segregation of the various sizes, shall not be permitted.

Placing riprap by dumping it at the top of the slope and pushing it down the slope shall not be permitted. No equipment shall be operated directly on the completed stone protection system. The desired distribution of the various sizes of stones throughout the mass shall be obtained by selective loading of the material at the quarry or other source; by controlled dumping of successive loads during final placing; or by other methods of placement which will produce the specified results. Each truckload shall be representative of the gradation requirements. Rearranging of individual stones shall be required to the extent necessary to obtain a well-graded distribution of stone sizes as specified above.

3.4 TESTS AND INSPECTIONS

3.4.1 Pre-Production

3.4.1.1 Material Quality

Before selecting a source for preparation of a demonstration stockpile, be reasonably certain that the source is capable of meeting the quality and source requirements specified in Section 1.5.1 and the respective sub sections.

3.4.1.2 Demonstration Stockpile at Source

Following submission of proposed stone source information and certifications, a representative sample of the stone proposed for use in construction shall be made available for a Government visual field review of quality and rock size at the quarry well prior to the start of full-scale quarry production. This sample shall consist of not less than 48 tons. The sample shall be handled in a manner to duplicate the type and conditions of actual handling, loading, hauling and unloading leading to placement at the work site. Results of the 48-ton sample visual field review shall be furnished to the Contracting Officer for approval prior to the mass production or delivery of any stone to the project site. From the approved 48-ton sample, deliver a representative one-half (roughly 24 tons) pre-production sample to the project site for stockpile in a suitable area where it shall remain undisturbed for use as a quality control reference for future deliveries. The other half of the approved sample shall remain undisturbed at the quarry where it shall serve as a quality control reference for quarry operations. The approved samples may be placed in the work after the last load of quarry production is delivered to site. The Contractor shall furnish all labor, equipment, and materials needed for the sample review. The Government may reject stone deliveries, or require modification of quarry operations, based on comparisons between current production and the approved samples.

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3.4.2 Placement Control

3.4.2.1 Quality Control Measures

Establish and maintain quality control for all work performed at the job site under this section to assure compliance with contract requirements.

Maintain records of the quality control tests, inspections and corrective actions. Quality control measures shall cover all construction operations including, but not limited to, the placement of all materials to the slope and grade lines shown and in accordance with this section.

3.4.2.2 Defiency Testing

Whenever there is reason to suspect that materials do not meet specified requirements, tests shall be performed as directed. If deficiencies are suspected during placement, tests shall be performed on Government selected samples of in-place material to determine the extent of the unacceptable material. Such testing may include but is not limited to specific gravity, drop tests, and gradation testing. All in-place unacceptable material shall be removed and replaced with acceptable material or shall be modified as directed by the Contracting Officer.

3.4.2.3 Gradation Test for Stone

Gradation tests shall be performed in accordance with ASTM D5519 Test Method A.

3.4.2.4 Standard Test Method for Gradation of Quarry Run Stone

a. Select a representative sample (Note No. 1), weigh and dump on hard stand.

b. Select specific sizes on which to run "individual weight larger than" test. Procedure is similar to the standard aggregate gradation test for "individual weight retained".

c. Determine the largest size stone in the sample. (100 percent size)

d. Separate by "size larger than" the selected weights, starting with the larger sizes. Use reference stones, with identified weights, for visual comparison in separating the obviously "larger than" stones.

Stones that appear close to the specific weight must be individually weighed to determine size grouping. Weigh each size group, either individually or cumulatively.

e. Paragraph d above will result in "individual weight retained" figures.

Calculate individual percent retained (heavier than), cumulative percent retained, and cumulative percent passing (lighter than. Plot percent passing on ENG Form 4794 provided in Appendix A.

NOTE NO. 1: The most important part of the test and the least precise is the selection of a representative sample. No "standard" can be devised; larger quarry run stone is best sampled at the shot or stockpile by given direction to the loader; small graded stone is best sampled by random selection from the transporting vehicles. If possible, all parties should take part in the sample selection and agree before the sample is run that the sample is representative.

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3.5 MAINTENANCE

The Contractor shall maintain the new stone until the contracted work is completed. Any displaced or damaged material shall be restored to the required lines and grades as provided in the contract. Contractor shall seek Government approval prior to undertaking restoration work that involves significant time, cost, or disruption to previously scheduled work.

3.6 STOCKPILE

Storage of stone at the worksite is not to be confused with off-site stockpiling of stone. If the Contractor elects to provide off-site stockpiling areas, the Contracting Officer shall be notified by the Contractor of all such areas. Stone stockpiles on-site and off-site shall be piled only as high as equipment will allow without operating any equipment on or against the rock. No equipment shall be allowed to operate on the stockpiles. Stone stockpiles will require constructed pads as approved by the Contracting Officer. Rock handling operations shall follow reasonable practices to minimize rock fractures, degradation, or segregation. Stone which has become contaminated with soil or refuse shall be removed from the site unless the contaminating material has been removed from the stone prior to stockpiling.

3.7 SCALES AND WEIGHHOUSE

Scales shall be standard truck scales of the beam type and of sufficient size and capacity to accommodate all trucks used in hauling material.

Scales shall be tested, approved, and sealed by an inspector of the State Inspection Bureau charged with scales inspection within the State of Missouri or the Contractor shall provide an equivalent certification if the services of an official inspection bureau of the State are not available.

Scales shall be recalibrated and resealed as often as necessary to ensure continuous accuracy. The number of standard weights necessary for testing the scales shall be on hand at all times.

3.8 LIST OF APPROVED QUARRIES

USACE Kansas City District-Geotechnical Branch Approved Rock Material List updated December 2016

QUARRIES COUNTY STATE APPROVED LEDGE

Damon Pursell Rock Ridge Quarry SW1/4 Sec 23 & NW1/4 Sec 26 T48N, R33W Lib t MO 816 926 0300

Jackson MO Winterset LS lower 17' Bethany Falls

LS

Missouri Rock, Inc - Orrick Quarry NW1/4 Sec. 14, T51N, R29W 7797 Highway O Orrick, MO 64077

Ray MO Lower 8 feet of Winterset

LS

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QUARRIES COUNTY STATE APPROVED LEDGE

Damon Pursell Rock Ridge Quarry SW1/4 Sec 23 & NW1/4 Sec 26 T48N, R33W Lib t MO 816 926 0300

Jackson MO Winterset LS lower 17' Bethany Falls

LS

REW Properties - 63rd & I-435 Lower 15 feet Winterset LS NE1/4 Sec 1, T48N, R33W

ESI CONTRACTING CORP.

KCMO 816-523-5081,

816-935-0912

Jackson MO Lower 15 feet Winterset LS upper 9 ft Bethany Falls

LS

immediately below Peanut ZAPAC-Limpus (Metropolitan)

Quarry Sugar Creek, MO SE1/4 Sec 13, T50N, R32W APAC-Missouri Div Sugar Creek, MO 816-257-2222

Jackson MO Winterset LS & Bethany Falls LS except Peanut Zone at top

Hunt Martin Materials (Martin Marietta Materials) Greenwood Quarry E1/2 Sec 11, T.46N., R31W.

PO Box 292 Greenwood, MO 64034 District Sales Manager O = 913-390-8396 C = 816-729-9324

Cass County

MO lower 16 feet of the Bethany Falls Limestone

Hunt-Martin Materials - Parkville Mine 7600 9 Hwy, Parkville, MO 64152 Sec 36, T51N, R34W 816-741-2550

Platte County

MO Bethany Falls Limestone

ATTACHMENT

1. ENG Form 4794

-- End of Section --

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