II.H.08.01_-_Optional_Bid_Item_0004-_Tunnel_Bulkheads.pdf

OPTIONAL BID ITEM 0004: TUNNEL BULKHEAD PLACEMENT

SCOPE OF WORK

OPTIONAL BID ITEM 0004

TUNNEL BULKHEAD PLACEMENT

Raystown Dam Huntingdon, PA

Baltimore District, USACE

General

Optional Bid Item 0004 is for placement of the Raystown Regulation Tunnel Bulkheads located at Raystown Dam.

Location

The project work site is located at Raystown Dam, Huntingdon, PA.

Special Requirements

Optional Bid Item 0004 Start Date. The scope of work under Optional Bid Item 0004 shall not begin until work on the following items are completed and operational:

1. Tainter Gate Repairs

2. Stoplog Rehabilitation

3. Warm Water Intake Installation

Bridge Capacity. Refer to Contract Specifications “Spillway Bridge Restrictions.”

Required Equipment. The contractor shall provide all equipment and personnel required to perform this contract. The contractor shall be responsible for providing all lifting hardware.

Contractor Tasks

The contractor shall perform the following tasks:

Task 1 – Establishment & Installation of Boat Restricted Zone

The contractor shall be responsible for establishing safety zones to minimize risks/hazards to the dive team for the duration of Bid Item 004. The contractor shall also be responsible for obtaining the required permits from the Pennsylvania Fish and Boat Commission for establishment of the zone. The contractor shall coordinate with controlling authorities (Contracting Officer and Pennsylvania Fish and Boat Commission) to establish the safety zone.

Task 2 – Bulkhead Rehabilitation (2x)

There are two steel bulkheads (19’-8” x 8’-0”) that require minor rehabilitation. Both bulkheads weigh approximately 12,000 pounds each. The bulkheads are located in a structure shown in drawing sheet C-2.

Rehabilitation Items:

1. Replacement of corroded washers and hardware on the side seal assemblies.

The “J” and bottom rubber seals are held in place by 3/4” diameter stainless steel bolts.

The 3/4” stainless steel bolt assembly shall be replaced with F3125, grade A325, hot dipped galvanized bolts, nuts and related washers.

2. Replacement of Rubber Seals.

The “J” Rubber seal (top and sides of the bulkhead) and bottom rubber seal of the bulkhead shall be replaced. Rubber seals shall be supplied as one piece, shop fabricated with fully vulcanized corners. The J bulb and bottom rubber seals shall match geometry shown on drawing sheet C-5. The rubber seals shall be field drilled based on results of the surveys (see Task 6).

The “J” and bottom rubber replacement seals shall meet the following requirements:

Rubber seals shall be Teflon clad rubber seals of the mold type only, compounded of natural rubber, synthetic polyisoprene, or a blend of both, and shall contain reinforcing carbon black, zinc oxide, accelerators, antioxidants, vulcanizing agents, and plasticizers.

Physical characteristics of the seals shall meet the following:

PHYSICAL TEST TEST VALUE TEST METHOD

SPECIFICATION

Tensile Strength 2500 psi (min.) ASTM D412 Elongation at Break 450 percent (min.) ASTM D412 300 Percent Modulus 900 psi (min.) ASTM D412 Durometer Hardness

(Shore Type A) 60 to 70 ASTM D2240

*Water Absorption 5% by weight (max.) ASTM D471 Compression Set 30% (max.) ASTM D395 Tensile Strength

(after aging 48 hours)

80% tensile strength (min.)

ASTM D572

Task 3 – Guide Slot Inspection & Report to Contracting Officer

Normal reservoir elevation is 786.00’. The top of the guide slots is located at elevation 746.00’. Please reference drawing sheet C-3 for guide slot dimensions. Steel plates and angles are embedded within the concrete guide slots to “guide” the bulkhead as it placed/removed.

The contractor shall inspect the full height of each slot. The contractor shall notify the Contracting Officer based on observed guide slot conditions whether there may be problems related to the anticipated work under the scope of Bid Item 0004.

The contractor shall provide a report to the Contracting Officer of the inspection findings. It is expected that the report will detail any potential obstructions/damages that will prevent Bulkhead placement and sealing of the tunnel opening.

Task 4 – Guide Slot Reparations

The Contracting Officer shall review the inspection findings and shall provide direction to the contractor for debris removal and corrective actions necessary. At minimum, the Contracting Officer shall direct the contractor to clean all sealing surfaces and remove all debris from the gate slot and sills necessary to install the bulkheads. The contractor shall complete reparations at the direction of the Contracting Officer.

Task 5 – Removal of Trashrack (2x)

After completion of slot inspections and slot reparations, the existing trash racks at the intake shall be removed. Removal of the trash racks shall only occur after bulkhead rehabilitation is completed. The trash racks are 8’-7” by 24’-6”, weighing approximately 6000 lb each.

Diver(s) are required to assist in hooking up the trashrack lifting chain to the lifting eye located on each side of the trashrack.

The contractor shall provide equipment, cribbing/dunnage, etc. to support government inspection of the trashracks. The contractor shall power wash trash racks to accommodate government inspection. After government inspection is completed, the trashracks shall be stored in the newly constructed Multi-Purpose Storage Building.

Task 6 – Sealing Surfaces Inspection/Sill & Slot Survey/Reparations

The contractor shall inspect the steel plates and angles within each slot. The inspector shall pay careful attention to the following sealing surfaces during inspection:

1. Intake Ceiling Plate (ST8 on drawing sheet C-4)

2. Vertical Seal Plate (ST2 on drawing sheet C-4)

3. Precast Bulkhead concrete sealing surface (ST9 on drawing sheet C-4)

The contractor shall provide the Government with a precast sill survey (+/- 1/16” tolerance) and a slot survey for review. Contractor shall take survey readings along the entire length of precast concrete sill at a minimum of 1 foot increments and note any deviations from level exceeding 1/8”. The Contracting Officer shall provide direction for any corrective repairs for the sealing surfaces and sill based on the sealing surfaces and sill inspection.

Task 7 – Transporting Bulkhead (2x)

The contractor shall lift up the steel bulkhead from its existing location (location shown on drawing sheet C-2) and move it to an accessible boat launch. The Corps has located an existing access road and boat launch that may serve as a location for launching the equipment the contractor chooses to use to place the bulkheads. The boat launch is denoted on drawing sheet C-2. Measurements of the water depth suggests minimum four to five feet depths directly in front of the ramp.

The contractor shall provide a ramp or any means necessary to transport the bulkheads from land to water to place the bulkheads.

Task 8 – Placing Bulkhead (2x)

The bulkheads shall be moved to the front of the upstream portal of the concrete guide structure for placement. The contractor shall ensure the bulkheads are oriented correctly and placed correctly within the guide slots (skin plate on the downstream side, see drawing sheet C-6) prior to placement. The contractor shall provide diver assistance to help guide the bulkhead into its final seal location, ensure debris is cleared from sealing surfaces during placement, and detachment of rigging.

For the final sealing stage, see drawing sheet C-6 for further clarification.

Task 9 – Leakage Assistance After Bulkhead Placement

The government shall walk up the tunnel to inspect sealing of the bulkhead against the tunnel opening. Prior to government inspection, the contractor shall control leakage by adjusting seals, stopping seals, placement of environmentally friendly cinders, diverting and pumping water, or other means necessary to facilitate Government access and walking inspections downstream of the tunnel after contractor’s bulkhead placement. Any downstream leakage shall be minimal, and shall not impact downstream inspection of the tunnel. The government inspection shall occur between five to ten business days after successful placement of the bulkheads.

Task 10 – Demobilization

The bulkheads will be left in place at the end of the Contract. The contractor shall require approval from Contracting Officer before demobilizing.

Diving

PART 1 General

1.1 General

This section covers the general requirements for contract diving operations to be performed as specified within this contract. Diving shall be performed in accordance with the latest edition of the U.S. Army Corps of Engineers Safety and Health Requirements Manual, EM 385-1-1, the U.S. Navy Diving Manual, OSHA 29 CFR 1910, Subpart T; and ADCI Consensus Standards inclusive of all other references listed therein. All diving operations shall be considered incidental to the work specified elsewhere herein. No separate payment for diving work will be made.

1.2 References

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

ASSOCIATION OF DIVING CONTRACTORS INTERNATIONAL (ADCI)

ADCI Consensus Standards for Commercial Diving and Underwater Operations

U.S. ARMY CORPS OF ENGINEERS (USACE)

EM 385-1-1 U.S. Army Corps of Engineers Safety and Health Requirements Manual ER 385-1-31 U.S. Army Corps of Engineers Hazardous Energy Control Program (HECP)

U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)

OSHA 29 CFR 1910, Subpart T Commercial Diving Operations

U.S. NAVY (USN)

U.S. Navy Diving Manual

1.3 Submittals

Government review and approval is required for dive submittals. Refer to “Submittals” for pertinent submittals that are required before work commences.

1.4 Qualified Dive Companies and Dive Team Personnel

Any domestic commercial dive contractor meeting standards set forth in the most recent edition of the USACE Safety and Health Requirements Manual, EM-385-1-1, shall be eligible to compete for routine diving work if able to demonstrate similar dive work experience as required by EM 385-1-1; examples include but are not limited to Surface decompression with oxygen (Sur-D-O2), NITROX (enriched air), mixed gas, deep, saturation, penetration, HazMat and/or contaminated water diving. The Dive Contractor shall have no dive related serious, willful, or repeat State or Federal OSHA safety citations within the 12 months preceding the commencement of dive operations.

Once awarded, contract performance is contingent upon the contractor's submission of an acceptable Dive Operations Plan, Activity Hazard Analysis, and Emergency Management Plan for the specific diving operation to be conducted. The contractor's shall ensure that all diver credentials and equipment certifications meet the standards outlined in the most recent edition of EM-385-1-1 or as stated by the presiding USACE Dive Coordinator/Dive Safety Officer.

1.5 Diving Environment

The estimated maximum working depth is approximately 175 feet fresh water (FFW) below water surface. The estimated maximum depth (distance from water surface to bottom) the diver(s) will be exposed to is approximately 175 feet below water surface. Turbidity may limit visibility to four (4) feet or less. The current water velocity through the work area is estimated to be negligible. Water temperature(s) are estimated to vary between 36 and 50 degrees F.

Underwater operations will not require diver(s) to perform work within confined spaces and / or enclosed areas or areas with an overhead. The overall work site shall be a restricted access area.

1.6 Dive Operations Plan and Schedule

No later than 28 working days prior to the first planned diving operation, the Dive Operations Plan, Dive Schedule, AHA, EMP, dive team credentials and equipment certifications shall be submitted for approval and to allow coordination at the project site and other concurrent work.

The Dive Operations Plan shall be prepared in accordance with EM 385-1-1 Section 30. The Dive Operations Plan and Schedule shall detail dive locations. Personnel and equipment certification shall be included in the plan. A site specific Emergency Management Plan shall be submitted in accordance with EM 385-1-1 Section 30 and be included in the Dive Operations Plan. A job specific Activity Hazard Analysis (AHA) shall be prepared in accordance with EM 385-1-1. Adjustments shall be coordinated with the USACE Dive Coordinator/Dive Safety Officer and Contracting Officer.

Scheduling Individual Dives:

The contractor must notify the Dive Coordinator / Dive Safety Officer and Contracting Officer in writing a minimum of ten (10) calendar days in advance of each scheduled dive. Failure to give the full ten (10) days notice may result in delays to the work if an on-site USACE Dive Safety Inspector (DSI) is not available. The Government is not liable for delays if the contractor fails to give the required ten (10) days written notice.

In the event it becomes necessary to cancel or reschedule a dive, the contractor is required to notify the Government at least two (2) work days prior to the first day of the scheduled dive during normal business hours. Failure to provide such notification will make the contractor liable for daily rate for the DSI from the date of the cancellation until the dive commences; the contractor will not be charged for more than ten (10) days delay for each dive cancellation.

However, each time a dive is cancelled or rescheduled, it is treated as a new dive for purposes of scheduling DSI’s and determining delay costs. When computing delay costs, a partial day is considered a full day; DSI delay costs will be permanent deducted from the contractor’s pay at the minimum rate of $1,000.00 per day.

1.7 Company Safe Practice Manual for Diving

Submit a Company Safe Practice Manual for Diving. The manual shall have the minimum requirements as outlined in EM 385-1-1 Section 30. If a current manual is not on file with the U.S. Army Corps OF Engineers, Baltimore District, a copy must be furnished to NAB.

1.8 Dive Safety Inspector; Dive Coordinator/Dive Safety Officer

Dive Safety Inspector: EM 385-1-1 requires the Baltimore District provide a Dive Safety Inspector (DSI) to be onsite at all times during diving operations. A DSI will be provided based on the contractor’s approved Dive Operations Plan and General Schedule. The Dive Operations Plan and General Schedule must include anticipated dive schedules and durations. Any changes to the dive schedule must be provided to the Dive Coordinator/Dive Safety Officer and Contracting Officer with no less than ten (10) calendar days notice.

Dive Coordinator/Dive Safety Officer: A Dive Coordinator/Dive Safety Officer will be designated for this contract by the Baltimore District and/or North Atlantic Division to review all dive related documentation and provide oversight to the Dive safety Inspector as needed. The position of Dive Safety Inspector and Dive Coordinator/Dive Safety Officer may be simultaneously held by one person if qualified.

1.9 Resolution of Conflict

EM 385-1-1 and, if applicable, a supplemental waiver or Memorandum of Agreement (MOA) shall be the controlling authority(s) for implementation of all contract diving policy.

PART 2 Products - NOT USED

PART 3 Execution

3.1 Dive Team Composition and Dive Equipment

Minimum dive team staffing shall, unless a waiver is approved by the Dive Coordinator / Dive Safety Officer, be comprised of the following personnel levels: a single working diver requires a five (5)-man crew as defined in EM 385-1-1 and for two in-water working divers, a seven (7)-man crew shall be required, which includes the addition of one (1) stand-by diver and one (1) stand-by tender. For depths exceeding 100 ft. a minimum six (6)-man crew is required. Any use of breathing gas with oxygen content more than 21% is considered mixed gas diving. A minimum six (6)-man crew shall be required for all mixed gas diving. Use of SCUBA methodology is not authorized for this contract. In addition to the dive team personnel addressed in the above references, minimum required certified chamber crew personnel shall be provided as diving operations dictate. If a crane is used, a certified crane operator who shall not be included as a dive-team member must be exclusively dedicated to crane operations. Surface-supplied air diving equipment with 2-way voice communication shall be used by divers and standby divers. An independent reserve air system (30 cubic foot/3000 PSI bailout bottle or larger) for all divers is required. At a minimum, all HP and LP air supply compressors supplying breathing air, tanks, helmets and other related equipment must comply with the requirements of EM 385-1-1, 29 CFR 1910, Subpart T, the U.S. Navy Dive Manual and all other prevailing regulations. All dive team members must meet the requirements as listed in this document.

3.2 Contractor-Furnished Diving Support Equipment

An operational dual lock recompression chamber(s) capable of recompression to a minimum of 165 FSW shall be required to be on-site and available for immediate use for divers working at all depths. Sufficient on-site chamber facilities shall be furnished to service multiple divers working simultaneously on differing recompression schedules. All recompression treatment tables will comply with the most recent edition of the U.S. Navy Dive Manual. Use of hot water suits and a hot water diving system is required for all diving required by this contract. A dive vessel or a floating or suspended dive platform shall be furnished from which diving operations will be staged and will contain an appropriately heated shelter and toilet facilities for all dive team members when temperature and / or wind-chill factor is below 60 degrees-F. Man-basket(s) shall be provided for each working diver as needed. All necessary top-side equipment such as cranes, trucks, personnel vehicles, and appropriately-powered underwater hand and power tools shall be furnished by the contractor to enable accomplishment of all required dive work.

3.3 Contractor-Provided Special Underwater Equipment

The contractor is expected to furnish all appropriate tools, equipment, and materials needed to accomplish the tasks as stated in both “Contractor Tasks” and paragraph 3.6.

3.4 Safe Clearance Procedures

A safe clearance system is used by USACE project personnel to insure continuity of service and safety to personnel and equipment. Any work performed which requires taking project operating equipment out of service shall be done only after formal clearance is obtained through the GQAR. Clearances will be issued only by the Contracting Officer/Dam Operator in accordance with ER 385-1-31. The contractor shall coordinate with Contracting Officer for implementation of the hazardous energy control plan in accordance with EM 385-1-1 section 30. The Government Diving Safety Inspector will keep the Contracting Officer/Dam Operator informed of all diving activity underway. Clearances violated by contractor personnel will be cause to immediately and permanently ban the person(s) from the project site. Submit a Critical Lift Plan for all identified critical lifts in accordance with EM 385-1-1 as part of the pre-work submittals.

3.5 Boat Restricted Zone/Safety Zone

See Tasker 1.

3.5.1 Safety Requirements

a. In addition to the requirements of EM 385-1-1, the following safety items must be met prior to entry into the BRZ.

b. As a minimum, each vessel must meet Coast Guard safety standards for boat day and night operation. Included are fire extinguishing capability, personal safety devices, running and anchor lights and audible warning device capable of being heard anywhere within the BRZ. In addition, each boat wishing to enter the BRZ shall display a current State inspection sticker on the boat demonstrating the equipment meets current state safety standards.

c. A marine band radio (VHF) capable of communication with the Contracting Officer /Dam Operator must be available to the boat operator. Failure to maintain communication with the Contracting Officer/Dam Operator during the period boats are operating within the BRZ is cause for removal from the BRZ and for future BRZ access denial.

d. The boat operator shall remain at the boat controls and have no other duties while inside the BRZ.

e. A throw ring and rescue bag with throw line shall be available. The rescue line length shall be of sufficient length to reach personnel which have gone overboard. A minimum length of 75 feet of buoyant line is required.

f. A spotlight which can be easily operated by the boat operator must be available.

g. A second boat of sufficient size, capable of safely removing "ALL" personnel from the work zone, must be standing by for rescue purposes. Both boats must remain in radio contact with each other and the Contracting Officer/Dam Operator. The rescue boat is not to perform any work. It is to be manned by a boat operator and at least one rescue individual.

h. Both boats must be powered by engines capable of motoring upstream at twice the speed of the quickest flow that will be encountered inside the BRZ while fully loaded and operational.

i. Each boat must have two motors, & be of sufficient size to safely remove "ALL" personnel from the work zone.

j. Each motor must have a separate fuel system to isolate any fuel contamination problems.

k. Each boat shall have an adequate size tow line capable of towing a disabled boat to safety.

l. The Project will issue identification flags for all vessels that are granted permission to enter the BRZ. These flags shall be displayed clearly and prominently at all times the boat is in the BRZ. If diving, a 1-meter square Code Alpha Flag as well as a "Diver Down" flag must be flown a minimum of five feet above the vessel's highest point.

m. All boat operators must present their credentials prior to initiation of work. This will include all licenses, certifications and a resume of appropriate experience. Each operator must be approved by the Operations Project Manager (or their Representative) prior to beginning work.

n. Boat operators shall have and review latest river charts in the BRZ area.

3.6 Diving Work Description (See drawings and Contractor Tasks for more information)

Normal reservoir elevation is 786.00. Diving shall be as required to support the following underwater tasks:

Guide Slot Inspection;

Guide Slot Debris Removal/Reparation as required by Contracting Officer;

Removal of (2) Trashrack;

Seal Plate Inspection @ Intake Ceiling (~ELEV 642.58);

Seal Plate Inspection @ Vertical Sealing Surface (~ELEV 614.00-648.00);

Precast Bulkhead Seal Inspection (~ELEV 623.00);

Sealing surfaces Reparation– seal plate, bulkhead seal, etc. as required by Contracting Officer;

Placement of (2) Bulkheads Leakage Assistance

Safety

The contractor shall comply with all federal, state, and local safety regulations. The contractor shall also comply with 01 35 26 Governmental Safety Requirements. The contractor shall also comply with the USACE Safety and Health Requirement Manual, EM 385-1-1. Information regarding acquiring EM 385-1-1 may be found on the USACE Headquarters website at https://www.usace.army.mil/Safety-and-Occupational-Health/Safety-and-Health-Requirements- Manual/.

Prior to commencement of work under this contract, the contractor shall submit to the government an Accident Prevention Plan (APP) and Activity Hazard Analysis (AHA) in accordance with EM 385-1-1. For safety related to Diving, refer to “Diving” section above.

The contractor shall designate an employee responsible for overall supervision of accident prevention activities. Such duties shall include: (1) assuring applicable safety requirements are incorporated in work methods and (2) inspecting the work to ensure the safety measures and instructions are actually applied. The safety plan must be submitted in writing for acceptance by the Contracting Officer. The designated individual must be able to demonstrate his/her familiarity and understanding of the safety requirements over a prescribed trial period. The safety supervisor shall have authority to act on behalf of the contractor’s general management to take whatever action is necessary to assure compliance with safety requirements. The safety supervisor is required to be on site when work is being performed.

Submit a Critical Lift Plan for all identified critical lifts in accordance with EM 385-1-1 as part of the pre-work submittals.

Accident Reporting: In the event of an accident or injury involving contractor personnel or equipment in performance of work, the contractor must immediately notify the Contracting Officer’s Representative by the most expedient means feasible. The contractor shall complete forms furnished and/or provided a written description of the incident within 24 hours of notification to do so.

The work area is not accessible to the general public, but government personnel may be present within the work site. It is the responsibility of the contractor to maintain a safe work site, and to ensure that the work site and any potential hazards are clearly marked.

Submittals

Submittals shall be provided in accordance with requirements of the Division 01 Specifications.

Submittals required before work begins and after work is completed are listed below.

Pre-work submittals: Submittals designated with a ‘G’ require government approval, “DO” indicates District Office approval, otherwise the submittal is for information only.

1. Accident Prevention Plan (APP); G, DO

2. Schedule; G, DO

3. Work Plan; G, DO

4. Crane Technical Data Sheet; G, DO

5. Crane Operator Qualifications; G, DO

6. Critical Lift Plan; G, DO

7. Rigging Plan; G, DO

8. Load Test Plan; G, DO

9. Company Safe Practices Manual; G, DO

10. Dive Team Personnel Credentials G, DO to include:

a. Commercial Dive Training diploma from an accredited commercial dive school;

b. Dive Specialty Training if applicable to this contract (welding, mixed gas, saturation, etc.)

c. Recompression Chamber Operator

d. Health and Safety certifications including CPR, First Aid, BBP, diver-specific

Emergency Oxygen Administration;

e. Dive Logs / Dive Supervisor Logs – must be specific to dive team duties of this contract, must be from previous 12 months prior to commencement of dive operations; must show related work experienced required by this contract, such as Sur-D-O2 mixed gas, working with differential pressures, etc.

f. Annual Diving Physical

11. Dive Operations Plan and Schedule; G, DO

12. Activity Hazard Analysis; G, DO

13. Emergency Management Plan; G, DO

14. Equipment certifications, to include:

a. Certificate(s) of air quality;

b. Pneumatic gauge calibration;

c. Master test gauge calibration;

d. LP and HP hose tests;

e. Dive helmet inspection;

Construction submittals:

1. Guide Slot Inspection Report;

2. Slot Survey;

3. Precast sill survey. 1/16” tolerance;

4. Seal Submittal/Seal Fabrication drawings; G, DO

5. Steel Hardware/Bolts; G, DO

Post-work submittals: Two paper or digital copies of the following shall be submitted within 7 days to the Contracting Officer. All daily reports, as-built drawings, and other general submittals shall be submitted in accordance with the requirements of the Division 01 Specifications.