31_62_23.13.pdf

Green Brook, Segment C-1

AMENDMENT # 1

SECTION 31 62 23.13

CAST-IN-PLACE CONCRETE PILES, STEEL CASING

PART 1 GENERAL

Work this specification in conjunction with Section 31 63 29.

1.1 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.

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2015; Errata 1 2015; Errata 2 2016) Structural Welding Code - Steel

ASTM INTERNATIONAL (ASTM)

ASTM A252 (2010) Standard Specification for Welded and Seamless Steel Pipe Piles

ASTM D3966/D3966M (2007) Standard Test Methods for Deep Foundations Under Lateral Load

NATIONAL READY MIXED CONCRETE ASSOCIATION (NRMCA)

NRMCA QC 3 (2015) Quality Control Manual: Section 3, Plant Certifications Checklist:

Certification of Ready Mixed Concrete Production Facilities

1.2 SYSTEM DESCRIPTION

Perform the work through a general Contractor or a specialty subcontractor specialized in the specified flood wall system and having experience installing the specified piling system under similar subsurface conditions.

1.2.1 Subsurface Soil Data

Subsurface soil data logs are as indicated within the Attachments to this Contract.

1.2.2 Equipment

Submit descriptions of all pile installation equipment to be employed in the work, prior to commencement of pile installations.

1.3 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. Submittals with an "S"

SECTION 31 62 23.13 Page 1 are for inclusion in the Sustainability eNotebook, in conformance to Section 01 33 29 SUSTAINABILITY REPORTING. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Drilling And Laboratory Testing Procedures; G, DO Field Testing Procedures; G, DO

SD-02 Shop Drawings

Installation; G, RO, DO

SD-03 Product Data

Equipment; G, RO, DO Pile Lateral Load Test Plan; G, RO, DO Qualifications of 3rd Party NJ Licensed Professional Engineer/Firm overseeing the Test Pile Lateral Load Test; G, RO, DO Procedures to fill Annular Space at pile tip; G, RO, DO Drill Pile Casings; G, RO, DO

SD-06 Test Reports Load Test Report; G, RO, DO Survey; G, RO, DO Subsurface Report; G, RO, DO

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Concrete

Conform materials, mixing, and placing of concrete to the requirements of Section 03 30 00.00 10 CAST-IN-PLACE CONCRETE. Ready-mix plant equipment and facilities shall be certified in accordance with NRMCA QC 3. Minimum compressive strength at 28 days shall be 4000 psi. Maximum coarse aggregate size shall be 1/2 inch.

2.1.2 Casings

Provide casings with an outside diameters not less than 20 inch and thickness of 0.625. Casing steel is to be EWR straight seam pipe pile ASTM A252, Grade 3 (MOD) 50 ksi. Provide product data for drill pile casings.

Leave casings permanently in place. Provide casing drilling equipment with minimum torque capacity and downward force capacity suitable for the pipe pile to be drilled into the bedrock.

PART 3 EXECUTION

3.1 PREPARATION

The Contractor shall retain a third party Geotechnical Engineer or Geologist to drill 2 borings locations along the length of the floodwall alignment to determine the subsurface materials profile to the tip depth of the piles.

The borings will be drilled at the locations shown on the drawings (Structural Plans S-101D and S-103D) with one of the borings drilled at the location of the required lateral load test. Both borings shall be completed prior to the Contractor conducting the lateral load test. The Contractor

SECTION 31 62 23.13 Page 2 shall be responsible for utility clearance to ensure no existing utilities are damaged by the borings or equipment. The borings shall be sampled continuously to a depth of 5 feet below the planned tip depth of the pile at each location. Samples will be collected at 5 foot intervals to the required completion depth. Standard Penetration Test (SPT) methods and procedures (140# hammer, thirty-inch drop, 2 inch split spoon) will be applied to collect soil samples. The number of blows required to drive the split spoon every 6 inches will be recorded. Samples will be collected and stored in clearly labeled plastic jars (1 pint). Boring identification, sample number, depth interval and blow counts will be clearly printed on both the top and sides of each jar. Soil samples will be described using the Unified Soil Classification System and the Burmister method to quantify the major and minor components (gravel, sand, silt and clay). Minor components will be described as “trace” (0-10%), “little” (10-20%), “some” (20-35%) or “and” (35-50%). Upon reaching SPT refusal (defined as N-values from SPT testing are greater than 50 blows/inch),use rock coring techniques to obtain rock core and drill to the required depth. The borings and rock cores shall be performed in accordance with EM 1110-1-1804 and ASTM D1586 and ASTM D2113 under the observation of the Geotechnical Engineer or Geologist, and the soil and rock samples shall be photographed and classified in the field prior to transport. Following completion of the borings, all boreholes shall be properly grouted in accordance with NJDEP regulations. Repair of any settled boreholes shall be the responsibility of the Contractor.

The Contractor shall obtain samples of rock for assessment of Elastic Modulus by performing laboratory testing on rock samples collected from the borings.

At least 2 tests shall be performed (one from each boring) to determine the Elastic Modulus, and they shall consist of uniaxial compression testing method as listed in EM 1110-1-2908 Section 4-21a, and be performed in accordance with ASTM D7012 Method D Guidelines for the test method. The soil rock samples shall be retained by the Geotechnical Engineer for one year after submittal of the results, and then delivered to a Corps approved facility for longer term storage in case additional testing is required. At least two weeks prior to drilling, the Contractor shall submit to the Government for approval their proposed drilling and laboratory testing procedures and field testing procedures. Within three weeks of completion of field activities, the Contractor shall submit a report of the results to the Government for review. The report shall include photographs of the rock cores taken in the field, boring logs, the results of the testing, and comparison to the empirical method presented in EM 1110-1-2908 Section 4-22b. Absolutely no production piles shall be ordered or installed prior to Government review and approval of the report and test results. The Contractor shall build into their construction schedule a minimum three week period for Government review and approval of the Contractor's Subsurface report.

3.2 INSTALLATION

Pipe piles are required to extend to the elevations shown. Submit drawings demonstrating compliance of installation equipment and steel casing with contract documents. Include in the drawings shop and erection details, casing details, end closures, splices, driving helmets, and reinforcement.

A lateral pile load test is required prior to installation of any production piles. The load test is discussed in a subsequent section of the specifications. The following paragraphs describe the required installation procedures for the load test pile as well as the production piles. It is critical that the same procedures are followed for both the load test and production piles so that the test pile accurately models the expected performance of the production piles.

SECTION 31 62 23.13 Page 3

Drill pipe piles to at least elevation shown or deeper. Remove all loose or soft materials, drilling fluids and water from within the piles. It is critical that the annular space that remains after drilling between the pipe piles and rock/overburden is completely filled with concrete to ensure full contact between the pipes and the surrounding rock/overburden. A common method to accomplish this once the hole has been drilled to the required depth is to partially fill the pile with concrete, raise the pile to allow concrete to flow out of the bottom of the pile and fill the entire borehole, then spin the pile back down to the bottom of the hole and seat it in the bedrock. However, the means and methods of accomplishing a complete filling of the annular space with concrete to ensure full contact between the pipes and the surrounding rock/overburden are up to the contractor. The Contractor shall submit to the Government for approval the procedures they propose to use to ensure full contact. Only Government approved methods shall be employed.

Establish lines, levels, and pipe pile centerline locations, staked and maintained by a registered surveyor or engineer. Survey final pile locations and provide to Government for review. Submit a certified copy of the survey.

3.2.1 Filling of Casings

Visually inspect each casing after its final installation and prior to depositing the concrete and placing the reinforcement. Notify the Contracting Officer prior to each such inspection to allow for quality assurance inspections of all casings. The inspection will verify the integrity of the casing throughout its length and the absence of distortion and reduction in area. Deposit concrete in the casing in a continuous operation by means of a funnel or hopper after all mud, water and other extraneous material has been removed from its interior.

3.2.2 Cutting of Casings

Cut casings with an acetylene torch or saw with prior approval by the Contracting Officer.

3.2.3 Welding

Perform shop and field welding, qualification of welders, and inspection of welds in accordance with AWS D1.1/D1.1M.

3.2.4 Splicing

Splices may be used after review by the Contracting Officer. No more than two splices per full length of casing will be permitted. They shall be able to transmit any vertical and lateral forces adequately, and in addition, develop no less than 50 percent of the flexural capacity of the ordinary pile casing cross section. Make lateral joints with a continuous full penetration butt weld in accordance with AWS D1.1/D1.1M or as approved by the Contracting Officer.

3.3 FIELD TESTS AND INSPECTIONS

3.3.1 Test Piles

Submit a complete report on the load test, within 14 days of completion of load test, including, but not limited to, a description of the pile

SECTION 31 62 23.13 Page 4 installation equipment, deflection records for both test piles and reaction piles, complete test data, and analysis of test data. The report shall be prepared by or under the direct supervision of a registered Professional Engineer (P.E.) licensed in the State of New Jersey experienced in pile load testing and load test analysis.

3.3.1.1 Lateral Load Test

Perform a load test in accordance with ASTM D3966/D3966M loading method. The load test pile shall be sacrificial and is not to be used in the construction of the floodwall. The load test pile will be loaded to 90101 kips (200%100% of design load) and 113135 kips (250% 133% of design load) in loading increments as described under ASTM D3966 over two consecutive cycles (design load = 45 kips). Terminate the cyclic loading test if at any point during the test the deflection at point of load application equals or exceeds 4.2 inches. Perform load test at the Government approved location in the vicinity of the floodwall as shown on the Drawings, but no closer than 4 pile diameters from the wall limits to avoid disturbing the subsurface conditions along the wall alignment.

Additional load testing, at the expense of the Government, may be required.

Pile and concrete shall have been in place a minimum of 28 days before load testing to ensure full concrete strength.

Perform loading, testing, and recording of data under the direct supervision of a registered Professional Engineer (P.E.) licensed in the State of New Jersey. The P.E. shall perform analysis of the load test and present the results in a signed and sealed report. The registered professional engineer shall be provided and paid for by the Contractor.

After testing the test pile and any reaction structures must be cut-off to below gound level or removed from the worksite.

3.3.2 Concrete Testing

During Concrete placement, strength tests will be made by a testing service provided and paid for by the Contractor in accordance with requirements of Section 03 30 00.00 10 CAST-IN-PLACE CONCRETE. Take at least two specimens from each random batch and one test will be made for every 3 piles with no less than two tests for any 1 day's operation.

-- End of Section --

SECTION 31 62 23.13 Page 5

1.3 SUBMITTALS

3.3.2 Concrete Testing