TechSpec_21B0015_Amend-0003.pdf

SUBMITTAL FORM,Jan 96 PREVIOUS EDITION IS OBSOLETE PAGE 1 OF 5 PAGES

W912EF21B0015

McNary Powerhouse Intake Deck Concrete Beam Rehabilitation

01 11 01.00 28 SD-01 Preconstruction Submittals

1.6 I CEquipment List

1.10 I CPre-Construction On-Site

Inspection report

1.11 I CProject Superintendent

SD-07 Certificates

1.12 G CKey Personnel Substitution

01 14 00.90 28 SD-01 Preconstruction Submittals

1.4 I CAnti Terrorism (AT) Level 1

1.7 I CiWATCH, CORPS Watch, or See

Something, Say Something

1.8 I CLevel 1 OPSEC training

1.10 I CPre-Screen Candidates Using

E-Verify Program

1.3 G CBiographical Information

01 32 01.00 28 SD-01 Preconstruction Submittals

1.3 G CProject Scheduler Qualifications

3.4.1 G CPreliminary Project Schedule

3.4.2 G CInitial Project Schedule

3.6.2 G CPeriodic Schedule Update

01 35 29.10 28 SD-01 Preconstruction Submittals

1.7 G CAccident Prevention Plan (APP)

1.8 G CActivity Hazard Analysis (AHA)

1.9 I CSafe Clearance

1.9 I CAuthorized Individuals

1.7.2.2 G CStandard Lift Plan

SUBMITTAL REGISTER

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McNary Powerhouse Intake Deck Concrete Beam Rehabilitation

01 35 29.10 28 1.7.2.3 G CCritical Lift Plan

1.13.5 G STCrane Wheel And Outrigger

Loading Diagram And Deck

Protection For Outriggers

1.6.1.1 G CSSHO And Alternate SSHO

1.6.1.2 G CCompetent Person Qualifications

1.15.1 G SORadiography Operation Planning

Work Sheet

SD-06 Test Reports

1.4 I CMonthly Exposure Reports

1.13 I CNotifications and Reports

1.13.2 I CAccident Reports

1.13.3 I CLHE Inspection Reports

SD-07 Certificates

1.6.1.3 I CCrane Operators/Riggers

1.7.2.3 I CNaval Architecture Analysis

1.7.2.4 I CNaval Architecture Analysis

1.10.1 I CConfined Space Entry Permit

1.10.1 I CHot Work Permit

1.13.4 I CCertificate of Compliance

1.15 I CLicense Certificates

01 45 04.00 28 SD-01 Preconstruction Submittals

3.2 G CContractor Quality Control (CQC)

Plan

01 55 10.00 28 SD-01 Preconstruction Submittals

1.10 G STTransport Loading Diagrams

SUBMITTAL REGISTER

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McNary Powerhouse Intake Deck Concrete Beam Rehabilitation

01 55 10.00 28 1.18 I CDust Control Plan

1.14 I CFloating Plant

1.8.1 G CDebris Containment Plan

1.7 G STAccess Plan

1.7 G STWork Plan

1.15 G CEvacuation Plan For BRZ Work

01 57 20.00 28 SD-01 Preconstruction Submittals

1.6 G ECCEnvironmental Protection Plan

1.6.2 G ECCPlan for Concrete On-Site Wash

Area

01 78 00.00 28 SD-11 Closeout Submittals

3.1 G CFinal Shop Drawings

3.2.1 I CWorking As-Built Drawings

3.3 G CFinal As-Built Drawings

3.4 G GERecord Drawings

3.6 G CGovernment Issued Items

03 01 00.01 28 SD-05 Design Data

1.6 G STDesign Data

SD-07 Certificates

1.4 G STDesigner of Record Qualifications

03 01 00.02 28 SD-01 Preconstruction Submittals

1.5.3.1 G STTesting Agencies Qualifications

1.5.3.2 G STQuality Control Personnel

Qualifications

1.5.3.4 G STWorker Qualifications

SUBMITTAL REGISTER

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McNary Powerhouse Intake Deck Concrete Beam Rehabilitation

03 01 00.02 28 1.8 G STQualification For Epoxy

Reinforcing Installers

2.2 R STFormwork System

2.3 A STEquipment For Concrete

Preparation

1.5.3.3 G STContractor Qualifications

3.4.6.4 A STBond Test Procedures

SD-02 Shop Drawings

3.2.1 R STFormwork Shop Drawings

3.3.1 R STReinforcing Shop Drawings

SD-03 Product Data

2.6 A STPost-Installed Epoxy Adhesive

2.7 G STLow-Pressure Epoxy Adhesive

SD-06 Test Reports

3.4.6.4 R STBond Test Result

03 30 00.00 28 SD-01 Preconstruction Submittals

1.7 G GTQualifications

3.4.4 D GTHot Weather Placing

3.4.3 D GTCold Weather Placing

SD-03 Product Data

2.1.4 D GTMembrane-Forming Curing

Compound

SD-05 Design Data

1.5 D GTMaterials And Mix Design -

Preliminary

1.6 R GTMaterials and Mix Design - FINAL

SUBMITTAL REGISTER

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McNary Powerhouse Intake Deck Concrete Beam Rehabilitation

03 30 00.00 28 SD-06 Test Reports

3.9.2 G GTTests Results

SD-07 Certificates

3.9.1 G GTTesting Agency And Inspector

Qualifications

03 60 00.01 28 SD-01 Preconstruction Submittals

3.2.1 G STDrilling Procedures

SD-03 Product Data

3.3.1 G STNon-Shrink Grout

SD-06 Test Reports

3.2.1 D STConcrete Imaging Report

SUBMITTAL REGISTER

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McNary Powerhouse Intake Deck Concrete Beam Rehabilitation W912EF21B0015 Amend-0003

SECTION TABLE OF CONTENTS

DIVISION 03 - CONCRETE

SECTION 03 01 00.02 28

FORM AND PUMP PLACEMENT

PART 1 GENERAL

1.1 DESCRIPTION OF WORK

1.2 DEFINITIONS

1.2.1 Form and Pump

1.2.2 Delamination

1.2.3 Rehabilitation

1.2.4 Repair

1.2.5 Termination Joint

1.2.6 Unsound Concrete

1.3 REFERENCES

1.4 SUBMITTALS

1.5 QUALITY ASSURANCE

1.5.1 General Requirements

1.5.2 Quality Control Plan

1.5.3 Qualifications

1.5.3.1 Testing Agencies Qualifications

1.5.3.2 Quality Control Personnel Qualifications

1.5.3.3 Contractor Qualifications

1.5.3.4 Worker Qualifications

1.5.3.5 Regulatory Requirements

1.5.4 Pre-Construction Meeting

1.5.5 Access Plan

1.5.6 Work Plan

1.5.7 Debris Containment Plan

1.6 ACCEPTANCE OF REHABILITATION WORK

1.6.1 General Requirements

1.6.2 Tolerances

1.6.3 Appearance

1.7 PROTECTION OF COMPLETED REHABILITATION WORK

1.8 QUALIFICATION FOR EPOXY REINFORCING INSTALLERS

PART 2 PRODUCTS

2.1 PRODUCT DELIVERY, HANDLING AND STORAGE

2.2 FORMWORK SYSTEM

2.2.1 Formwork Materials

2.2.2 Formwork Design Calculations

2.2.2.1 Design Requirements

2.2.2.2 Formwork Loads and Pressure

2.3 EQUIPMENT FOR CONCRETE PREPARATION

2.3.1 Hydro-Demolition Equipment

2.3.2 Mechanical Chipping Equipment

2.3.3 Other Abrasive Blasting

2.4 SELF-CONSOLIDATING CONCRETE (SCC)

2.5 REINFORCEMENT AND REINFORCEMENT SUPPORTS

2.5.1 Steel Bars and Wires

2.6 POST-INSTALLED EPOXY ADHESIVE

SECTION 03 01 00.02 28

2.7 LOW-PRESSURE EPOXY ADHESIVE

PART 3 EXECUTION

3.1 GENERAL REQUIREMENTS

3.1.1 Examination

3.1.2 Protection

3.1.3 Quality Control of Surface Preparation

3.1.4 Clean up

3.1.5 Safety

3.2 FORMWORK

3.2.1 Formwork Shop Drawings

3.2.2 Formwork Installation

3.2.3 Formwork Removal

3.3 REINFORCING

3.3.1 Reinforcing Shop Drawings

3.3.2 Mild Steel Rebar Doweling

3.3.3 Conventional Rebar Reinforcing

3.4 CONCRETE SECTION ENLARGEMENT

3.4.1 Form and Pump Placement

3.4.2 Ground Penetrating Radar (GPR) Scanning

3.4.3 Surface Preparation

3.4.4 Concrete Pumping

3.4.4.1 Notification Prior to Placement

3.4.4.2 Pumping Equipment

3.4.4.3 Pressurization of the Formwork

3.4.5 Curing

3.4.6 Quality Control

3.4.6.1 Self-Consolidating Concrete (SCC)

3.4.6.2 Test Placement

3.4.6.3 Visual Testing

3.4.6.4 Bond to Substrate Testing

3.4.6.5 Non-Destructive Testing

3.5 POST-INSTALLED EPOXY ADHESIVE INSTALLATION

3.6 CRACK REPAIR

3.6.1 General Requirements

3.6.2 Sealing

3.6.3 Epoxy Injection

-- End of Section Table of Contents --

SECTION 03 01 00.02 28

SECTION 03 01 00.02 28

FORM AND PUMP PLACEMENT

PART 1 GENERAL

1.1 DESCRIPTION OF WORK

This specification provides the minimum requirements for concrete beam section enlargement utilizing the "Form and Pump" method of concrete placement. The contractor shall furnish all materials, tools, equipment, transportation, necessary storage, access, labor and supervision required for all structural strengthening work using Form and Pump concrete enlargement for the McNary Powerhouse Intake Deck Concrete Beam Rehabilitation.

The following specification sections contain additional requirements for the concrete section enlargement items being designed by the Contractor:

SECTION 03 01 00.01 28 CONCRETE SECTION ENLARGEMENT

SECTION 03 30 00.00 28 SELF-CONSOLIDATING CONCRETE (SCC)

SECTION 03 60 00.01 28 CONCRETE DRILLING AND PATCHING

1.2 DEFINITIONS

1.2.1 Form and Pump

Form and Pump as used in this specification refers to the placement of the concrete into a closed form with high performance self-consolidating concrete (SCC) pumped under pressure. Formwork pressurization improves the bond between the new and existing concrete, provides adequate consolidation of concrete around newly placed rebar, and ensures complete filling of the formwork.

1.2.2 Delamination

A planar separation in a material that is roughly parallel to the surface of the material.

1.2.3 Rehabilitation

Repairing or modifying an existing structure to a desired useful condition.

1.2.4 Repair

The reconstruction or renewal of concrete parts of an existing structure for its maintenance or to correct deterioration, damage, or faulty construction of members or systems of a structure.

1.2.5 Termination Joint

The interface where a placement of repair material meets existing concrete, the edge of an expansion joint, or other existing surfaces.

1.2.6 Unsound Concrete

Concrete that is fractured, delaminated, spalled, deteriorated, defective, contaminated or otherwise damaged.

1.3 REFERENCES

AMERICAN CONCRETE INSTITUTE (ACI)

ACI 117 (2010; Errata 2011) Specifications for Tolerances for Concrete Construction and Materials and Commentary

ACI 237R (2007) Self-Consolidating Concrete

ACI 318 (2019) Building Code Requirements for Structural Concrete (ACI 318-19) and Commentary (ACI 318R-19)

ACI 347R (2014; Errata 1 2017) Guide to Formwork for Concrete

ACI 347.2R (2017) Guide for Shoring/Reshoring of Concrete Multistory Buildings

ACI 355.4 (2011) Qualification of Post-Installed Adhesive Anchors in Concrete (ACI 355.4) and Commentary

ASTM INTERNATIONAL (ASTM)

ASTM A193/A193M (2019) Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service and Other Special Purpose Applications

ASTM C881/C881M (2015) Standard Specification for Epoxy-Resin-Base Bonding Systems for Concrete

ASTM C1077 (2017) Standard Practice for Agencies Testing Concrete and Concrete Aggregates for Use in Construction and Criteria for Testing Agency Evaluation

ASTM C1583/C1583M (2013) Standard Test Method for Tensile Strength of Concrete Surfaces and the Bond Strength or Tensile Strength of Concrete Repair and Overlay Materials by Direct Tension (Pull-off Method)

ASTM D4580/D4580M (2012) Standard Practice for Measuring Delaminations in Concrete Bridge Decks by Sounding

ASTM E329 (2020) Standard Specification for Agencies Engaged in Construction Inspection, Testing, or Special Inspection

INTERNATIONAL CONCRETE REPAIR INSTITUTE (ICRI)

ICRI 210.3R (2013) Guide for Using In-Situ Tensile Pulloff tests to Evaluate Bond of Concrete Surface Materials

ICRI 310.2R (2013) Selecting and Specifying Concrete Surface Preparation for Sealers, Coatings, Polymer Overlays, and Concrete Repair

1.4 SUBMITTALS

Review notations following the Submittal titles indicate the SUBMITTAL CLASSIFICATION (G, I, D, C, R, A), followed by the REVIEWING AUTHORITY.

See SECTION 01 33 00 SUBMITTAL PROCEDURES, paragraphs SUBMITTAL CLASSIFICATION, "Contractor Action Codes", and "Reviewing Authority" for definitions of review notations. Submit in accordance with SECTION 01 33 00

SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Testing Agencies Qualifications ; G, ST

Quality Control Personnel Qualifications ; G, ST

Worker Qualifications ; G, ST

Qualification For Epoxy Reinforcing Installers ; G, ST

Formwork System ; R, ST

Equipment For Concrete Preparation ; A, ST

Contractor Qualifications ; G, ST

Bond Test Procedures ; A, ST

SD-02 Shop Drawings

Formwork Shop Drawings ; R, ST

Reinforcing Shop Drawings ; R, ST

SD-03 Product Data

Post-Installed Epoxy Adhesive ; A, ST

Low-Pressure Epoxy Adhesive ; G, ST

SD-06 Test Reports

Bond Test Result ; R, ST

1.5 QUALITY ASSURANCE

1.5.1 General Requirements

a. Follow the requirements of Section 03 30 00.00 28 SELF-CONSOLIDATING CONCRETE (SCC) for Work involving self consolidating concrete.

b. Installation and removal of work site access platforms, ladders, fall protection, to include surface preparation debris containment.

c. Installation and removal of all formwork for concrete enlargement.

d. Furnishing, placing, finishing and curing all cementitious materials required for concrete enlargement.

e. Furnishing and installing all required reinforcing steel, dowels, and anchors for concrete enlargement applications.

f. To protect personnel from overexposure to toxic materials, conform to the applicable manufacturer's Safety Data Sheets (SDS) or local regulations. Submit manufacturer's SDS for all potentially hazardous materials.

f. Inspection and testing of surface preparation, placement of reinforcing steel, as well as new concrete bond to substrate must be in accordance with provisions included herein and the Contract Documents.

e. Sampling and testing of materials, as well as inspection and testing of work, must be in accordance with established procedures, manufacturer's instructions, specific instructions from the Contracting Officer if given, or recommended practices as referenced herein and the Contract Documents.

f. Trial batches and testing requirements for various repair materials specified are the responsibility of the Contractor.

g. The testing agency must inspect, sample, and test repair materials and concrete production as required. When it appears that material furnished or work performed by Contractor fails to conform to Contract Documents the testing agency will immediately report such deficiency.

1.5.2 Quality Control Plan

Submit a quality control plan as specified in Sections 01 45 04.00 28 CONTRACTOR QUALITY CONTROL and 03 30 00.00 28 SELF-CONSOLIDATING CONCRETE

(SCC).

1.5.3 Qualifications

The submittals must identify agencies and individuals who will be working on this contract and their relevant experience. Do not make changes in approved agencies or personnel without prior approval of the Contracting Officer.

1.5.3.1 Testing Agencies Qualifications

In addition to the requirements of Section 01 45 04.00 28 CONTRACTOR QUALITY CONTROL, agencies that test concrete materials shall meet the requirements of ASTM C1077. Testing agencies that test or inspect placement of reinforcing steel shall meet the requirement of ASTM E329.

Submit data on qualifications of Contractor's proposed testing agency for acceptance.

1.5.3.2 Quality Control Personnel Qualifications

Field tests of repair materials required must be made by an ICRI Concrete Surface Repair Technician Tier 2. Submit resumes, pertinent information, past experience, training and education of all operators of specialized demolition equipment. a. All required testing and inspections shall be performed by personnel holding current industry certifications for tests and inspections performed.

b. Final surface preparation inspections must be performed by an ICRI Concrete Surface Repair Technician, Tier 1.

c. Submit current certifications, resumes, pertinent information, past experience, training and education of all testing personnel, inspection personnel, and operators of specialized demolition equipment.

1.5.3.3 Contractor Qualifications

The contractor performing the repair work must have completed a minimum of four (4) Form and Pump enlargement projects similar in size and scope to this project in the past ten (10) years. Submit information, including name, dollar value, date, description of work, and point-of-contact for similar projects which demonstrates the required experience and training.

1.5.3.4 Worker Qualifications

a. Each worker engaged in the use of specialized removal or application equipment, including hydromilling equipment operators, epoxy injection, epoxy anchor and reinforcement installation, formwork installation, pumping of self consolidating concrete, work site access, debris containment, fall protection, and any other aspects of this work must have satisfactorily completed an instruction program and three years of experience in the operation of the equipment.

b. Workers installing adhesive anchors and reinforcing must be ACI Adhesive Anchor Installer certified or equivalent.

1.5.3.5 Regulatory Requirements

Perform all work in accordance with applicable Federal, State, and local safety, health, and environmental requirements. The Contractor is responsible for obtaining all permits required by Federal, State, and local agencies for the performance of the work.

1.5.4 Pre-Construction Meeting

Conduct a pre-construction meeting as outlined in SECTION 01 11 01.00 28 to discuss repair materials performance requirements, control provisions, and roles and responsibilities for the work to ensure that the Contractor's personnel understand all aspects of the repair material, its properties and application procedures.

1.5.5 Access Plan

Contractor shall submit their work access methods describing access to be used for the work in accordance with 01 55 10.00 28 "ACCESS TO WORK AREA".

Contractor shall account for the existing condition of intake deck, beam and pier walls in access plan. Anchorage to concrete shall maintain

SECTION 03 01 00.02 28

minimum clearances from existing cracks in the structure.

1.5.6 Work Plan

Contractor shall submit their work plan in accordance with 01 55 10.00 28

"ACCESS TO WORK AREA".

1.5.7 Debris Containment Plan

Contractor shall submit their debris containment methods to be used for the work in accordance with 01 55 10.00 28 "DEBRIS CONTAINMENT SYSTEM".

Contractor shall account for the existing condition of intake deck, beam and pier walls in debris containment plan. Anchorage to concrete shall maintain minimum clearances from existing cracks in the structure.

1.6 ACCEPTANCE OF REHABILITATION WORK

1.6.1 General Requirements

a. Completed concrete rehabilitation work must conform to applicable requirements of Contract Document and this specification. The Contractor is responsible to bring Work into compliance with requirements of Contract Documents if the Concrete repair work fails to meet one or more requirements of Contract Documents.

b. Correct rejected repair work by removing and replacing or by strengthening with additional construction acceptable to the Contracting Officer. Use repair methods that meet applicable requirements for function, durability, dimensional tolerances, and appearance.

c. Submit proposed work plan, repair methods, materials, and modifications to the Work needed to correct rejected repair work to meet the requirements of Contract Documents.

1.6.2 Tolerances

a. Construction tolerances for repairs must conform to ACI 117 . For conditions not shown or that are different than indicated in the Contract Documents, notify the Contracting Officer before proceeding with the work at those locations.

b. Inaccurately formed concrete surfaces resulting in concrete members with dimensions that exceed ACI 117 tolerances are subject to rejection.

1.6.3 Appearance

Concrete surfaces not meeting the requirements of the Contract Documents must be brought into compliance.

1.7 PROTECTION OF COMPLETED REHABILITATION WORK

a. Do not allow construction loads to exceed the loads that a structural member or structure is safely capable of supporting without damage.

Provide supplemental support if construction loads are expected to exceed safe load capacity.

b. Protect repaired and adjacent areas from damage by construction traffic, equipment, and materials. During the curing period, protect repair materials from damage by mechanical disturbances, including load-induced stresses, shock, and vibration.

c. Protect repair materials from environmental damage by weather events during the length of the curing period.

1.8 QUALIFICATION FOR EPOXY REINFORCING INSTALLERS

Epoxy reinforcing and anchor installers shall be qualified for the particular type of epoxy adhesive to be installed. Certification shall include written and performance tests in accordance with the ACI/CRSI Adhesive Anchor Installer Certification program as prescribed in ACI 318 , within 12 months prior to performing work on this contract. The anchor installers shall be required to repeat the certification program when, in the opinion of the Contracting Officer, their work indicates a reasonable doubt as to their proficiency. Certification shall be submitted for those passing the test and upon approval, they shall be considered qualified.

Those not passing shall be disqualified until passing. All expenses in connection with qualification or requalification shall be borne by the Contractor.

Alternately, the Contractor can arrange for the epoxy manufacturer's representative to provide onsite installation training for all of their anchoring products specified. The Contracting Officer must receive documented confirmation that all of the Contractor's personnel who install anchors are trained prior to the commencement of installing anchors.

PART 2 PRODUCTS

Products or materials used must conform to the requirements included herein as well as the Contract Documents. The usage of other products or materials not covered by this requirement or specified in the Contract Documents are permitted upon approval by the Contracting Officer.

Additional information and submittals for products and materials not included in this document including product data, samples, design data, test reports, certificates, manufacturer's instructions, and field reports must be submitted as requested by the Contracting Officer.

2.1 PRODUCT DELIVERY, HANDLING AND STORAGE

a. Deliver materials in factory-sealed containers with the manufacturer's labels intact and legible with verification of date of manufacture and shelf life.

b. Products shall be stored according to the manufacturer's requirements and shall avoid contact with soil and moisture.

2.2 FORMWORK SYSTEM

Formwork System must be approved prior to fabrication and installation of associated materials and equipment. Formwork System submittal must include each of the following items:

a) Formwork Materials

b) Formwork Design Calculations

2.2.1 Formwork Materials

a. Plywood Forms shall be APA approved "Structural Plyform," or approved class I or class II with thickness required to support concrete at the rate at which it is poured.

b. Steel Forms may be used in lieu of wood, at the project engineer's option.

c. Wood framing shall be standard grade or better, Douglas Fir.

d. Form Coatings and Form sealer shall be non-staining, non grain raising, free of mineral oils or other non-dry ingredients and leaving no bond-inhibiting residues on concrete.

e. Form ties shall be approved type by manufacturer for conditions of installation. No exposed metal shall be allowed within 1 inch of surface after tie removal. Exposed ends of steel used for form anchoring shall be coated to minimize corrosion.

f. Install and remove formwork without damaging or staining the existing structure or repair material.

g. Forms used for SCC must be tight enough to hold the material that is used without leaking. All surfaces where bond is not desired, but which are exposed to the SCC, must be treated with a form release agent.

2.2.2 Formwork Design Calculations

2.2.2.1 Design Requirements

a. Formwork design and detailing shall conform to ACI 347R unless otherwise noted.

1. Shall prevent leakage or washing out of cement mortar

2. Shall resist spread, shifting, and settling after concrete placement

b. Shoring shall conform to ACI 347.2R unless otherwise noted.

c. Shall carry vertical and lateral loads to ground either independently or in combination with portions of structure which have adequate strength.

2.2.2.2 Formwork Loads and Pressure

a. Vertical Loads: Vertical loads should include both the dead and live loads. Dead loads include the weight of the formwork plus the weight of reinforcement and the concrete. Live loads include the weight of workers, equipment, material storage, runways, and impact.

b. Lateral Pressure of Concrete: For Form and Pump, pressures in excess of the equivalent hydrostatic head will occur under closed form systems. Formwork design and shoring should accommodate the expected liquid head pressures due to the fast casting rate of the self consolidating concrete. SCC formwork shall be designed per ACI 347R .

The formwork shall be designed for full hydrostatic head of concrete, a minimum allowance of 25% for pump surge pressure, and minimum 2 psi internal pressure from pumping.

2.3 EQUIPMENT FOR CONCRETE PREPARATION

Means and methods used for surface preparation must be selected and used such as to minimize damage to the structure and to the concrete substrate that remains. All existing concrete surfaces to receive enlargement shall be roughened to achieve concrete surface profile of 1/4" which corresponds to CSP 6 profile or better, as specified by ICRI.

Concrete surface profiling shall be achieved using one of the methods listed below in order to achieve a CSP 6 or higher surface profile to the enlargement substrate. Removal equipment and techniques must be suitable to produce concrete surface profiles and level of cleanliness in designated areas as required by this specification.

2.3.1 Hydro-Demolition Equipment

a. Hydro-Demolition equipment must include a trailer-mounted water tank, pumps, high-pressure hose, wand with safety release cutoff control, nozzle, and auxiliary water re-supply equipment. The water tank and auxiliary re-supply equipment must be of sufficient capacity to permit continuous operations.

b. Use protective covers and barriers to protect adjacent surfaces not intended to be repaired from water blasting and over-spray.

c. Use equipment capable of delivering pressures of 15,000 psi or greater for concrete removal and surface preparation.

d. A mock-up shall be performed to confirm that the proper profile can be achieved as there are many variables including the strength of the existing concrete

e. When using hydro demolition, the following items shall be addressed in the EQUIPMENT FOR CONCRETE PREPARATION.

1. Source of water

2. Protecting the surrounding areas, specifically the Fish Collection Channel below, from the infiltration of water and debris.

3. Methods for containment of "waste water".

4. Handling of "waste water" including the filtering and disposing.

5. Providing safe access to the work area and surfaces for the technicians who perform the work.

2.3.2 Mechanical Chipping Equipment

a. This method uses electric or pneumatic chipping guns to remove the top layer of the concrete surface

b. The concrete surfaces shall be free of any contaminants that may interfere with bond.

c. After the surface has been completely chipped, the surface shall be blasted using sandblasting or high pressure water blasting (5000 psi) to remove loose and fractured materials in the concrete that can affect the bond.

d. "Bush hammering" shall not be used to achieve the specified surface profile.

2.3.3 Other Abrasive Blasting

a. This method uses compressed air to propel an abrasive blast media at the substrate in order to remove the top layer of concrete and create a CSP 6 or greater profile

b. As this method is not viable on some concrete materials, a mock-up shall be performed to confirm that the proper profile can be achieved as there are many variables including the strength of the existing concrete, and the blast media utilized.

2.4 SELF-CONSOLIDATING CONCRETE (SCC)

Self-Consolidating Concrete shall be a special high flow concrete suitable for the Form and Pump procedures. SCC materials must meet the requirements specified in Section 03 30 00.00 28 SELF-CONSOLIDATING CONCRETE (SCC).

2.5 REINFORCEMENT AND REINFORCEMENT SUPPORTS

2.5.1 Steel Bars and Wires

a. Reinforcement and reinforcement support must meet the requirements specified in Section 03 30 00.00 28 SELF-CONSOLIDATING CONCRETE (SCC).

b. Submit mill certificates and shop drawings as requirement by SECTION 03 01 00.01 28 and SECTION 03 30 00.00 28 SELF-CONSOLIDATING CONCRETE

(SCC).

2.6 POST-INSTALLED EPOXY ADHESIVE

Epoxy adhesive for post-installed reinforcing bars and anchors shall contain the following minimum salient characteristics:

1. Approved for installation in water saturated concrete conditions.

2. Approved for cracked concrete installation conditions.

3. Approved for installation temperatures ranging from 25 degrees to 100 degrees Fahrenheit.

4. Approved by ACI 355.4

5. Threaded inserts and bolts for replacement of removable exclusion screen bolted connection shall be ASTM A193/A193M Grade B7, hot-dipped galvanized or zinc plated, unless approved otherwise.

2.7 LOW-PRESSURE EPOXY ADHESIVE

Cracks shall be repaired with low-pressure epoxy that conforms to ASTM C881/C881M, Type I/IV, Class B/C, Grade 3 having medium to gel viscosity.

PART 3 EXECUTION

3.1 GENERAL REQUIREMENTS

3.1.1 Examination

Locate area of unsound concrete or delamination using hammer sounding or chain drag sound methods in accordance to ASTM D4580/D4580M . Denote and mark perimeter boundaries and notify the Contracting Officer to approve the unsound concrete layout boundaries.

3.1.2 Protection

Protect pedestrians, motorized traffic, mechanical, and electrical equipment, surrounding construction, project site, and surrounding buildings from damage or injury resulting from concrete rehabilitation work. All construction work shall be preformed in accordance with SECTION

01 57 20.00 28 ENVIRONMENTAL PROTECTION.

a. Construct dust and debris barriers surrounding repair work perimeter to control dust, debris, and to protect and control construction traffic.

b. Dispose of runoff from wet demolition or surface preparation operations in accordance with all local ordinances. Disposal methods must avoid soil erosion, avoid undermining pavements and foundations, damage to landscaping and vegetation, and minimize water penetration through other parts of buildings.

c. Collect and neutralize alkaline wastes and acid wastes and dispose in accordance with local, state, and federal regulations.

d. Comply with local noise ordinances during demolition operations.

e. Perform demolition work and surface preparation work in a manner that minimizes disturbances of operations. Coordinate work with the Contracting Officer.

f. Submit an Environmental Protection Plan for approval by the Government in accordance with SECTION 01 57 20.00 28 "ENVIRONMENTAL PROTECTION

PLAN" .

3.1.3 Quality Control of Surface Preparation

Evaluation of prepared substrate must be continuously monitored to assure that the prepared substrate surface meets project requirements.

3.1.4 Clean up

a. Clean and remove all spills and leaks of injection adhesive and stains caused by the injection adhesives.

b. Dispose wastewater used for cutting and cleaning without staining or damaging the existing surfaces of the structure or the environment of the project area. The method of disposal must meet all the requirements of SECTION 01 57 20.00 28 ENVIRONMENTAL PROTECTION.

3.1.5 Safety

a. Provide Material Safety Data Sheets (MSDS) for products on site reviewing them before work begins.

b. Provide safety guards, maintenance, and warnings for all machinery and equipment.

c. Have personal protection equipment practice in place - eye protection and face guards.

d. Have all workers in contact with wet cementitious material wear protective gloves and clothing.

e. Provide eyewash facilities on-site with location signage.

f. Provide dust masks for workers operating mixers.

g. Have confined space procedures in place including adequate ventilation in closed spaces before operating equipment or using products that emit potentially dangerous or toxic exhaust, fumes, or dust.

h. Provide secured storage available for all hazardous or flammable materials.

i. Conduct safety meetings prior to beginning repair operations.

3.2 FORMWORK

Execution of formwork and shoring must meet the following requirements and those specified in "FORMWORK SYSTEM" and SECTION 03 30 00.00 28

SELF-CONSOLIDATING CONCRETE (SCC).

3.2.1 Formwork Shop Drawings

Formwork shop drawings of all formwork system shall be submitted to the Government for review and no formwork shall be delivered to the job site until the related shop drawings have been reviewed by the Government.

Formwork shop drawings shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES. No partially complete shop drawing sheet will be reviewed. Formwork shop drawings shall be of such nature as to clearly indicate all details and position of all formwork and components.

3.2.2 Formwork Installation

a. Construct forms to sizes, shapes, lines, and dimensions to match existing adjacent surfaces and textures. Provide forms that match openings, offsets, chamfers, anchorages, inserts and other features as shown in "Design Drawings" required by SECTION 03 01 00.01 28 paragraph "Design Data". Construct forms to accommodate installation of products by other trades. Provide forms for easy removal to minimize damage to concrete surfaces and adjacent surfaces. Apply form release coating over formwork surfaces prior to each concrete placement. Form release agents must not be applied to or come in contact with the repair area concrete substrate or reinforcement.

b. Forms shall be sufficiently tight to prevent loss of mortar from the concrete, and braced to remain true during and after concrete placement within tolerances of section of this specification.

c. No wooden elements shall be allowed to remain in the concrete.

d. Provide vent openings at the top of formwork or wherever necessary to vent entrapped air, bleed water and loose slurry materials.

e. Plug vents to pressurize the formwork after bleed water and entrapped air is removed, and good material is observed.

f. Construct elements to meet the allowable tolerances of the dimensions, elevations, and positions shown and specified in "Design Drawings" as required by SECTION 03 01 00.01 28 paragraph "Design Data".

g. Deposit concrete only when the forms and placement of the reinforcement has been checked and approved by the Field Superintendent/Project Manager.

3.2.3 Formwork Removal

a. Maintain forms in place until the concrete has attained a minimum strength of 3,000 psi.

b. Do not damage repair material during removal of formwork. Perform needed repair and treatment required on vertical surfaces at once and follow immediately with specified curing. Remove all formwork anchors embedded in existing concrete. Fill anchor holes and repair all damage to existing concrete at anchor holes.

c. Form ties and bug holes shall be rubbed out with an approved repair material.

3.3 REINFORCING

The type and amount of reinforcing shall be determined in accordance with SECTION 03 01 00.01 28 CONCRETE SECTION ENLARGEMENT paragraph "Design Data".

3.3.1 Reinforcing Shop Drawings

Reinforcing shop drawings of all reinforcing shall be submitted to the Government for review and no reinforcing shall be delivered to the job site until the related shop drawings have been reviewed by the Government.

Shop drawings shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES. No partially complete shop drawing sheet will be reviewed. Reinforcing shop drawings shall be of such nature as to clearly indicate all details and position of every bar.

3.3.2 Mild Steel Rebar Doweling

a. Dowels layout and drilling may be done either before or after the surface preparation at Contractor's option. If drilling is performed prior to surface preparation, the depth of the drilling holes shall account for this loss in surface when measuring the depth of the hole. It is a good practice to drill at least 1/4" deeper than specified.

b. All drilled holes shall be properly cleaned after the surface preparation is complete. Hole cleaning shall be achieved per epoxy Manufacturer's Printed Installation Instructions (MPII).

c. An approved epoxy adhesive shall be used to fix the rebar to the concrete. Proper amount of epoxy shall be placed into the hole prior to the dowel installation to ensure that the space around rebar is completely full. Contractor shall use a "Piston Plug" system to install epoxy into drilled holes on all horizontal and overhead applications.

d. Dowel bars shall be set to the proper depth and the proper distance out from the surface.

3.3.3 Conventional Rebar Reinforcing

Reinforcing steel splices shall not be located in the middle of a span.

The use of mechanical splices shall be permitted. Submit details for all mechanical splices, to include: size, quantity, locations, and type to the Government for approval. Mechanical splices shall conform to ACI 318 , Type 1 or Type 2.

3.4 CONCRETE SECTION ENLARGEMENT

3.4.1 Form and Pump Placement

Form and Pump means placing the concrete into a closed form with a concrete or grout pump. Closed forms shall be used to allow for pressurization to be achieved. Pressurization improves the bond between the new and existing concrete and allow the new concrete section to work monolithically with the existing structure. The concrete enlargement shall include any additional reinforcing requirements for additional shear, bending, compression, and punching shear strengths as required in SECTION

03 01 00.01 28 CONCRETE SECTION ENLARGEMENT.

3.4.2 Ground Penetrating Radar (GPR) Scanning

In order to confirm As-Constructed reinforcing, the Contractor shall scan each beam using GPR prior to surface preparation and doweling for reinforcing. Submit "Concrete Imaging Report" in accordance with 03 60 00.01 28 CONCRETE DRILLING AND PATCHING. If quantity and spacing of beam reinforcing differs from As-Constructed drawings, submit results to Designer of Record (DOR) to confirm Design Drawings and Design Calculations are still valid. If Design Drawings and Design Calculations are no longer valid, the Contractor shall notify the Contracting Officer and the DOR. DOR shall provide updated Design Drawings and Design Calculations to provide the required shear capacity as required in 03 01 00.01 28 "DESIGN STANDARDS". Updated design shall be submitted prior to drilling and installing reinforcing.

3.4.3 Surface Preparation

a. Use equipment and methods specified in the paragraph titled EQUIPMENT FOR CONCRETE PREPARATION and the Contract Documents to produce a sound, rough, open-pore surface at locations where bonding between existing and new concrete is required.

b. Clean all surfaces from contaminant and remove unsound concrete. All laitance, dust, dirt, oil, curing compound, existing coatings, and any other matter that could interfere with bonding concrete to the repair material must be removed.

c. Follow the procedures of the paragraphs titled CRACK REPAIR and CORROSION AND SURFACE REPAIR. The concrete surface must be in good condition and all cracking, surface repair, and corrosion related problems must be adequately addressed prior to proceeding with concrete strengthening procedures.

d. Insure that materials used for repairs are compatible with materials used for strengthening. Consult with the repair material manufacturers for information concerning material compatibility.

e. Surfaces not intended to be strengthened must be covered as needed to protect against contamination and spills.

f. Surfaces intended to be strengthened must be protected before application so that no materials that can interfere with bond are redeposited on the surface.

g. The prepared surface must have a concrete surface profile equivalent to CSP 6 as defined by ICRI 310.2R .

h. The target surface profile shall be confirmed by comparing the prepared surface to a standard CSP 6 or greater surface profile chip that is available by ICRI. Inspection shall be carried out for each plane of the enlargement substrate (e.g. upstream face of beam, downstream face of beam, bottom of beam, underside of intake deck slab), or every 20 square foot of surface preparation, whichever is greater. Obtain acceptance by the Government of surface preparation before proceeding with Work. If the Work is rejected, perform additional operations to the satisfaction of Government.

3.4.4 Concrete Pumping

The concrete shall be placed by pumping into the formwork from ports and valves, to pressurize the formwork.

3.4.4.1 Notification Prior to Placement

The Contractor shall provide a minimum 3 calendar day notice to the Government prior to placement of concrete.

3.4.4.2 Pumping Equipment

a. Standard concrete pump

1. Trailer Pumps

2. Boom pumps

3. Small hydraulic piston style pump

b. If bagged material is used appropriate concrete mixers shall be used as required by the manufacturer.

c. Lines may range from 2" to 5" diameter depending on aggregate size and distance between the pump and the formwork ports. The lines shall be primed with a Portland cement grout. Pump non-structural priming material into a waste container. 'Pumping Aid' or 'Slick line chemical' shall not be used without any prior approval by the Government.

d. Ports are fabricated section of piping made to be installed on the formwork.

1. The ports shall be designed not to weaken the formwork.

2. Port locations shall be selected to allow for free flowing of the material into the forms.

3. The ports shall be placed at a low point in the formwork system to ensure the concrete is pushed up and away. Additional ports shall be placed as needed to ensure proper consolidation and travel of the concrete.

3.4.4.3 Pressurization of the Formwork

a. This operation should only be done with experienced personnel due to safety concerns and potential damage to the formwork and structure when the work is performed by an inexperienced contractor.

b. Pumping shall begin at a low point and from near an end/termination location.

c. Efforts shall be made not to stop the pumping operation as the pumping pressures can increase substantially when the movement of the material stops.

d. Personnel should carefully watch "windows", vent pipes and ports installed in the forms for proper flow, consolidation and bleeding of air and concrete from the formwork.

e. The vents and vent pipes on the forms that allow air to escape shall not be closed until "good" concrete is seen coming out of each location.

f. Care must be exercised in the final pressurization because the excessive pump-line pressure may cause the form to fail. Pressure gauges shall be attached to the pump line near the placement port or on the formwork to monitor the cavity pressure reaches the minimum 2 psi above the material head pressure inside the form. Final pressurization readings at these gauge locations are to ensure pressurization of formwork to create intimate contact with the substrate for bond. Gate valves or similar must be used to ensure the forms remain pressurized after pumping.

3.4.5 Curing

For Self Consolidating Concrete Work, follow the requirements indicated in this specification and SECTION 03 30 00.00 28 SELF-CONSOLIDATING CONCRETE

(SCC).

a. Curing should commence immediately after finishing. Setting time is dependent on temperature and humidity.

b. Curing shall be achieved using one of the following methods:

1. Moist cure with wet burlap and polyethylene.

2. Approved water based compatible curing compound.

c. Cure formed concrete surfaces, by moist curing with forms in place for full curing period or until forms are removed with curing times no less than seven (7) days. If forms are removed prior to seven (7) days, continue curing by methods specified above.

3.4.6 Quality Control

3.4.6.1 Self-Consolidating Concrete (SCC)

a. Contractor shall work with ready-mix concrete supplier to develop a Self-Consolidating Mix in accordance with 03 30 00.00 28 and these specifications.

b. Quality control testing shall be performed with trial batches of developed SCC mix design to ensure the mix is suitable for Form and Pump placement in accordance with ACI 237R .

c. Quality control testing shall be witnessed by personnel experienced in SCC mixes and familiar with Form and Pump placement as outlined in 03 30 00.00 28 . The initial set time shall be determined to confirm the entire pumping operation is complete prior to the initial setting process beginning to prevent problems with pumping or cold joints from occurring.

3.4.6.2 Test Placement

a. A full beam enlargement shall be performed on one (1) beam to ensure proper surface preparation and bond between the section enlargement and the existing concrete substrate. Each phase of the repair shall be examined and approved prior to proceeding with the full scope of the work. This shall include: surface preparation, reinforcing installation, formwork installation, concrete placement and bond to substrate testing.

b. Contractor shall closely monitor surface preparation methods, reinforcement installation, and SCC placement throughout the project once placement has been approved with successful inspection and testing.

3.4.6.3 Visual Testing

After stripping of forms, visual tests shall be performed to confirm the placement of repair material has achieved complete consolidation.

3.4.6.4 Bond to Substrate Testing

a. A minimum of three (3) pull tests are required for each bond test.

Submit Bond Test Procedures to include: beam number, size, location, test method, and repair of tested surfaces for approval prior to the test. Submit Bond Test Result for each beam tested in accordance with ICRI 210.3R and ASTM C1583/C1583M . Bond Test Results shall also be documented on daily QA/QC reports.

b. The location of each test shall be coordinated with GPR scans to ensure existing or new reinforcing is not disturbed or damaged by these tests.

c. Minimum strength of new concrete for bond test shall be 3,000 psi or greater.

d. Bond tests shall be performed on the beam or on the pier wall immediately adjacent to the beam.

e. Perform bond test on the first two (2) beams repaired. Upon successful testing of the first two (2) beams, the Contractor shall perform testing on two (2) more beams to be selected by the Contracting Officer, for a total of four (4) beams. The bond test for the remaining beams shall be approximately midway through the project, and towards the end of the project. Submit beam numbers for testing with bond test procedures.

3.4.6.5 Non-Destructive Testing

The complete repair area shall be hammer-sounded or evaluated by other non-destructive methods to determine overall integrity. Any hollow sounds may represent poor bond or voids and shall be corrected.

3.5 POST-INSTALLED EPOXY ADHESIVE INSTALLATION

Install epoxy adhesive reinforcing and anchors per the manufacturer's printed installation instructions (MPII). Horizontal and overhead anchors and reinforcing shall be installed using piston plug systems.

3.6 CRACK REPAIR

3.6.1 General Requirements

a Repair cracks in concrete beams and slabs as shown in contract drawings. Cracks shall be repaired with low-pressure epoxy adhesive.

Cracks are not to be excavated or "V" notched by grinding. The low pressure grout injection shall occur through drill holes drilled into the crack fitted with ports and the surface of the crack shall be sealed with a dam of epoxy resin that is bonded at the surface.

b. Remove foreign material, such as dirt, oil, grease, or other chemicals, from the cracks before injection using compressed air, low-pressure water, or vacuuming. Allow wet surfaces to dry at least 24 hours.

c. Do not repair cracks when the temperature of the concrete is below freezing and moisture conditions indicate the possibility of ice on the internal surfaces of the crack.

d. Do not apply epoxy if the temperature of the concrete is not within the range of application temperatures recommended by the manufacturer of the epoxy.

e. Assume the following crack characteristics:

1. Crack widths are 1/8" or less, typical.

2. No void spaces within the cracks.

f. See Sheet S-302 for additional information. Notify the Contracting Officer if conditions differ from those shown and specified, prior to proceeding with crack repair. If void spaces are found during crack repair, notify the Contracting Officer immediately.

3.6.2 Sealing

For epoxy injection, apply a surface seal over all exterior faces of the crack that can be reached to contain the injection adhesive in the crack.

3.6.3 Epoxy Injection

a. Install the injection entry and venting ports using flush mounted or drilled fittings per proprietary manufacturer's instructions.

b. Space the ports as required by the manufacturer.

c. Inject the epoxy using material manufacturer's recommended equipment.

d. Apply recommended manufacturer's injection pressure.

e. For vertical or inclined…