B.01.01 B-PR Big 3_Industry Day_AfternoonSession.pdf

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“The views, opinions and findings contained in this report are those of the authors(s) and should not be construed as an official Department of the Army position, policy or decision, unless so designated by other official documentation.”

Material Suppliers/Vendors and Heavy Equipment Dealers Antilles Integrated Project Office (IPO) Programs and Project Management Division 17 August 2022

INDUSTRY DAY

PUERTO RICO BIG 3

FLOOD RISK MANAGEMENT

SUPPLEMENTAL PROJECTS

2AGENDA

• Opening Remarks – Lyan Garcia

• Projects Overview – Jorge Ayala

• Rio Puerto Nuevo

• Rio de La Plata

• Rio Grande de Arecibo

• Sub-Contracting Opportunities – Jorge Ayala

• Construction Considerations – Mark Waddell

• Testing Requirements – Mark Waddell

• ERDC Inspection & Validation of Laboratories – Michael Wielputz

AFTERNOON SESSION

Specific requirements to be considered by material suppliers/vendors, and heavy equipment dealers.

3HOW TO SUBMIT QUESTIONS

• All questions to be submitted through ProjNet

• Deadline: 5:00 pm, ET on 26 August 2022

• The Solicitation Number is: W912EP22Z0033

• The Bidder Inquiry Key is: 38K5UQ-U5Q2TS https://www.projnet.org

4SAM.gov

• Please visit SAM.gov after Industry Day

• All presentations and the transcript will be posted

Solicitation No.:W912EP22Z0033

Rio Grande de Arecibo

Rio de la Plata

Rio Puerto Nuevo

LOCATIONS

File Name

6RPN CONTRACTS OVERVIEW

7RPN CONTRACTS OVERVIEW

• RPN Supplemental Contract “La Chuleta” Awarded Summer 2022

• RPN Supplemental Contract 1: Advertise: Early Winter 2024

• RPN Supplemental Contract 2: Advertise: Spring 2023

• RPN Supplemental Contract 3: Advertise: Winter 2023

• RPN Supplemental Contract 4: Advertise: Winter 2025

• RPN Supplemental Contract 5A: Advertise: Spring 2024

• RPN Supplemental Contract 5B Advertise: Summer/Fall 2025

• RPN Supplemental Contract 6: Advertise: Winter 2026

• RPN Supplemental Contract 7: Advertise: Summer 2026

*TENTATIVE

RPN Disposal Area – La Chuleta San Juan Harbor

La Chuleta

• Magnitude of Construction: $4.4M

• NTP Issued: August 2022

• Period of Performance: 1 year

La Chuleta

9RPN Supplemental Contract 1 Supplemental Contract 1

• Upper Margarita Channel (Sta. 56+00 to Sta. 89+60)

• Construction of concrete channel to tie to existing stilling basin

Sewer Line Relocation under Concrete Channel

• Magnitude of Construction: $100M to $250M

• Estimated Advertisement: Winter 2024

• Period of Performance: 4.5 years

• 95% design complete

• Limited construction footprint

• Constructability: phased work, sheet pile installation (under bridge) water diversion of existing channel, utilities relocations

• 121,100 cy of soil mixing

• 6,000 tons of steel sheet pile

• 181,000 cy of excavated material for disposal

• 145,000 cy of suitable fill

• 30,000 cy of concrete for

30-foot concrete channel

• 2,000 tons of reinforcing steel

Soil Mixing

Soil Mixing

Sheet Piles for Water DiversionChannel

Construction - Built in Sections

RPN Supplemental Contract 1

• 121,100 cy of soil mixing

• 6,000 tons of steel sheet pile

• 181,000 cy of excavated material for disposal

• 145,000 cy of suitable fill

• 30,000 cy of concrete for

30-foot concrete channel

• 2,000 tons of reinforcing steel

RPN Supplemental Contract 1

Channel Construction - Built in Sections

• Roosevelt Avenue Bridge with a temporary detour bridge construction

• Six-lane, pre-cast pre-stressed concrete beam bridge

• 95% design complete

• Magnitude of Construction: $25M to $100M

• Estimated Advertisement: Spring 2023

• Period of Performance: 4 years

RPN Supplemental Contract 2

Channel Improvement

• 110 Ea. six-foot diameter concrete-drilled shaft piles (~90 feet deep)

• 90 Ea. five-foot diameter concrete-drilled shaft piles (~90 feet deep)

• 19,000 cy of concrete

• 7,000 tons of reinforcing steel

• 119,000 cy of excavated material for disposal

Fl ow

RPN Supplemental Contract 2

Drilled Shaft

• Main channel walls, composite steel pipe pile/steel sheet pile walls

• Magnitude of Construction: $250M to $500M

• Estimated Advertisement: Summer 2023

• Period of Performance: 5.5 years

RPN Supplemental Contract 3

Supplemental Contract 3

• 1,600 six-foot diameter concrete drill shaft piles

(~100 feet deep)

• 200,000 cy of concrete

• 46,000 tons of reinforcing steel

• 600,000 cy of excavated material to be disposed

• 25,000 cy of suitable fill

• 8,000 tons of steel sheet pile

Sheet Piles

Drilled Shafts

Guardrail

Concrete Cap

Drilled Shaft

Sewer Siphon

Utility Bridge Four crews work on a different section of the river at same time

48” Potable Watermain (DI)

Supplemental Contract 4

• Bridge replacement of four major existing bridges over the Piñero Avenue Interchange 4A-1) Las Americas Expressway Bridge 4A-2) Piñero Avenue Bridge East 4A-3) NE Access Ramp Bridge 4A-4) SE Access Ramp Bridge

• Concrete channel construction

• Magnitude of Construction: $250M to $500M

• Estimated Advertisement: Summer 2025

• Period of Performance: 5 years

RPN Supplemental Contract 4

• Replacement design analysis is underway

• Maintenance of traffic

• Six-foot diameter concrete drill shaft for bridge abutments and channel walls

• Channel bottom will be articulated concrete block mattresses (ACBM)

Channel Improvement

• 1,200 Ea. five-foot diameter concrete drilled shaft piles (~90 feet deep)

• 70,000 cy of excavated material for disposal

• 83,000 cy of concrete

• 4,000 tons of reinforcing steel

• 304,000 square feet of ACB

• 3,500 tons of sheet pile

Pi ñe ro Av en ue

• Replacement design analysis is underway

• Maintenance of traffic (~184K vehicles/day in 2017)

Temporary Bridge

Replaced Bridge Deck

Demolished Bridge Deck

Supplemental Contract 5A Notre Dame Bridge

• Notre Dame Bridge replacement

• Channel works underneath bridge

• Temporary one-lane bridge

• Permanent pedestrian bridge

• Maintenance of traffic through Calle Notre Dame

• Magnitude of Construction: $25M - $100M

• Estimated Advertisement: Spring 2024

• Period of Performance: 3 years

CALLE SORBONA

CALLE GALILEO

Temporary one-lane bridge to be transformed into a permanent pedestrian bridge

Notre Dame Bridge replacement

RPN Supplemental Contract 5A

Supplemental Contract 5A Notre Dame Bridge

• Six-foot diameter concrete drill shaft for bridge abutments and channel walls

• Channel bottom will be ACBM

• 100 Ea. 6-foot dia. concrete drilled shaft piles (~106 feet deep)

• 14,000 cy of concrete

• 3,505 tons of reinforcing steel

• 9,000 LCY of excavated material to be disposed.

• 5,000 cy of suitable fill

• 636 tons of steel sheet pile

• 1,000 tons of Riprap

RPN Supplemental Contract 5A

Supplemental Contract 5B Piñero Bridge West and Josefiña Channel

• Piñero Avenue Bridge West replacement

• Channel works underneath bridge and downstream

• Maintenance of traffic on Piñero Avenue

• Magnitude of Construction: $100M - $250M

• Estimated Advertisement: Fall 2025

• Period of Performance: 3.5 years

• 200 Ea. five-foot diameter concrete drilled shaft piles (~90 feet deep)

• 52,000 cy of concrete

• 2,250 tons of reinforcing steel

• 76,000 cy of excavated material to be disposed

• 1,400 LCY of suitable fill

• 14,000 tons of steel sheet pile

• 102,000 square feet of ACBM

RPN Supplemental Contract 5B

Existing Abutment Drilled Shafts

ACBM

Channel Improvement

• Five-foot diameter concrete drill shaft for bridge abutments and channel walls

• Channel bottom will be ACBM

New Bridge Deck

Existing Abutment

Supplemental Contract 5B West Piñero Bridge

Supplemental Contract 6

• Main Channel Improvements (Sta. 147+40 to Sta.

240+00) - PR HWY 1

• Buena Vista Bridges - Two replacement bridges

• Buena Vista Diversion Channel (Sta. 0+00 to Sta.

42+37)

• Five-foot diameter concrete drill shaft for bridge abutments and channel walls

• Channel bottom will be ACBM

• Magnitude of Construction: $250M to $500M

• Estimated Advertisement: Summer 2026

• Period of Performance: 5.25 years

Contract 5A Notre Dame Bridge

RPN Supplemental Contract 6

• 7,000 tons of reinforcing steel

• 2,000,000 LCY of excavated material to be disposed

• 330,000 LCY of suitable fill

• 8,000 tons of steel sheet pile

• 321,000 square feet of ACB

Buena Vista Diversion Canal

• 1,300 Ea. five-foot diameter concrete drilled shaft piles (~80 feet deep)

• 80,000 cy of concrete

Buena Vista Diversion Canal

RPN Supplemental Contract 6

Excavation Limits

Supplemental Contract 7

• Replacement of 10 bridges

• Quebrada Josefiña Channel and Stilling Basins

• Quebrada Doña Ana Channel and Stilling

• Work cannot start until the completion of Contract 3

• Magnitude of Construction: $250M to $500M

• Estimated Advertisement: Spring 2026

• Period of Performance: 5.5 years

RPN Supplemental Contract 7

Supplemental Contract 7

• 75,000 cy of concrete

• 2,000 TN of reinforcing steel

• 300,000 LCY of excavated material to be disposed

• 100,000 LCY of suitable fill

• 3,200 TN of steel sheet pile

RPN Supplemental Contract 7

Constructability (Means and Methods):

• Limited Space: Constructing flood walls under existing bridges with low overhead clearances, limited construction staging, and access.

• Water Diversion and Care: Working within the channel footprint along the rivers while maintaining existing flow.

• Material Disposal and Hauling: Cutting from the channel and disposal.

• Traffic Control: Maintaining traffic during construction in highly urban area.

• Long Lead Items: Steel Sheet Pile, Steel Reinforcement, Large Quantity Concrete, Steel Electric Poles

RPN Challenges

Arecibo

Rio de la Plata

32RIO DE LA PLATA

Disposal Area

East Levee

West Levee

Disposal Area

Disposal Area

East Levee

Channel

Channel

Channel

72” Water Line

Dorado Bridge

PR HWY-2

PR HWY-22

PR-2 Bridge and Road Re-alignment

33RDLP CONTRACTS OVERVIEW

• RDLP Supplemental Contract 1: Advertise: Fall 2023

• RDLP Supplemental Contract 3: Advertise: Fall 2026

• Super-Aqueduct Relocation: TBD

SUPPLEMENTAL CONTRACT 1

MAIN PROJECT FEATURES:

2,234,000 yd3 channel excavation 1,962,000 yd3 levee fill placement 272,000 yd3 scour protection stone placement 4 – concrete culvert structures through the levees

Pre-cast concrete pipe (5-7 feet in diameter) Cast-in-place concrete inlet and outlet head walls Composite flap gates

ADDITIONAL PROJECT FEATURES:

• Maintenance road on levee crest and within project boundaries

• Drainage ditches

• Utility relocations

Water lines Sewer lines Electrical lines Telecommunication lines

• Disposal areas for excavated material

• Potential for wetland mitigation

Rio De La Plata

Levee

Channel

SUPPLEMENTAL CONTRACT 1

Rio De La Plata

• Magnitude of Construction: $250M to $500M

• Estimated Advertisement: Fall 2023

• Period of Performance: 3.5 years

East Levee Stone Protection

West Levee Stone Protection

Channel Centerline

Centerline

SUPPLEMENTAL CONTRACT 3

MAIN PROJECT FEATURES:

1,222,000 yd3 channel excavation 224,000 yd3 levee fill placement 101,000 yd3 scour protection stone placement

ADDITIONAL PROJECT FEATURES:

• Maintenance road on levee crest and within project boundaries

• Drainage ditches

• Utility relocations Water lines Sewer lines Electrical lines Communication lines

• Disposal area for excavated material

Rio De La Plata

Disposal area

East Levee

Disposal area

SUPPLEMENTAL CONTRACT 3

Rio De La Plata

• Magnitude of Construction: $100M to $250M

• Estimated Advertisement: Fall 2026

• Period of Performance: 3 years

East Levee

Channel Centerline

Seepage Berm

Stone Protection Stone Protection

SUPER-AQUEDUCT RELOCATION

MAIN PROJECT FEATURES:

• Relocate (approx. 1,000 feet) a 72-inch-diameter potable water line below the new channel

• The water line is a Prestressed Concrete Cylinder

Pipe (PCCP)

• Supplies water to 600,000 people

• From Arecibo to San Juan

• Heavy coordination with PRASA

• Water line shall remain in service during relocation Will require hot tapping existing line Will require temporary diversion water line during construction

ADDITIONAL PROJECT FEATURES:

• Channel excavation

• Disposal area for excavated material

Magnitude of Construction: $10M to $25M Estimated Advertisement: 2025 Period of Performance: 2 Years

Rio De La Plata Super-Aqueduct

Disposal area Channel

Arecibo

Rio de la Plata

40RIO GRANDE DE ARECIBO

East Levee

West Levee

Disposal Area

Disposal Area

East Levee

Channel

Channel

Channel

72” Water Line

Dorado Bridge

PR HWY-2

PR HWY-22

PR-2 Bridge and Road Re-alignment

41RGDA CONTRACTS OVERVIEW

• RGDA Supplemental Contract 1: Advertise: Fall/Winter 2023

*SUPPLEMENTAL CONTRACT 1 CONSISTS OF ORIGINAL CONTRACTS 2A AND 3

East Levee

West Levee

Disposal Area

Disposal Area

East Levee

Channel

Channel

Channel

72” Water Line

Dorado Bridge

PR HWY-2

PR HWY-22

PR-2 Bridge and Road Re-alignment

Rio Grande de Arecibo (Arecibo) General Project Overview

Project Features

• 1.3-mile-long levee

• Terminal Floodwall at the mouth

• 350-foot micropile founded wall under

PR-2

• 3 single span bridge replacements and associated road work

• 1.4 miles of channel improvements on the Santiago

• Mitigation area

• Drainage ditching

Status

• Magnitude of Construction: $100M to

$250M

• Advertisement: Fall 2023

• Period of Performance: 5 years

43Levee Details

Levee Alignment

Existing Condition Along Levee Alignment

Levee alignment

44Levee Details Quantities

• Compacted limerock 470,000 CY embankment

• Sand/random fill 50,000 CY

• Riprap and bedding 40,000 TN

• Soil bentonite cutoff wall 10,500 CY

Cutoff wall Stone Protection

Stone Protection

45Channel Details

Santiago Channel Location

Existing Santiago Channel

46Channel Details

• Riprap and bedding 10,000 TN

• Excavation 325,000 CY

Specific Considerations

• Flow in existing channel will need to be maintained.

• Coordination with the completion of the bridges.

• Fill disposal in the borrow site.

Typical Channel Section

Stone Protection

40’

Excavated Material

Terminal Floodwall Details

Terminal Floodwall Location at the Mouth of the Rio Grande de Arecibo

Arecibo Channel at the Floodwall Location

Levee alignment Flood Wall

Levee

Santiago

48PR-2 Floodwall Details

PR 2 Floodwall (in Green) Location Crossing PR 2

PR 2 Bridge at Floodwall Crossing

Fl oo dw al l

Levee

Levee

49PR-2 Floodwall Details

• Reinforced concrete, 4,000 ksi 1,000 CY

• 9.625-inch micropile 16,000 LF

Specific Considerations

• Micropile will be installed for the PR-2 wall under the bridge. Approximately 15-20 feet of clearance will be available.

• Temporary dewatering will be required for the PR-2 wall construction.

Typical PR 2 Floodwall Section

Micropiles

Base

Stem

50Bridge Details

Constitution Bridge 2

PR 10

Bridge

Constitution Bridge 1

Bridge Locations

Existing Constitution 1 Bridge Existing PR 10 Bridge

Levee

51Bridge Details

Typical Bridge Section

Quantities

• Precast prestressed 36-inch

“Florida” beams, 8,000 ksi

3,900 LF

• Reinforced concrete, 5,000 ksi 3,500 CY

• Drilled shafts, 36-42 inches 4,500 LF

Specific Considerations

• Constitution 1 and 2 will be completed concurrently and prior to PR 10.

• Full road closure is anticipated for bridge replacement.

Therefore, there will be no temporary bridges.

Drilled Shafts

Super Structure

~102’

52Others - Features

Constitution 2 Bridge Siphon

PR 10 Bridge Siphon

Wetland Mitigation Area

Along the Santiago Channel

• 12- to 42-inch culverts 3,200 LF

• Siphon structures 2 EA

(12- to 36-inch pipes)

Near the East Approach of PR-2

• Mitigation area 13 AC

• Mangrove habitat

PR HWY 2

Potential Sub-Contracting Opportunities Exist for:

• Trucking and hauling

• Sheet pile installation, pile driving

• Drilled shaft construction

• Reinforcing steel

• Structural and nonstructural concrete

• Stone and armor protection

• Utilities Relocation - electrical, telecommunications, sewer, and potable water related work

Note: This list is not all inclusive of potential sub-contracting opportunities

Sub-Contracting Opportunities

Potential Sub-Contracting Opportunities Exist for:

• ACBM installation

• Soil reinforcement

• Embankment and levee construction

• Micro piles, auger cast piles, jet grouting

• Sod and hydroseeding

• Suppliers: concrete, asphalt, aggregates, stone, steel, precast concrete, etc.

• Services: surveyor, geotechnical and structural consultants, material testing, environmental monitoring, etc.

Note: This list is not all inclusive of potential sub-contracting opportunities

Sub-Contracting Opportunities

Estimated Quantities for the Main Supply Needs

Suppliers:

• Concrete: Approx. 570,000 CY

• Reinforcing Steel: Approx. 75,000 Tons

• Steel Sheet Piles: Approx. 46,000 Tons

• ACBM: Approx. 760,000 SQFT

• Stone Protection: Approx. 420,000 CY

• Soil Improvement: Approx. 121,000 CY

Note: This list is not all inclusive

Estimated Quantities for the main supply needs Hauling and trucking:

• Excavation: Approx. 7,660,000 CY

• Fill: Approx. 3,344,000 CY

HEAVY EQUIPMENT

Heavy Equipment Required:

• Excavator

• Dozer

• Loader

• Backhoe loader

• Roller compactor

• Sheepsfoot roller

• Crane

• Water truck

• Dump truck (on-road and off-road)

Note: This list is not all inclusive

• Drill rig

• Generators

• Pumps

• Vibratory hammer

• Impact hammer

• Power unit

SERVICES

Services:

• QC Staff Personnel: Surveyors, Geotechnical and Structural Consultants, Scheduler, Environmental Monitoring (Puerto Rican Boa Monitor, Manatee Observer, Environmental Compliance Inspections), etc.

• Safety Personnel

• Vibration Monitoring

• Material Testing

Aggregates C 88 – Soundness of Aggregates C 117 - Material Finer than 75 μm (No. 200) Sieve C 127 - Density, Relative Density, and Absorption of

Coarse Aggregates C 128 - Density, Relative Density, and Absorption of

Fine Aggregates C 131 – Resistance to Degradation by Abrasion and

Impact C 136 - Sieve Analysis of Aggregates C 566 - Total Moisture Content

Concrete C 39 - Compressive Strength of Cylindrical

Specimens C 143 – Slump C 231 - Air Content by Pressure C 1064 - Temperature of Concrete

Masonry C 109 - Compressive Strength of Cement Mortars Using Cube Specimens

Soils D 698 - Compaction Characteristics by Standard Effort D 1556 - Density & Unit Weight by Sand Cone D 1557 - Compaction Characteristics by Modified Effort D 2166 - Unconfined Compressive Strength D 2216 - Water Content D 2487 – Classification of Soils D 4253 - Maximum Index Density by Vibratory Table D 4254 - Minimum Index Density D 4318 – Liquid Limit, Plastic Limit, and Plasticity Index D 6938 – Density and Water Content by Nuclear Methods

Note: This list is not all inclusive of all the required tests

Material Testing

SAJ: QUALITY CONTROL MANAGEMENT FOR CONTRACTORS (CQM-C)

5 W’s

Who: Jacksonville District (SAJ) What: CQM-C Certification Information as required by Contract Specification 01 45 XX When: Offered Monthly by USACE/NAVFAC Where: University of North Florida (UNF) Why (info):

- 2021 HQ Update CQM-C Content

- SAJ CQM-C – University of North Florida facilitates all course signup & payment

- SAJ - 4 classes annually, NAVFAC – 8 classes annually

- Certifications valid for 5 years

- NAVFAC & USACE class certificates qualify for both Army & Navy Project

- Additional class offerings through other USACE districts and UNF

- CEU’s are available for attending

UNF Classroom/Virtual Training

1. SAJ & NAVFAC returned to classroom format in July of 2022, all COVID-19 restrictions have been lifted and normal classroom classes are being offered.

2. Beginning Jan 2023, One (1) virtual class offered annually, recertification students only.

3. SAJ schedule and UNF link are shown on the next slide

SAJ/NAFAC: CQM-C FY-2022 SCHEDULE

Construction Quality Management for Contractors (CQM-C) Classes

UNF registration website: https://www.unf.edu/ce/construction-and-trade.html

- Completion certificate valid for 5 years. At the end of 5 years, students must take this course again to re-certify.

- Online Recertification for CQM-C is offered once annually by Jacksonville District.

- Google search: University of North Florida Continuing Education or UNF CQM-C to find

Dates: Offered by:

January 2023 (Virtual) USACE February 2023 NAVFAC March 2323 NAVFAC April 2023 USACE May 2023 NAVFAC June 2023 NAVFAC July 2023 USACE August 2023 NAVFAC September 2023 NAVFAC October 2023 USACE November 2023 NAVFAC December 2023 NAVFAC blockedhttps://www.unf.edu/ce/construction-and-trade.html

GEOTECHNICAL MATERIALS COMPLETION REPORT

Geotechnical, and Materials Construction Report (GMCR)

– GMCR serves as the permanent record of construction. Report is primary resource for post-construction evaluation and renovation.

– ER 1110-1-1901 (2017): Engineering and Design, Construction Project Geotechnical and

Materials Completion Report governs Major USACE Projects

• ER 1110-1-1901 Project Geotechnical and Materials Completion Report for Major USACE Projects (army.mil)

– Final Report Government Responsibility

• Report dependent on Construction Data (i.e. Material Testing Results and As Builts)

Supplemental Projects Require GMCR

GMCR Contractor Effects/Actions

– Significant Material Data Testing Submission

• Under 01 45 08 – Geographic Information System Data Requirements-Quality Control and Quality Assurance Data.

• Not a typical contract requirement, but will be required for the entire supplemental program

– Increased As-Built Drawing and Submittal Surveillance

• Provide foundational knowledge for future analysis

• Directly inserted into final GMCR Report https://www.publications.usace.army.mil/Portals/76/Publications/EngineerRegulations/ER_1110-1-1901.pdf?ver=HFqPQkfpyUOmcAgsJKG2kQ%3d%3d

QA/QC TESTING REQUIREMENT / INFORMATION

• QA testing is mandated by USACE regulation ER 1180-1-6 to ensure that each construction contractor implements and maintains an effective Contractor Quality Control program

• QA Testing regulations required USACE to validate varying percentages of performed QC Testing (5%, 10% or even 20%)

• GMCR reports for supplemental work are dependent of QA Testing results

• Stop work orders will occur if the gov’t fails to perform QA testing

• Currently - Puerto Rico doesn’t have a government testing lab to perform QA testing and relies 100% on commercial labs, these labs can only perform the testing they are validated for at the time of testing

• Supplemental Program projects have “NEW” testing requirements that will require USACE Validation. The “Validation” process can take a substantial amount of time and effort

• ERDC Lab Certification Website: https://mtc.erdc.dren.mil/searchvalidation.aspxspx

• Government & Contractors can not use the same lab on a project

QA/QC TESTING REQUIREMENT / INFORMATION

• Jaca & Sierra Testing Laboratories:

• 19 validations of 69

• MGV-GES Lab:

• 17 validations of 69

• Geo-Engineering:

• 18 validations of 69

• Victor E Rivera Associates:

• 4 validations of 69

• Suelos PSC :

• 4 validations of 69

• GEO CIM:

• 16 validations of 69

• SPEC Group PSC:

• 15 validations of 69

• Validated Labs in Puerto Rico.

• 28 of 69 Verification Tests have “NO” “validated lab” in Puerto Rico (41%)

EXP Date Estate Testing Lab Validated 12/16/2023 PR Jaca & Sierra Testing Laboratories- Trujillo Alto, PR 4/12/2024 PR MGV-GES Lab Inc. - Vega Baja, PR 6/28/2024 PR Geo-Engineering, LLC- San Juan, PR 7/6/2022 PR Victor E Rivera Associates, LLC- Ponce, PR 3/24/2023 PR Suelos PSC - San Juan, PR 4/9/2023 PR GEO CIM, Inc. - Guaynabo, PR 5/3/2023 PR SPEC Group PSC - San Juan, PR

Statistics for Laboratories validated in Puerto Rico

0 20 40 60 80

Validated Lab Not Available Validated Lab Available Total No. Tests Requirements

Sheet1

EXP Date Estate Testing Lab Validated

None lab Validated Test 113 12/16/23 PR Jaca & Sierra Testing Laboratories- Trujillo Alto, PR 141/280

Total Test 280 4/12/24 PR MGV-GES Lab Inc. - Vega Baja, PR 105/280

6/28/24 PR Geo-Engineering, LLC- San Juan, PR 111/280

7/6/22 PR Victor E Rivera Associates, LLC- Ponce, PR 32/280

3/24/23 PR Suelos PSC - San Juan, PR 16/280

4/9/23 PR GEO CIM, Inc. - Guaynabo, PR 110/280

5/3/23 PR SPEC Group PSC - San Juan, PR 89/280

Estimate of Required QC & QA Tests Total testing of reviewed Contracts (5 contracts reviewed):

– ~228,000 QC Tests required

– ~21,500 QA Tests required

– 69 different test procedures

Estimated Supplemental Calculation

– Program total cost @ $2.5B

– 5 projects @ $1.1B

– Sample size ~45% of program total

Supplemental Program Total Estimate:

– ~507,000 QC Tests

– ~48,000 QA Tests

ERDC INSPECTION & VALIDATION OF LABORATORIES

5 W’s Who: U.S. Army Engineer Research and Development Center (ERDC)

Michael P. Wielputz, P.E. Materials Regional Technical Specialist What: Materials Testing Center (MTC) When: August 17, 2022 Where: Vicksburg, Mississippi Why: (topics)

- Inspection & Validation of Laboratories

- LABORATORY INVESTIGATIONS AND TESTING

- Quality Assurance of Laboratory Testing Procedures

- Validation Program

- Lab Validation

- Laboratory Training Requirements

- Commercial Laboratory Inspection/Testing Issues

ER 1110-1-8100 LABORATORY INVESTIGATIONS AND TESTING

ER 1110-1-8100 assigns the inspection and validation of laboratories performing materials testing (aggregate, bituminous materials, concrete, rock, soil, and other construction materials) for the districts to the MTC.

Materials Testing Center (MTC)

A center established at the U. S. Army Engineer Waterways Experiment Station (CEWES) to provide materials testing (soil, rock, concrete, asphalt, and other construction materials) and inspection and validation of:

CQC labs, laboratories utilized by the district, Architect/Engineer (A/E) labs, construction contractor labs, and project materials QA laboratories as required ER 1110-1-261 (superseded by New ER 1110-1-8100).

ER 1110-1-261, Quality Assurance of Laboratory Testing Procedures (to be superseded by New ER 1110-1-8100)

An initial validation shall be performed prior to performance of testing and at least every two (2) years thereafter.

(1) Inspection. Inspection shall be performed by the MTC in accordance with American Society for Testing and Materials (ASTM) E329.

(2) Audit. A laboratory may be validated by auditing if it has been accredited by the Concrete and Cement Reference Laboratory (CCRL) or AASHTO Materials Reference Laboratory (AMRL) within the past two years in accordance with ASTM E329. Audit shall be performed by the MTC. Inspection by MTC may be required after auditing if one or more of the critical testing procedures required in the project specification were not included in the CCRL or AMRL inspection report or if there is any concern that the laboratory may not be able to provide required services.

Note: Need to verify that the inspections cover all the test methods required.

ERDC Materials Testing Center (MTC) Full Service Materials Testing Lab Manages the Materials Testing Lab Validation

Program

Validation Program Director – Chad Gartrell, P.E.

chad.a.gartrell@erdc.dren.mil Phone: 601-634-2313 Government Cell: 601-618-8154

SAD Materials Testing Regional Technical Specialist Michael P. Wielputz, P.E. michael.p.wielputz@usace.army.mil Phone: 678-354-0310 Government Cell: 470-363-9749

Website Access https://mtc.erdc.dren.mil/

Lab Validation+ Request a Validation Search for a Validation mailto:michael.p.wielputz@usace.army.mil

ERDC SLIDES 1-10

Currently, the ACI Certifications that will be required (per ASTM C1077 & D3740), along with the testing methods covered by each, are as follows:

Aggregate Testing Technician Level 1 ---- aggregate testing including ASTM D75, C702, C117, C127, C128, C136, C566, and C40.

Aggregate/Soils Base Testing Technician ---- soils testing including ASTM D75, C702, D421, D422, D4318, D2216, D698, and D1557.

Concrete Strength Testing Technician ---- concrete strength testing including ASTM C617, C1231, C39, and C78.

Concrete Field Testing Technician Grade 1 ---- fresh concrete testing including ASTM C172, C1064, C143, C138, C231 and/or C173, and C31.

Note: Where access to ACI Training is difficult to get, USACE provides ACI workshops and administers the written and performance exams. Contact Mike Wielputz at: michael.p.wielputz@usace.army.mil

Laboratory Training Requirements

Laboratory Training Requirements

Puerto Rico ACI Certifications

ACI Training in Powidz, Poland

ACI Training Requirements Costs

Which certifications are requested and how many students each?

Typically, the more students, the less cost per student Desired location for training? (travel, lodging, per diem, etc) Timeline for training?

Logistics Required Classroom of adequate size for group

White board or large writing pad Sufficient power outlets Video projector and screen or video wall screen Lab space or work area for mixing concrete and hands-on demos Adequate light Water Cement, gravel, sand or ready-mix

Interested?

Contact Chad Gartrell or Mike Wielputz for more details.

Commercial Laboratory Inspection/Testing Issues

United States Testing Issues Accreditation (AASHTO Materials Reference Laboratory) and/or Validation (USACE) offers only a “snap-shot” in time (2 yr) of Laboratory Capability – often represents the “best of the best”

ERDC - MTC Validation represents a 1st level of basic minimal Quality Assurance – Completely necessary for “even playing field”

Validation by Desk audit of AMRL process is sometimes insufficient to uncover potential issues of non-compliance

2nd level of Quality Assurance is most critical to ensure day-to-day operations are compliant – Project Engineers, Geotech Engineers & Quality Assurance Representatives.

Laboratory Validations – Contact the MTC Providing Inspections/Validation Providing Audit/Validation Provides guidance on unusual ASTM or other

Methods such as Rock Testing Handbook (RTH), CRD-C Methods, ACI, Mil Standards, etc.

Review/Validation for adding ASTM methods Cost depends on complexity and quantity of methods (desk audit or inspection) Disputes resolution for conflicting lab data Investigates claims for erroneous/bad data