SOW_EauGalle__20180822_-_Solicitation_Rev.pdf

SCOPE OF WORK – EAU GALLE CONDUIT, SANDBLAST AND PAINT W912ES-18-B-0014

Statement of work Page 1

I. General Overview

A. Project Description.

This scope specifies requirements for refurbishing the Eau Galle Dam outlet works. The work involves paint removal from the existing 300 ft steel conduit lining, ultrasound inspection of steel liner thickness, and repainting the liner. The conduit will be sandblasted and painted with a vinyl paint system. The work shall be accomplished between December 1st 2018 and February 28th, 2019 while the government will make all reasonable efforts to maintain the pool level below the crest of the morning glory (Elevation 940) during this time.

Because the conduit is the only flow path through the dam the work within the conduit is to be performed while maintaining a minimum flow rate for downstream environmental purposes and continue to safely work within the conduit under higher flow conditions. See section III.B for Alternate flow plan requirements. The Contractor must be prepared to evacuate the conduit for higher flows in the case of a flood event (see II.B).

Options to this contract include removal of lead based paint from the morning glory structure and repainting of the morning glory structure with a vinyl paint system, or hot-dip galvanizing the removable portions of the morning glory structure and painting the non-removable sections. The Contractor is required to provide a 100% lead containment for the removal of the existing morning glory paint system which contains lead. Another option includes painting the sluice gate operating machinery and specified fixed metals.

B. Project Location.

Eau Galle Dam is located on the north side of the City of Spring Valley, WI. Site coordinates are 44° 51’21”N; 92° 14’22”W. (see ATTACHMENT 1, Figure 1-1).

II. General Requirements

A. Project Execution.

i Project Schedule and Completion Date:

Because the Eau Galle Dam does not have an alternate flow path the work within the conduit needs to be performed during what is a normally a period of reduced flows. Work within the conduit shall be performed after December 1st 2018 and be completed, with all equipment removed, by February 28th, 2019. Options, if exercised, shall be completed as defined in Commencement, prosecution and Completion of work and Prosecution of Work Clause (52.211-10).

Statement of work Page 2

B. Work Restrictions and Coordination with Others i Work Restrictions

1) The Eau Galle dam and outlet structure regulates the water level of the Eau Galle reservoir, provides a constant flow to the Eau Galle River and maintains essential river habitat. The Eau Galle Dam regulates downstream flow through the outlet conduit and a minimum of 11 CFS shall be maintained at all times during the work period except as stated herein. The Government will make all reasonable efforts to maintain the Eau Galle Reservoir water level below the morning glory intake. The Government will perform all necessary low flow gate operations to maintain the reservoir level and pass flows through the conduit and/or the contractor installed alternate flow/bypass works system (see III.B) for the duration of the project. The Government and Contractor shall maintain close communication and coordinate all work efforts and low flow gate operations for personnel, equipment and environmental protection and safety.

2) The Contractor shall submit an engineered plan signed by a Licensed Professional Engineer detailing the method for maintaining work progress with these flow rates during the specified performance period (see section III.B).

3) The outlet works conduit interior is a confined space as defined by OSHA. Formulate and implement confined space entry procedures that comply with OSHA requirements. Submit specified confined space entry procedures in accordance with section 01 33 00 Submittal Procedures.

4) Emergency flood stop work clause. The Government will make all reasonable efforts to maintain the Eau Galle Reservoir water level below the morning glory intake elevation for the duration of the work however the possibility exists that the water level in the Eau Galle Reservoir may rise due to normal climate events (snow, rain, melting etc.). As a result of increased water levels the water flow through the conduit may have to be increased, above the 10% exceedance levels to maintain the water level, or in extreme circumstances to keep the water from over topping the morning glory (940’ elevation). To minimize the risk of personnel injury, environmental damage or damage to the Eau Galle Dam and contractor equipment, the contractor shall form a contingency plan to temporarily stop all work and clear the conduit of all equipment, debris, materials and personnel within 8 hours. Close coordination between the contractor on site representative and the Eau Galle Dam Operations staff is necessary for safe operations.

5) Cleanliness: To minimize the risk of inadvertent environmental damage and general work place safety the contractor is responsible for daily removal and clean-up of all debris, waste, hazardous, excess or unused materials, sand blast grit etc. The contractor is responsible for safe storage and proper disposal of all waste and materials in accordance with applicable laws and regulations.

Storage of materials not staged for immediate use within the conduit is not acceptable.

6) Containment: The contractor is responsible for setting up proper containments in and around the work area necessary for lead paint removal (morning glory), containment and control of all dust and blast media, environmental conditions for proper paint application, work site safety etc.

Statement of work Page 3

7) There is no onsite utility power or equipment. The Contractor shall furnish suitable power for air compressors, lighting, vacuums, and other work items.

8) The Contractor is responsible for snow removal necessary to the project’s execution.

9) The reservoir level will be maintained at or less than the morning glory intake elevation of 940.0 feet for the duration of the work. All Gate operations will be performed by the Government.

10) The work limits, lay down and staging areas are show in ATTACHMENT 1 Figure 1-2.

C. Measurement and Payment i COMPENSATION

The payment provided for in the contract shall constitute full compensation for furnishing all materials and for performing all work under the contract in a complete and acceptable manner.

The contract work shall include providing plant, equipment, tools, supplies, labor, supervision, incidental materials, quality control, environmental protection, and meeting safety requirements, and for performing all work required for which separate payment is not otherwise provided.

Compensation for all work shown, specified, or essential to completion of the project (whether or not the specific material or operation is indicated) shall be included on the bid schedule. The payment provided for in the contract includes compensation for all risk, loss, damage, and expense arising out of the nature of the work or its prosecution, subject to conditions of the contract.

Payment for each contract line item will constitute full compensation for furnishing the materials and constructing the work complete in place as specified.

ii JOB PAYMENT ITEMS

Payment items for the work of this contract for which contract job payments will be made are listed in the BID SCHEDULE and described below. All costs for items of work, which are not specifically mentioned to be included in a particular job or unit price payment item, shall be included in the listed job item most closely associated with the work involved. The job price and payment made for each item listed shall constitute full compensation for furnishing all plant, labor, materials, and equipment, and performing any associated Contractor quality control, environmental protection, meeting safety requirements, tests and reports, and for performing all work required for which separate payment is not otherwise provided.

Statement of work Page 4

1. Outlet Conduit Sandblasting and Maintenance Painting

(a) Payment: Payment will be made for furnishing materials, equipment, labor, and performing all operations necessary for existing paint removal and repainting of the Outlet Conduit liner as specified. Work includes, but is not limited to flow diversion, sand blasting, lead and paint containment, collection and proper disposal of all waste, debris, vacuum / collection of all blast media on a daily basis, and repainting the Outlet Conduit liner. All incidentals shall be included in the price bid. Incidentals include, but are not be limited to, confined space requirements such as ventilation, diversion and control of water, containment and collection of wastes, dirt and debris, sealing joints, and grouting as required. Include the costs of performance and payment bonds for this item in this CLIN. Payment will be made for performance and payment bonds for this item required by this contract in accordance with FAR 52.232-5.

(b) Unit of Measure: job.

2. Paint Morning Glory

(a) Payment: Payment will be made for furnishing materials, equipment, labor, and performing all operations necessary for the lead paint removal, surface preparation and repainting of the Morning Glory structure as specified on a Job basis, without removing the removable grates on the structure; that is, the exposed accessible areas of the grates and structure would be recoated without removing any grates from their anchor bolts. Work includes, but is not limited to lead containment and removal and paint containment, daily collection and proper disposal of debris, waste, hazardous waste, and repainting of the Morning Glory structure. All incidentals shall be included in the price bid. Incidentals include, but are not be limited to, temporary shelters and work platforms, 100% lead containment and collection of wastes and appropriate disposal of waste and hazardous materials. Include the costs of additional performance and payment bonds for this option in this line item. Payment will be made for performance and payment bonds required by this contract in accordance with FAR 52.232-5.

Options 0002 Paint Morning Glory and Option 0003 Hot-dip Galvanize the Removable Morning Glory Grates are mutually exclusive options. If Option 0002 is exercised and awarded then no award or consideration shall be given for Option 0003.

(b) Unit of Measure: job.

3. Hot-dip Galvanize the Removable Morning Glory Grates

(a) Payment: Payment will be made for furnishing materials, equipment, labor, and performing all operations necessary to hot-dip galvanize the removable portions of the structure, and conduct mechanical surface preparation and paint the fixed metal portions of the morning glory. Anchor bolts, if damaged, will be replaced by the contractor. 100% lead containment is required, whether on site or off site. Include the costs of additional performance and payment bonds for this option in this line item. Payment will be made for performance and payment bonds required by this contract in accordance with FAR 52.232-5. Options 0002 Paint Morning Glory and Option 0003 Hot-dip Galvanize the Removable Morning Glory Grates are mutually exclusive. If Option 0003 is exercised and awarded then no award or consideration shall be given for Option 0002.

Statement of work Page 5

(b) Unit of Measure: job.

4. Paint Sluice Gate Operating Machinery and Specified Metals

(a) Payment: Payment will be made for painting all metals above the floor of the sluice gate operating deck including the sluice gate operators, fixed ladders, and the A-frame hoist beam that spans across the operating deck. Use the moisture cure urethane (MCU) System 23-F-Z for this option. Work includes but is not limited to surface preparation, painting, and the containment and disposal of wastes. Deck grating is not included in this coating work. Include the costs of additional performance and payment bonds for this option in this line item.

Payment will be made for performance and payment bonds required by this contract in accordance with FAR 52.232-5. This option, if exercised may be awarded in conjunction with any or none of the other options.

(b) Unit of Measure: job.

III. Technical Requirements

A. EXISTING CONDITION

1) The existing structure is the original Eau Galle Dam and outlet works installed in 1965. Eau Galle River flow through the dam enters at two points; the morning glory intake and the gated low flow inlet, both connecting to the upstream end of the outlet works conduit. This 9-foot diameter (horseshoe shape) concrete conduit tunnels 700 feet straight through the base of the dam. This conduit is the only means of controlled flow out of the reservoir.

2) Because the morning glory intake has no gated shut off control the government will make all reasonable efforts to maintain the pool level below the crest of the morning glory to facilitate work on the morning glory and the conduit liner. ATTACHMENT 3, Figure 3-1 through Figure 3-3 show the morning glory and adjacent areas. Figure 3-4 shows the recommended conduit access point at the south side of the dam.

3) To provide reinforcement to the center of the concrete conduit there is a 300-foot long steel conduit liner reinforcing the center part of the conduit. This conduit is indicated on the reference drawings including M31a.1-S-14/4, M31a.1-L-45/5.1 and M31a.I-INS-52/10. The 300-foot long steel conduit liner was installed in about 20-foot long sections to approximately align with the original concrete conduit monolith joints (see M31a.1-P-64/9). The end gaps between steel sections are filled with elastomeric joint sealant. The two far ends of the steel conduit liner were grouted to provide a smooth flow transition between the steel liner and the existing concrete surfaces (see M31a.1-P-64/12). ATTACHMENT 2 is a reference drawing index.

B. ALTERNATE FLOW PLAN

1) GENERAL. Eau Galle Dam is regulated to pass a minimum flow of 11 to 13 CFS (cubic feet per second) to maintain the Eau Galle River trout population. This regulated river flow routes only through the conduit with the steel conduit liner to be recoated. This Paragraph specifies requirements for the contractor’s alternative flow plan required to divert and regulate regulated river flow to allow for specified recoating work.

Statement of work Page 6

2) FLOW PLAN REQUIREMENTS. The contractor is responsible to provide an alternate flow or bypass works designed to pass a minimum constant flow of 11 CFS and a divert or contain a maximum flow of at least 27 CFS providing a safe, dry working environment for performing work within the conduit. The 11 CFS constant flow requirement is essential to maintaining safe downstream habitat while the 27 CFS corresponds to the historical flow exceedance levels (see Section 01 14 00.00 13 Work Restrictions). For example, the flow plan may include a temporary pipe system placed within the conduit to segregate flow and keep the conduit liner dry, or decking to work above the flow, or a longitudinal wall to work alongside the flow, or other engineered options. The plan shall include a reliable flow rate measurement system to continuously monitor and verify flow rate.

3) To facilitate the installation or removal of the alternate flow system, the Contractor may reduce the flow rate through the conduit to 5 CFS for a maximum of 4 hours. At no time shall the flows be reduced to less than 5 CFS. The reduction of flow requires close coordination with the Eau Galle Dam Operations Staff. One method of maintaining minimum flows for a very limited duration is to pump water out of the downstream stilling basin.

C. CONDUIT LINER COATING

1) EXISTING CONDITION. The inner surface of the steel conduit liner has its original epoxy coating. ATTACHMENT 3 Figure 3-5 through Figure 3-7 show a representation of the condition of the conduit liner during the October, 2016 Inspection. Figure 3-5 and Figure 3-7 are samples of the condition near the low water line of the conduit liner while Figure 3-6 shows a sample of the condition at the top of the steel liner.

2) SURFACE PREPARATION. The contractor shall remove all existing epoxy coatings from the steel conduit liner in accordance with SSPC-SP 5 (White Metal Blast Cleaning). Remove all failed or ineffective portions of the elastomeric compression joint from the steel conduit liner seams before blast cleaning, and restore the watertight seal of the liner seam with the injectable joint sealant, per manufacturer instructions, after recoating the liner. Restore any failed grout at the transition monoliths located at the upstream and downstream ends of the steel conduit liner.

Remove and replace any failed grout at the recessed anchor nuts to restore the flush surface condition as indicated on reference drawing M31a.1-P-64/13.

3) NEW COATING SYSTEM. Apply the new vinyl paint system in accordance with Section 09 97 02.

4) JOINT SEALANT. Remove failed or ineffective portions of the elastomer sealant applied at the perimeter of the conduit liner sections. Install the new joint sealant after the paint system.

a. New joint sealant and installation details shall be same as existing joint sealant and installation details. Existing joint sealant is Sikaflex-1a moisture-cured, 1-component, polyurethane that meets:

Federal specification TT-S-00230C, Type II, Class A.

ASTM C-920, Type S, Grade NS, Class 35, use T, NT, O, M, G, I.

Statement of work Page 7

5) CONDUIT LINER NUMBERING SYSTEM. Each conduit liner section is currently labeled with the stencil number system as indicated in Figure 3-8. Contractor shall document the existing conduit liner section stenciled numbering system and restore after the new coating is applied. Use similar stencil print style and character size as existing stencil numbering. Label each conduit liner section in the same location as the existing stencil numbering. Stencil coating shall be chosen specifically to be compatible with the substrate, and be of a contrasting easily visible color. New stencil labels shall be applied within the allowable recoating time window of the substrate coating.

D. ULTRASOUND THICKNESS MEASUREMENTS

1) The contractor shall measure and document conduit liner steel thickness of the fifteen steel conduit liner sections. The contractor shall furnish a hand-held ultrasound thickness meter designed for outdoors field-use conditions of this work. Take representative ultrasound steel thickness readings 15 places per each 20-foot long conduit liner section for a total of 225 steel thickness readings to be taken for the entire conduit liner system. All conduit liner thickness measurements shall be made when coatings are removed in the blast cleaned state. A group of five testing locations will be at the center of the conduit liner ceiling cross-section, 18 inches to either side of that center ceiling point following the curvature of the liner, and 12 inches up from the base of the liner on each side. This grouping will be taken at the mid-span of the 20-foot long conduit liner and 2-feet inward from the edge of the liner section toward the center.

2) Ultrasound gauge shall be designed for the outdoors field use conditions of this work. Provide certification of current gauge calibration by the manufacturer; within one year or at an interval specified by the manufacturer. Gauge shall be advertised as capable of (+/-) 0.005-inch thickness resolution, or better, for the 3/8-inch thick conduit liner as installed.

3) Contractor shall verify that the applied coatings meet the manufacturers Dry Film Thickness (DFT) specifications in accordance with Section 09 97 02 PAINTING; OUTLET WORKS. DFT measurements shall be taken at nine locations on each 20-foot long conduit liner section for a total of 135 DFT measurements for the entire conduit liner. A group of three (3) testing locations will be at the center of the conduit liner section, at top-center, and six (6) inches up from the base of the liner on each side. This grouping will be taken at the mid-span of the 20-foot long conduit liner and six (6) inches inward from the edge of the liner section toward the center.

E. MORNING GLORY INTAKE DETAILS, AND PAINT SYSTEM FOR

FIXED METALS (applies to Morning Glory Options 002 and 003).

1) COMPONENTS TO BE PAINTED. This paragraph specifies protective coatings to be applied to fixed metal parts and trash racks of the morning glory intake structure. The morning glory parts are indicated on the reference drawings M31a.1-L-45/6.1 and 7.1. Morning glory components to be coated include all steel surfaces located above elevation 939.5. These parts include the grates or trash racks, the full height (11.0 foot high) curved protective plates on each vertical concrete column, and the steel embeds that frame the removable trash rack part. Morning glory steel components shall be coated with vinyl paint to comply with UFGS 09 97 02 SYSTEM 5-E-Z. The

Statement of work Page 8 paint system requires white metal surface preparation and containment for removed coatings.

Topcoat color shall be medium gray as approved.

2) LEAD PRIMER SURFACE PREPARATION AND CONTAINMENT. The morning glory steel parts are all coated with the original lead-containing paint system. Removal of the lead based primer will require 100% lead containment both inside and outside of the structure, and worker air quality procedures (see section 09 27 02). The contractor shall use suitable procedures to preclude environmental lead contamination. If removing lead primer on site, use of a blasting media capable of stabilizing heavy metals (see section 01 14 00.00 13) is required. Where mechanical surface preparation methods are necessary, utilize vacuum recovery to minimize lead contamination.

Suitable barriers shall also be used to prevent drips and runs on structures that are not specifically required to be painted. Install suitable protective coverings to protect the threads of all exposed anchor fasteners to be reused.

3) LIFTING and HANDLING. The contractor is responsible to comply with the applicable safety standards. Each of the eight (8) side racks weighs about 3500 pounds. Each of the eight (8) top racks weighs about 1000 pounds. These trash racks all have original lead containing coatings. The racks are held in place with stainless steel anchor bolts and nuts which are expected to be reusable.

The morning glory is located out on the water, which increases work difficulty. The contractor shall plan and submit the intended staging and hoisting procedures for review (see section 01 33 00).

4) ANCHOR BOLT PROTECTION. Use thread protection methods. Existing stainless steel anchor bolts can be easily damaged during the work, and some thread galling may be expected.

Some of these fasteners may require more than a wrench for disassembly. The contractor shall formulate and apply procedures to minimize galling and other potential damage to anchor fasteners. The contractor shall chase existing anchor bolt and nut threads with an appropriate thread tap and die system. Any anchor bolts apparently damaged beyond reusability shall be reported to the Contracting Officer.

F. HOT-DIP GALVANIZE THE REMOVABLE MORNING GLORY

GRATES (OPTION)

1) All removable morning glory components including the side racks and top racks shown on reference drawing M31a.1-L-45/7.1 shall be blast cleaned and hot-dip galvanized in accordance with ASTM A123. Each of the eight (8) side racks to be galvanized weigh about 3500 pounds.

Each of the eight (8) top racks to be galvanized weigh about 1000 pounds. The racks are held in place with stainless steel anchor bolts and nuts which are expected to be reusable. A major part of this work is the removal and reinstallation of these trash racks, due to the morning glory location out on the water away from the reservoir shoreline. The contractor shall disassemble and remove the trash rack components from the morning glory, transport them to and from the galvanizing facility, and finally reinstall the galvanized components back on the morning glory. The contractor shall plan and submit the intended hoisting and transport procedures for review. The contractor shall apply specified protective coatings to the morning glory fixed metals when the racks are removed.

Statement of work Page 9

2) The fixed and removable morning glory steel parts are all coated with the original lead-containing paint system. The contractor shall use mechanical surface preparation with vacuum recovery to minimize lead contamination, or a blast media that fixes the lead, as specified.

3) Furnish 4-foot tall temporary closures to prevent debris flow through side rack bays. Temporary closures shall be installed whenever side racks are removed for galvanizing work. Timber and/or steel closures are acceptable, for example, a lashed together stack of 14 each 4” x 6” x 10’ timbers may suffice.

G. SLUICE GATE OPERATING MACHINERY AND SPECIFIED METALS

(OPTION).

Components to be coated include all of the metals above the floor of the sluice gate operating deck include the sluice gate operators, fixed ladders, and the A-frame hoist beam that spans across the operating deck. Deck grating is not included in this coating work. Utilize MCU paint system per Section 09 97 02 using power tool surface preparation or sandblasting. Color shall be medium gray, as approved. Coating thicknesses shall be as recommended by the coating manufacturer. This option is not constrained to the December – February period of performance.

IV. ATTACHMENTS

ATTACHMENT 1- PROJECT LOCATION MAP

ATTACHMENT 2- REFERENCE DRAWINGS INDEX

ATTACHMENT 3– SITE PHOTOGRAPHS

Statement of work Page 10

ATTACHMENT 1 - PROJECT LOCATION MAP

Figure 1-1 Eau Galle Dam: North side of Spring Valley, WI. Coordinates 44° 51’21”N; 92° 14’22”W

Statement of work Page 11

Figure 1-2: Eau Galle Dam work limits, lay down and staging areas.

Statement of work Page 12

ATTACHMENT 2 - REFERENCE DRAWINGS INDEX

EAU GALLE DAM REFERENCE DRAWINGS:

M31a.1-S-14/1 GENERAL PLAN & VICINITY MAP M31a.1-S-14/4 OUTLET WORKS PLAN & PROFILES M31a.1-INS-52/10 OUTLET WORKS MARKER POINTS

MORNING GLORY INTAKE REFERENCE DRAWINGS

M31a.1-L-45/3.1 PLANS & SECTIONS W / REINF.

M31a.1-L-45/4.1 SECTIONS W/ REINF.

M31a.1-L-45/5.1 TRASH BEAMS & COLUMNS M31a.1-L-45/6.1 TRASH BEAMS & COLUMNS M31a.1-L-45/7.1 INTAKE STEEL TRASH RACK M31a.1-L-45/8.1 DIVERSION & LOW FLOW STRUCTURE

CONDUIT REPAIR REFERENCE DRAWINGS

M31a.1-P-64/8 SITE PLAN M31a.1-P-64/9 PLAN AND ELEVATION SECTIONS M31a.1-P-64/10 MONOLITH 14 & 15 CONDUIT REPAIR DETAILS M31a.1-P-64/11 LINER PLAN, DETAILS & SECTIONS M31a.1-P-64/12 MISCELLANEOUS DETAILS M31a.1-P-64/13 ANCHOR AND STUD LAYOUT AND DETAILS M31a.1-P-64/14 INSTRUMENT PLACEMENT AND DETAILS

Statement of work Page 13

ATTACHMENT 3 – SITE PHOTOGRAPHS

Figure 3-1 Morning Glory intake and sluice gate control structure with stairway. Stairway provides access to sluice gate structure and morning glory from the access road at top of dam.

Statement of work Page 14

Figure 3-2 Morning Glory intake structure. (Note worker on riprap slope of dam)

Statement of work Page 15

Figure 3-3: Sluice gate structure (left) and Morning glory intake (right)

Statement of work Page 16

Figure 3-4 Recommended access to conduit liner is through the outlet works discharge on the down stream side of the dam.

Statement of work Page 17

Figure 3-5: Conduit liner at 12 & 13 (low) near normal water line (Photo October 2016).

Statement of work Page 18

Figure 3-6 Conduit liner at top of conduit at segment 16 & 17 (Photo October, 2016).

Statement of work Page 19

Figure 3-7: Conduit liner at 19 (low) (Photo October 2016)

Statement of work Page 20

Figure 3-8: Conduit liner showing numbering system (Photo October, 2016)