35 50 56 Amendment 0002.pdf

LD5A, LD8 and LD10 Anchorage Replacement W912ES21B0010

SECTION TABLE OF CONTENTS

DIVISION 35 - WATERWAY AND MARINE CONSTRUCTION

SECTION 35 50 56

MITER GATE ANCHORAGES REMOVAL AND INSTALLATION

PART 1 GENERAL

1.1 REFERENCES

1.2 SUBMITTALS

1.3 SUBMITTAL DESCRIPTIONS

1.3.1 Work Plan

1.3.2 Erecting Engineer

PART 2 PRODUCTS

2.1 MATERIALS AND STANDARD ARTICLES

PART 3 EXECUTION

3.1 SEQUENCE OF WORK

3.1.1 Work Accomplished Prior to Lock Closure

3.1.2 Work Accomplished during Winter Lock Closure

3.2 SURVEY CONTROL SYSTEM

3.2.1 Survey Control Work Plan

3.2.2 Survey Control Records

3.3 CONCRETE DEMOLITION

3.4 REPLACEMENT ANCHORAGE FRAME AND PIN PLATE INSTALLATION

3.5 CONCRETE PLACEMENT

3.6 INSPECTION OF MITER GATE RECESS

3.7 SHORING AND POSITIONING OF MITER GATES DURING ANCHORAGE DEMOLITION

3.7.1 Shoring of Miter Gates Placed in Recess

3.8 REMOVAL PROCEDURE FOR MITER GATE ANCHORAGE BARS AND RELATED

COMPONENTS

3.9 CONCRETE AND GATE ANCHORAGE DEMOLITION

3.10 RE-INSTALLATION PROCEDURE FOR MITER GATE ANCHORAGE BARS AND

RELATED COMPONENTS

3.10.1 Installation Of Replacement Gudgeon Bushings and Pins

3.10.2 Line Boring

3.11 MITER GATE ADJUSTING

3.12 DIVING REQUIREMENTS

3.12.1 Dive Operation Plan

3.12.2 Diving Safe Practices Manual

3.12.3 Dive Personnel List with Qualifications

3.12.4 Dive Activity Hazard Analysis

-- End of Section Table of Contents --

SECTION 35 50 56 Page 1

SECTION 35 50 56

MITER GATE ANCHORAGES REMOVAL AND INSTALLATION

PART 1 GENERAL

1.1 REFERENCES

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

U.S. ARMY CORPS OF ENGINEERS (USACE)

EM 385-1-1 (2014) Safety and Health Requirements Manual

RESEARCH COUNCIL ON STRUCTURAL CONNECTIONS (RCSC)

RCSC S348 (2014; Errata 2015) RCSC Specification for Structural Joints Using High-strength Bolts

1.2 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Work Plan; G , STR

Dive Operation Plan; G , SO

Diving Safe Practices Manual; G , SO

Dive Activity Hazard Analysis; G , SO

Dive Personnel List with Qualifications; G , SO

Survey Control Work Plan; G , STR

Survey Control Records; G , STR

Miter Gate Recess Inspection Report; G , STR

Visual Verification Of Shoring System

Erecting Engineer; G

Line Boring Plan

SECTION 35 50 56 Page 2

1.3 SUBMITTAL DESCRIPTIONS

1.3.1 Work Plan

The work plan shall include, at a minimum, the following information:

a. Designation of miter gate(s) to be placed at miter and miter gate(s) to be shored in the recess, and proposed sequence of work; i.e.

work to proceed on gates concurrently or consecutively.

b. Shoring information with regard to jack types, blocking plan, and installation of same. Work plan shall include methods and design calculations for gate tie-back system prepared and signed by a Registered Professional Engineer. After installation, visual verification of shoring system including images or video. See additional shoring requirements in the Shoring of Miter Gates Placed in Recess Paragraph of this section.

c. Delivery plan for materials and assemblies to the lock.

d. Tools and machinery planned for use in demolition and installation of new anchorage frames, removal and re-installation of gate anchorage bars and connecting pins.

e. Plan for locating anchorage in proper position; templates or patterns planned for use.

f. Plan for assembly of slip-critical anchorage pin plate connections, including tensioning method and description of required verification testing.

g. Plan for inspection of miter gate recesses.

h. Plan to prevent the miter gates from being frozen in.

i. Plan a method to fit anchorage bars and gudgeon pin into gudgeon hood to ensure proper alignment and assembly. Anchorage bars should be dry fit prior to final reassembly to avoid potential delays.

Discuss corrective actions and measures that will be taken in the event the gudgeon assembly does not fit up properly.

1.3.2 Erecting Engineer

a. Provide the services of an erecting engineer to supervise and direct the erection and installation of the equipment. The erecting engineer must be a Professional Engineer in the Mechanical Engineering discipline with machine design experience, or be a millwright with 5 years of experience on heavy civil navigation projects. Submit proposed erecting engineer professional engineering license or provide the millwrights work experience demonstrating 5 years of experience on heavy civil navigation projects for approval.

b. The erecting engineer must be present for anchorage leveling, anchor bar installation, and miter gate testing.

c. The erecting engineer must verify the fits and the tolerances of mating components prior to erecting.

SECTION 35 50 56 Page 3

PART 2 PRODUCTS

2.1 MATERIALS AND STANDARD ARTICLES

Materials and standard articles shall conform to the respective specifications and other designated requirements. Sizes shall be as specified or shown on the drawings. Where material requirements are not specified, materials furnished shall be suitable for the intended use and shall be subject to the approval of the Contracting Officer.

PART 3 EXECUTION

3.1 SEQUENCE OF WORK

3.1.1 Work Accomplished Prior to Lock Closure

This work shall be conducted with the navigation lock open, prior to the close of navigation.

a. Establish Survey Control System, as specified herein.

b. Anchor rod demonstration testing.

c. Inspection of miter gate recesses, as specified herein.

3.1.2 Work Accomplished during Winter Lock Closure

Winter lock closure work shall be accomplished in the following sequence:

a. Shoring of gate(s) / placement of gate(s) at recess position; load relief to anchorages, as specified herein.

b. Disassembly of anchorage bars and connecting pins, as specified herein.

c. Demolition of concrete (as necessary) and existing anchorage frame, as specified herein.

d. Concrete drilling and installation of anchor rods as specified in SECTION 03 01 33 ANCHOR ROD INSTALLATION and herein.

e. Installation of dowels and concrete, as specified herein and in

SECTION 03 30 53.01 CAST-IN-PLACE CONCRETE.

f. Installation of replacement anchorage frames, as specified herein.

g. Installation of pin plates into replacement anchorage frames, as specified herein, unless installed in the shop.

h. Reassembly of existing anchorage bars with new anchorage pins and government provided gudgeon bushings and pins, as applicable, as specified herein.

i. Removal of shoring / release of recessed gate and adjustment of anchorages, as specified herein

3.2 SURVEY CONTROL SYSTEM

The Contractor shall create a Survey Control System to re-establish the

SECTION 35 50 56 Page 4 location of the new anchorage pins in the same location as the existing anchorage pins. The replacement anchorage frames shall be installed on the same horizontal alignment as the existing anchorage bars and the vertical alignment shall have a constant elevation based on the elevation of the existing anchor bars at the location of the gudgeon pin centerline.The control points shown on the Survey Control Point drawing shall be used to define the horizontal and vertical alignment of the replacement anchorage frames. After anchorage frame installation and before grouting under the anchorage frame the Contractor shall resurvey and provide to the Contracting Officer evidence installation meets required tolerances shown on the Survey Control Point drawing. The Contractor may add additional control points as necessary to ensure the Survey Control System is adequate to achieve the specified accuracy below.

The system shall provide a positional uncertainty based on a 95-percent confidence level.

The positional tolerance of all points located, established, or identified as part of this survey shall have a maximum positional uncertainty of 5% relative to all other points located, established, or identified as part of this survey.

The control system may be independent and local at each anchorage replacement location.

3.2.1 Survey Control Work Plan

The Contractor shall prepare a Survey Control Work Plan describing the methods that will be used for the Survey Control System and shall contain, at a minimum, the following information.

a. Description of the horizontal coordinate system that will be used to locate and measure all survey points. Identification of projected coordinates systems, if used, shall have a minimum of three recoverable survey reference points.

b. Description of the vertical measurement system used to locate and measure all survey points. Identification of the vertical measurement system shall, at a minimum, contain the reference datum and units of measure. Local vertical systems, if used, shall have a minimum of three recoverable reference points.

c. Description of an appropriate error propagation and other measurement design theory to select the proper instruments, field procedures, geometric layouts and computational procedures to control and adjust random and systematic errors in order to achieve the allowable positional tolerance of all survey points.

3.2.2 Survey Control Records

The Contractor shall maintain records of all field measurements, notes, sketches, and computations relating to all survey points recovered, established, or computed. Survey Control Records shall also include a Contractor provided Survey Point Report identifying, at a minimum, point descriptions and recovery information, point establishment methods, and point coordinate values along with positional error estimates.

SECTION 35 50 56 Page 5

3.3 CONCRETE DEMOLITION

Provide the survey control records for approval. Concrete demolition cannot be started prior to Government approval and until after the close of navigation. Remove existing light standards that interfere with concrete demolition and store for reinstallation. Remove anchorage recess steel grating, hand railing, and other miscellaneous metals and retain for reinstallation. Concrete demolition shall be in accordance with SECTION 02 41 00 STRUCTURAL DEMOLITION and 03 30 53.01 CONCRETE WIRE SAWING.

3.4 REPLACEMENT ANCHORAGE FRAME AND PIN PLATE INSTALLATION

After concrete demolition, demolition of the top portion of the existing anchorage frame, and the anchor rod demonstration tests are complete, anchor rod holes shall be drilled and anchor rods installed. The Contractor shall be aware of embedded conduits and shall have taken previous measures to de-energize any conduits and re-route wiring. The Contractor shall use a template, pattern, or other means to ensure anchor rods are precisely located in order for the anchorage frames and connecting pin holes to be in the correct locations. After the anchor rods are installed and grouted, the Contractor shall install the anchorage frame, and, using a template, pattern, or other means, properly position the anchorage frame. The contractor shall level and vertically adjust the anchorage frame using the leveling bolts as shown on the drawings. After the anchorage frame is properly positioned, both horizontally and vertically, grout shall be installed under the anchorage as shown on the drawings. The Contractor shall ensure that grout completely fills the void between the anchorage frame and the concrete below; the Contractor shall also block out the anchor rod holes in the anchorage frame bottom flange to prevent grout from filling the holes. After the grout has cured, the anchor rod nuts and washers shall be installed as shown on the drawings.

After the anchorage frame is installed the pin plates may be installed if not installed at the shop; install the pin plates and shims as shown on the drawings. Please note that as specified on the drawings, all pin plates and shims shall be matched to a particular anchorage frame to provide a clearance fit of 0.01 inches or less at any point within the faying surfaces. Some small adjustments in pin hole location may be accomplished by using the small clearance available in the bolt holes. Pin plates shall be aligned using the actual or dummy pin to ensure that top and bottom pin plates are on the same vertical axis. The Contractor shall ensure that all pin plates and shims are aligned and flush with one another. After proper alignment of the pin plates and shims is achieved, install the connecting bolts and washers as shown on the drawings. The bolts shall be pretensioned in accordance with Research Council on Structural Connections "Specification for Structural Joints Using ASTM A325 or A490 Bolts", for slip-critical joints, RCSC S348. The Contractor shall ensure that faying surfaces for this connection are coated with a primer for slip critical joint as specified in SECTION 09 97 02 PAINTING:

HYDRAULIC STRUCTURES. The Contractor shall complete preinstallation verification tests in accordance with RCSC S348 Section 7.2.

3.5 CONCRETE PLACEMENT

The Contractor shall install reinforcing steel and place new concrete into demolished areas as shown on the drawings. After the pin plates are installed and the pin hole locations have been verified as correct, the Contractor shall install dowels and backfill demolished concrete areas with new concrete as shown on the drawings. Reinforcing dowels shall be installed with epoxy grout as shown on the drawings and as specified.

SECTION 35 50 56 Page 6

Recess framing angles shall be fabricated and installed as shown on the drawings. Shoring shall not be removed, or hydraulic head shall not be released, as applicable, until all components of the anchorage frames, anchorage bars and connecting pins are installed, all new concrete has achieved the specified strength as specified in SECTION 03 30 00, CAST-IN-PLACE CONCRETE and the Contractor has received written approval from the Contracting Officer.

3.6 INSPECTION OF MITER GATE RECESS

At least six weeks prior to lock closure, the Contractor shall conduct a dive survey of the miter gate recess floor planned for use in shoring the gates. The survey shall address the condition of concrete and the amount of silt and debris that may have accumulated in the recess. Diving operations shall be in accordance with Paragraph, Diving Requirements.

The Contractor shall furnish a written miter gate recess inspection report, which shall include images or video of the recess area of this survey to the Contracting Officer. The Contractor shall not proceed with installation of shoring until the survey has been submitted and approved by the Contracting Officer and all materials found during the survey within the recesses are removed.

3.7 SHORING AND POSITIONING OF MITER GATES DURING ANCHORAGE DEMOLITION

After lock closure, but before concrete demolition and demolition of the existing miter gate anchorages, the miter gates shall be supported by placing each leaf of the miter gate in the recesses and installing a tie back system and placing blocking under the miter end of each gate. The chamber will be maintained at either the upper or lower level using valve settings adjusted by the government. The approximate dry weight of the taller downstream 30-foot gate leaves is 65 tons per leaf. The gate weight does not include ice which may accumulate on the gate during the winter season. The shoring plan shall include ice removal as necessary to maintain a stable gate. The Contractor shall install and maintain a system, such as bubblers, to prevent the gates from being frozen in. A description of this system shall be included in the work plan.

3.7.1 Shoring of Miter Gates Placed in Recess

The miter gate leaves placed in the miter gate recesses shall be shored.

Shoring shall consist of hydraulic jacks and an arrangement of wood or steel blocking under the gate leaf and supported on the floor of the miter gate recesses. All Jacks, blocking and related equipment shall be furnished by the Contractor. The blocking and jacking system must be installed in the wet by divers provided by the Contractor. Diving operations shall be in accordance with Paragraph, Diving Requirements. Using the jacking system, the miter gate leaf shall be raised to the point that load to the anchorage bars is relieved. Blocking shall be installed so that load to the anchorage bars continues to be relieved but load to the jacks is relieved. For ease of reinstallation, the contractor may use jacks which can raise the gate beyond level for installation of gudgeon pin and anchorage arms.

The Contractor shall also design and provide an arrangement to tie the miter gate leaf to the lock wall in order to stabilize the gate leaf and further relieve load to the anchorage bars. A minimum of two tiebacks are required; one near the miter end of the gate leaf and one near the quoin end of the gate leaf. The contractor shall submit a shoring plan, which includes design calculations related to the jacks/blocking and tie-back

SECTION 35 50 56 Page 7 system prepared and sealed by a Registered Professional Engineer for Government approval in accordance with SECTION 01 33 00 SUBMITTAL PROCEDURES. Shoring shall not be removed until all components of the new anchorage frames, the existing anchorage bars and connecting pins are installed, all new concrete has achieved the specified strength as specified in SECTION 03 30 00, and the Contractor has received written approval from the Contracting Officer. The shoring system may be designed to lean the miter gate riverward slightly to aid in the installation of the gudgeon pin. If the contractor choses to have this as an option, it must be discussed in the shoring plan submittal for approval. The Contractor shall provide images or video to confirm the instillation of the shoring system to the Government.

3.8 REMOVAL PROCEDURE FOR MITER GATE ANCHORAGE BARS AND RELATED COMPONENTS

The miter gate leaves shall be placed in the recess and shored so that load to the anchorage bars is relieved. The Contractor shall record the distances between the centerline of connecting pins. During the removal procedure, the anchorage bars shall be supported by blocking or other means to prevent damage. At this point the anchorage pins shall be removed by using a crane. Any alternate method of removing the anchorage pins must first be approved by the Contracting Officer. After the anchorage pins are removed, the gudgeon pin shall be removed by use of a crane. Any alternate method of removing the gudgeon pin must first be approved by the Contracting Officer.

The anchorage bars shall be retained for re-use during the installation.

None of the associated hardware such as anchorage pins, gudgeon pins, and pin keepers shall be retained for re-use during the installation and shall become property of the Contractor.

After the gudgeon pin is removed, the anchorage bars shall be swung until clear of the gate and removed from the recess area. The Contractor shall clean and degrease the gudgeon pin plate area for inspection.

3.9 CONCRETE AND GATE ANCHORAGE DEMOLITION

Prior to demolition, the Contractor shall survey the location of all connecting pins in accordance with paragraph, Survey Control System, and the Survey Control Point drawing, to ensure that replacement anchorages are properly located. After the Survey Point Report has been submitted, in accordance with paragraph Survey Control Records, to the Government and the Contractor has received written approval from the Government, the Contractor may proceed with demolition. After the miter gate is shored, or mitered with hydraulic head applied, as applicable, and load to the anchorage frames is relieved, with anchorage bars and connecting pins removed, the Contractor shall proceed with concrete demolition and demolition of the top portion of the existing anchorage frame as shown on the drawings.

3.10 RE-INSTALLATION PROCEDURE FOR MITER GATE ANCHORAGE BARS AND RELATED

COMPONENTS

The Contractor shall ensure that all anchorage bars are set to the original distance between connecting pins measured before disassembly. The anchorage bars shall be moved into position and the new government provided gudgeon pin and bushing shall be installed. Next the anchorage pins and keeper plates shall be installed. Finally, the gudgeon pin keeper plates shall be reinstalled and lubrication lines shall be reconnected to the original

SECTION 35 50 56 Page 8 locations.

3.10.1 Installation Of Replacement Gudgeon Bushings and Pins

Gudgeon pins and bushings shall be provided by the government for installation after the anchorage bars are re-installed. The Contractor is responsible for performing all field installation, adjustment, and alignment.

3.10.2 Line Boring

Submit line boring plan including Contractor's proposed line boring experience for approval. To perform the line bore, add material to affected bore by arc welding. Ensure bore metal is preheated to at least 50° F. Preheating must be complete by heated forced air or heated blanket. Do not use flame to preheat bores. Add sufficient weld material so when the hole is rebored, a smooth bearing surface is achieved. Pocked or discontinuous bores are not acceptable as a finished product. Ensure the new bore is aligned by laser level or dry fitting anchorage arms with gudgeon pin.

3.11 MITER GATE ADJUSTING

After the existing anchorage bars have been re-installed, the shored miter gates shall have the shoring removed. Each gate shall be rotated throughout its full travel range, then the gate shall be moved to the miter position.

Adjustment of the anchorage bars shall consist of turning the sleeve nuts on the anchorage bars so that the quoin blocks and miter blocks are in firm contact when the gate is in the mitered position and the difference in elevation between the quoin end and miter end when measured from the top of the top horizontal girder is not greater than 1/2-inch in the miter position or the open position. Adjustment of the sleeve nuts for the anchorage bars is accomplished with the gate leaf in the mitered position.

The Government may conduct strain gage testing of the anchorage bars to determine the suitable adjustment of the anchorage bars. The Contractor shall make further adjustments based on this testing and as directed by the Contracting Officer. The gate that was mitered shall be completed last, so that at least one gate can maintain pool.

3.12 DIVING REQUIREMENTS

Prior to conducting any dive, the Contractor shall submit for approval a Dive Operation Plan and other submittals listed below and as required in EM 385-1-1 . The Contractor shall note in the Dive Activity Hazard Analysis the diving depths necessary and note the possibility of surface skin ice or debris.

A list and description of diving related submittal requirements follows.

3.12.1 Dive Operation Plan

EM 385-1-1 requires Government review and approval of the Contractor's diving operation plan. The diving operation plan must include the safe practices manual, activity hazard analysis, emergency management plan, dive personnel certifications, and breathing air certification.

SECTION 35 50 56 Page 9

3.12.2 Diving Safe Practices Manual

The safe practices manual shall include as a minimum, but is not limited to the following:

Contractors and USACE Districts/Labs with in-house dive teams shall develop and maintain a safe practices manual that encompasses their entire diving program. The safe practices manual shall be available at all times to the Government representative and all dive team members at each diving location. The safe practices manual shall include, as a minimum, the following:

a. Dive safety procedures and checklists;

b. Assignments and responsibilities of dive team members;

c. Equipment certifications, procedures, and inspection checklists;

d. Emergency procedures for fire, equipment failure, adverse weather conditions, and medical illness or injury and specific procedures for:

(1) Entrapped or fouled diver including fouled umbilical (suction and entanglement/debris;

(2) Actions upon loss of vital support equipment;

(3) Actions upon loss of gas supply;

(4) Action upon loss of communication;

(5) Lost diver plan (SCUBA Operations Only);

(6) Injured diver plan;

(7) Actions upon discovery of fire;

(8) Diver blow up/over rapid ascent to surface;

(9) Diver loss of consciousness; and

(10) Injury/illness of member of surface crew with diver in the water.

e. Procedure for internal safety inspections (frequency, checklists, etc.);

f. A complete copy of OSHA, 29 CFR 1910, Subpart T, and a statement of the employer's policy for ensuring compliance with the standard;

g. The appropriate U.S. Navy Table(s), including as a minimum:

(1) U.S. Navy Table of No-Decompression Limits and Repetitive Group Designation for No-Decompression Air Dives;

(2) U.S. Navy Residual Nitrogen Timetables for Repetitive Air Dives;

(3) U.S. Navy Standard Air Decompression Table.

h. A sample of the diving log to be used;

SECTION 35 50 56 Page 10

i. A sample of the repetitive dive worksheets or equivalent (dive profile method) to be used;

j. An outline of the fitness for duty (including medical) requirements for dive team members, and

k. An outline of administrative and record-keeping procedures

3.12.3 Dive Personnel List with Qualifications

Dive Team Member Qualification Documentation Requirements:

1. Dive team members must be the same personnel specified in the Dive Operation Plan.

2. The dive team must meet the minimum manning levels required in EM 385-1-1, Appendix G.

3. Each dive team member must have the following:

a. CPR Certification

b. First Aid Certification

c. Emergency oxygen systems certification

d. Licensed physician letter certifying fitness for diving

e. Diver training certification

f. Dive log

3.12.4 Dive Activity Hazard Analysis

A separate Dive Activity Hazard Analysis (AHA) must be completed for any diving operation and shall follow the format given in EM 385-1-1 , Section

1. Submit the AHA for review at least 15 days prior to the start of any diving operations. The analysis shall be reviewed during daily inspection to ensure the implementation and effectiveness of the activity's safety and health controls. The Dive AHA will be reviewed periodically (at least monthly) at the Contractor supervisory safety meeting and updated as necessary when procedures, scheduling, or hazards change.

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SECTION 35 50 56 Page 11