ECIFP.pdf

Engineering Considerations and

Instructions for Field Personnel

Shepherd Street Bridge Replacement

City of Cumberland, KY

Nashville District, USACE

Contract No. W912QR-14-D-0002

6/7/2017

Woolpert, Inc.

1 Easton Oval, Suite 310

Columbus, Ohio 43219

614.476.6000

Engineering Considerations and Instructions for Field Personnel |

Shepherd Street Bridge Replacement

US Army Corps of Engineers, Nashville District

June,, 2017

Introduction

Purpose

This document serves as the Engineering Considerations and Instructions to the Field Personnel for the replacement of the Shepherd Street Bridge over Looney Creek. The information provided is not intended to supersede or modify the requirements of the plans and specifications approved in the submittal.

Background

The project consists of the replacement of Shepherd Street Bridge, as part of the City of

Cumberland, Kentucky Flood Damage Reduction Project as authorized by Section 202 of the

Energy and Water Development Act of 1981 (PL96-367). The project includes the new bridge, along with the design of associated modifications and relocations of the approach roadways.

The new bridge will be a single-span concrete deck on pre-stressed concrete box beams with a

30-foot wide deck. Design calls for two 9-foot wide traffic lanes, one 5-foot wide pedestrian walkway, and associated shoulders and railings along the length of the bridge.

Scope of Work

Existing Bridge

Information on the existing Shepherd Street Bridge is limited, and no existing plans could be located. The bridge appears to be a single 39-ft span cast in place concrete slab on cast in place concrete beam bridge supported by wall type abutments. The roadway width is approximately

18-ft face-to-face of curb with sidewalks on either side for a total width of 26.25-ft.

The existing Shepherd Street Bridge is to be removed in its entirety.

Roadway and Structure Scope of Work

1. Summary of Work. Work will include the demolition of existing Salt building, removal of the existing Shepherd Street Bridge over Looney Creek and the construction of a new precast-prestressed concrete box beam bridge, installation of proposed waterline, excavation of channel and erosion control, and pavement construction.

2. Guidelines and Notes: The notes listed herein summarize approaches and areas of special attention for the contractor.

a. Maintenance of Traffic – Part width construction will not be used, therefore traffic will be rerouted to other existing bridges over Looney Creek (Blair Street and Martin

Avenue).

1 Easton Oval, Suite 310

Columbus, Ohio 43219

614.476.6000

Engineering Considerations and Instructions for Field Personnel |

Shepherd Street Bridge Replacement

US Army Corps of Engineers, Nashville District

June,, 2017

b. Existing utilities – Prior to beginning any work, the contractor shall temporary remove or relocate any existing utilities as necessary to complete the work. The contract documents shall provide a utility plan identifying the existing utilities to be relocated or abandoned, a preliminary relocation layout, and construction plans and specifications.

c. Excavation and erosion control – Site shall be prepared for erosion control and scour countermeasures. This includes any articulated concrete block, riprap, and turf mat indicated in the design plans and specifications. Connect drainage items where they terminate through the articulated concrete block. Install all erosion control items per the manufacturer’s instructions and recommendations (see attached).

d. Jack and bore – Maintain 4-feet of cover from the top of the carrier pipe to the bottom of the erosion control measures. Reference the provided geotechnical data for information regarding the rock under Looney Creek.

e. Epoxy-coated reinforcing bars – Provide epoxy coated reinforcing bars conforming to

ASTM A775. Use plastic coated or epoxy coated bar supports and tie wires to protect the epoxy coating from physical damage during placement and to prevent electrical coupling between mats. Repair any physical damage to the epoxy coating with patching material of the same composition and quality as original coating. If repair is required, clean and repair the damaged areas and allow adequate time before placing concrete. The field inspector shall approve the installation once patching has been done.

Upon delivery to the project and before use, stack reinforcing steel off the ground and keep it free from dirt, oil, grease, or avoidable rust. Before placing in the concrete, ensure the reinforcing steel is clean and free from loose rust.

1 Easton Oval, Suite 310

Columbus, Ohio 43219

614.476.6000

Engineering Considerations and Instructions for Field Personnel |

Shepherd Street Bridge Replacement

US Army Corps of Engineers, Nashville District

June,, 2017

f. Concrete Testing – Divide the concrete into lots and sublots. A lot consists of concrete of the same class. Approach slab concrete will be included with superstructure lot. Divide each lot into sublots of not more than 50 yd3 for obtaining samples. There should be no less than three (3) sublots in a lot.

Perform QC sampling for compressive strength at the point of discharge for each sublot from the load randomly determined by the field inspector. For each sublot, make one (1) set of three (3) – 4 x 8 inch QC compressive strength cylinders, conforming to ASTM standards. If a single reported compressive strength test result for a sublot of concrete is less than 88% of f’c, evaluate the location of low compressive strength concrete using either nondestructive testing or cores. If the nondestructive test results are greater than the specified f’c, the concrete can be accepted. If lower, the concrete must be cored, and subsequently patched, for further testing. If the core results are above 88% f’c, use the core strength results for calculating the compressive strength pay factor. If lower than 88% f’c, submit a plan for corrective action to the Engineer for approval. If three or more sublot compressive strength acceptance test results are less than f’c but greater than 88% f’c, an investigation will be required to determine the reasons for the consistent low strength.

g. Concrete Sealing – Store all sealer components in tightly sealed containers, in a dry location, and as recommended by the manufacturer. Deliver unopened drums or containers of the sealer or sealer components to the job site with the manufacturer’s numbered seal intact. Remove dust, dirt, oil, wax, curing compounds, efflorescence, laitance, coatings and other foreign materials from surfaces to be sealed.

h. Prebored Holes – Locate prebored holes as shown on the contract documents. For steel H-piles, provide augured hole diameters of at least 24 inches, and which produce satisfactory pile driving results. Backfill voids between the pile and the prebored hole with a 4,500 psi grout material satisfactory to the field inspector.

i. Piles – Install the piles so that they are within 12 inches from the location shown on the plans for piles capped below final grade, and within 3.0 inches from the plan location for pile caps above the ground surface. Piles not meeting this tolerance are defective piles. Replace, repair, or drive a substitute pile beside the defective pile.

The location tolerance does not apply to the substitute pile beside defective piles.

1 Easton Oval, Suite 310

Columbus, Ohio 43219

614.476.6000

Engineering Considerations and Instructions for Field Personnel |

Shepherd Street Bridge Replacement

US Army Corps of Engineers, Nashville District

June,, 2017

Shop Drawings

The following is a list of shop drawings to be provided to the design firm for quality control and final review:

Drainage:

• Catch Basins

• Articulated concrete block details

• Turf mat information and details

Water Work:

• Fire Hydrant

• Gate Valves

• Water meter valves

• Water meters

• Tees

• Reducers

• Thrust blocks

• Leak detection valves

Bridge:

• Box beams

• Elastomeric bearing pads

An inspection report for the demolition of the Salt building shall be provided by the Army Corps of Engineers including any information necessary for the complete and safe removal of the building, foundations, parking lot, and associated drainage items. Inspection should provide asbestos and lead testing at a minimum.

TURF MAT INSTALLATION GUIDE

INSTALLATION GUIDE

ROLLMAX™

ROLLED EROSION CONTROL

North American Green is the world’s leading provider of performance-guaranteed erosion control solutions. For more than 25 years, our line of erosion and sediment control products has kept our customers on solid ground. Our short-term and long-term Erosion Control Blankets (ECBs) and Turf Reinforcement Mats (TRMs) keep you one step ahead of just about any erosion challenge.

North American Green provides everything you need to know for quick, accurate erosion control installation tailored to your site. From start to finish, the North American Green® RollMax System™ product installation instructions are based on extensive research and field-proven techniques to ensure project success. The following pages offer instructions and guidelines for several scenarios you may encounter during the installation of the RollMax System.

EXPERIENCE YOU CAN RELY ON

We are the industry leader when it comes to providing comprehensive erosion and sediment control and turf reinforcement solutions. We have developed integrated systems and products with the sole objective to ensure absolute customer satisfaction. Our products are backed by the most thorough quality assurance practices in the industry. In addition, we provide comprehensive design assistance for every North American Green system.

For additional installation assistance with the RollMax System, please visit www.tensarnagreen.com, e-mail customerservice-nag@nagreen.com, or call 800-772-2040 and we will be happy to put you in touch with an erosion control specialist who can assist you.

RollMax™ Installation Guidelines:

Installation Made Easy

2"-5" (5-12.5 cm)

6' (1.8 m)

2"-5" (5-12.5 cm)

3' (0.9 m)

3.3' (1 m)

2"-5" (5-12.5 cm)

6' (1.8 m)

2"-5" (5-12.5 cm)

3' (0.9 m)

3.3' (1 m)

3.3' (1 m)

1.6' (0.5 m)

2"-5" (5-12.5 cm)

4' (1.2 m)

2"-5" (5-12.5 cm)

2' (0.6 m)

3.3' (1 m)

1.6' (0.5 m)

2"-5" (5-12.5 cm)

4' (1.2 m)

2"-5" (5-12.5 cm)

2' (0.6 m)

3.3' (1 m)

20" (0.5 m)

2"-5" (5-12.5 cm)

4' (1.2 m)

2"-5" (5-12.5 cm)

2' (0.6 m)

3.3' (1 m)

20" ( 0.5 m)

10" (25 cm)

10" (25 cm)

A B

D E

C

0.7 staples per sq yd 1.15 staples per sq yd

3.4 staples per sq yd 3.75 staples per sq yd

1.7 staples per sq yd

4:1 slopes (A)

3:1 slopes (B)

2:1 slopes (C)

1:1 and steeper slopes (D)

Medium/high flow channel (D)

High flow channel and shoreline (E)

NOTES:

Use ECMDS® for more accurate staple pattern selection.

The information presented herein is general design information only.

For specific applications, consult an independent professional for further design guidance.

FIGURE 1

When under the pressure of severe conditions, even the best erosion control products can’t function to their full potential without proper installation and anchoring. North American Green supplies a wide variety of fastener options for nearly every application and soil type.

For use in cohesive soils, wire staples are a cost-effective means to fasten RollMax™ System Rolled Erosion Control Products (RECPs). Available in 6 in., 8 in., 10 in. and 12 in.

lengths, our U-shaped staples reach various depths to ensure adequate pull-out resistance. For installation using our handy Pin Pounder installation tool, 6 in. V-top staples or 6 in. circle top pins are available.

Our biodegradable BioStakes® are available in 4 in. and 6 in.

lengths and provide an environmentally friendly alternative to metal staples. For an even more durable, deeper reaching yet all-natural anchoring option, our wood EcoStakes® are available in 6 in., 12 in., 18 in. and 24 in. lengths.

For severe applications needing the ultimate, long-lasting hold, try our 12 in. and 18 in. rebar staples, our 12 in. plastic ShoreMax® stakes, or our complete line of percussion earth anchors. The earth anchors reach deep into the soil strata to offer enhanced anchoring in the worst conditions. Our variety of earth anchors are designed for durability and holding power under extreme hydraulic stresses and adverse soil conditions.

STAPLE PATTERNS

Proper staple patterns must be used to achieve optimal results in RECP installation. We recommend the following general stapling patterns as guidance for use with our RECPs as seen in (Figure 1). Site-specific staple pattern recommen-dations based on soil type and severity of application may be acquired through our Erosion Control Materials Design Software (ECMDS®), www.ecmds.com.

STAPLE PATTERN GUIDE

SLOPE INSTALLATION STEPS

1. Prepare soil before installing RECPs, including any necessary application of lime, fertilizer and seed.

2. Begin at the top of the slope by anchoring the RECPs in a 6 in. (15 cm) deep x 6 in. (15 cm) wide trench with approxi-mately 12 in. (30 cm) of RECPs extended beyond the upslope portion of the trench. Anchor the RECPs with a row of staples/stakes approximately 12 in. (30 cm) apart in the bottom of the trench. Backfill and compact the trench after stapling. Apply seed to the compacted soil and fold the remaining 12 in. (30 cm) portion of RECPs back over the seed and compacted soil. Secure RECPs over compacted soil with a row of staples/stakes spaced approximately 12 in. (30 cm) apart across the width of the RECPs.

3. Roll the RECPs (3A) down or (3B) horizontally across the slope. RECPs will unroll with appropriate side against the soil surface. All RECPs must be securely fastened to soil surface by placing staples/stakes in appropriate locations as shown in the staple pattern guide.

4. The edges of parallel RECPs must be stapled with an approximately 2 in.-5 in. (5-12.5 cm) overlap depending on the RECP type.

5. Consecutive RECPs spliced down the slope must be end-over-end (shingle style) with an approximate 3 in. (7.5 cm) overlap. Staple through overlapped area, approximately 12 in. (30 cm) apart across entire RECPs width.*

*NOTE: In adverse soil conditions longer staples/stakes or earth anchors may be necessary to properly secure the RECPs.

The following slope guide outlines general recommendations for installing RollMax™ System temporary and/or permanent RECPs on sloping applications. Consult the staple pattern guide (Figure 1) for fastener spacing recommendations based on the slope severity.

Slope Installation

3A

3B

2 in.-5 in.

(5-12.5 cm)

12 in.

(30 cm)

6 in.

(15 cm)

6 in.

(15 cm)

3 in.

(7.5 cm)

Drawings Not To Scale

CHANNEL INSTALLATION STEPS

1. Prepare soil before installing RECPs, including any necessary application of lime, fertilizer and seed.

2. Begin at the top of the channel by anchoring the RECPs in a 6 in. (15 cm) deep x 6 in. (15 cm) wide trench with approxi-mately 12 in. (30 cm) of RECPs extended beyond the upslope portion of the trench. For supplemental scour protection, use RevetMax™ System ShoreMax® Mat at the channel/ culvert outlet as needed. Anchor the RECPs with a row of staples/stakes approximately 12 in. (30 cm) apart in the bottom of the trench. Backfill and compact the trench after stapling. Apply seed to the compacted soil and fold the remaining 12 in. (30 cm) portion of RECPs back over the seed and compacted soil. Secure RECPs over compacted soil with a row of staples/stakes spaced approximately 12 in. (30 cm) apart across the width of the RECPs.

3. Roll center RECPs in direction of water flow in bottom of channel. RECPs will unroll with appropriate side against the soil surface. All RECPs must be securely fastened to soil surface by placing staples/stakes in appropriate locations as shown in the staple pattern guide.

4. Place consecutive RECPs end-over-end (shingle style) with a 4 in.-6 in. (10-15 cm) overlap. Use a double row of staples staggered 4 in. (10 cm) apart and 4 in. (10 cm) on center to secure RECPs.

5. Full-length edge of RECPs at top of side slopes must be anchored with a row of staples/stakes approximately 12 in. (30 cm) apart in a 6 in. (15 cm) deep x 6 in. (15 cm) wide trench. Backfill and compact the trench after stapling.

6. Adjacent RECPs must be overlapped approximately 2 in.- 5 in. (5-12.5 cm) (depending on RECP type) and stapled.*

7. In high flow channel applications a staple check slot is recommended at 30 to 40 ft (9-12 m) intervals. Use a double row of staples staggered 4 in. (10 cm) apart and 4 in. (10 cm) on center over entire width of the channel.

8. The terminal end of the RECPs must be anchored with a row of staples/stakes approximately 12 in. (30 cm) apart in a 6 in. (15 cm) deep x 6 in. (15 cm) wide trench. Backfill and compact the trench after stapling.

* NOTE: In adverse soil conditions longer staples/stakes or earth anchors may be necessary to properly secure the RECPs.

The following channel guide outlines general recommendations for installing RollMax System temporary and/or permanent RECPs in concentrated flow applications. Consult the staple pattern guide (Figure 1) for fastener spacing recommendations based on the channel severity.

Channel Installation

CRITICAL POINTS

A. Overlaps and Seams B. Projected Water Line C. Channel Bottom/Side Slope Vertices

Horizontal staple/stake spacing should be altered if necessary to allow staples to secure the critical points along the channel surface.

6 in.

(15 cm)

6 in.

(15 cm)

4 4 in.-6 in.

(10-15 cm)

6 in.

(15 cm)

2 in.-5 in.

(5-12.5 cm)

4 in. (10 cm)

12 in. (30 cm)

A A

B BC C

6 in.

(15 cm)

4 in. (10 cm)

Below are recommendations for installing RollMax System temporary and/or permanent RECPs along shoreline and stream bank applications. Consult the staple pattern guide (Figure 1) for fastener spacing recommendations based on the bank severity.

Shoreline Installation

SHORELINE/STREAMBANK INSTALLATION STEPS

1. For easier installation, lower water level from Level A to

Level B before installation to allow bottom trenching.

2. Prepare soil before installing RECPs, including any necessary application of lime, fertilizer and seed.

3. Begin at the top of the shoreline by anchoring the RECPs in a 6 in. (15 cm) deep x 6 in. (15 cm) wide trench with approxi-mately 12 in. (30 cm) of RECPs extended beyond the upslope portion of the trench. Anchor the RECPs with a row of staples/stakes approximately 12 in. (30 cm) apart in the bottom of the trench. Backfill and compact the trench after stapling. Apply seed to the compacted soil and fold the remaining 12 in. (30 cm) portion of RECPs back over the seed and compacted soil. Secure RECPs over compacted soil with a row of staples/stakes spaced approximately 12 in. (30 cm) apart across the width of the RECPs.

4. Roll RECPs either (A) down the shoreline for long banks (top to bottom) or (B) horizontally across the shoreline slope. RECPs will unroll with appropriate side against the soil surface. All RECPs must be securely fastened to soil surface by placing staples/stakes in appropriate locations as shown in the staple pattern guide.

5. The edges of all horizontal and vertical seams must be stapled with an approximately 2 in.-5 in. (5-12.5 cm) overlap.

In streambank applications, seam overlaps should be shingled in the predominant flow direction.

6. The edges of the RECPs at or below normal water level must be anchored by placing the RECPs in a 12 in. (30 cm) deep x 6 in. (15 cm) wide anchor trench. Anchor the RECPs with a row of staples/stakes spaced approximately 12 in. (30 cm) apart in the trench. Backfill and compact the trench after stapling (stone or soil may be used as backfill). For installa-tion at or below normal water level, use of a ShoreMax Mat on top of the RECP or geotextile may be recommended.

Bottom anchor trench can be eliminated when using a ShoreMax Mat over RECP along the bottom edge.

NOTE: In adverse soil conditions longer staples/stakes or earth anchors may be necessary to properly secure the RECPs.

4A

12 in.

(30 cm)

6 in.

(15 cm)

6 in.

(15 cm)

2 in.-5 in.

(5-12.55 cm)

4B

LEVEL B

12 in.

(30 cm)

LEVEL A

Special Installation Instructions

Drawings not to scale

3 ft (0.9 m)

5 ft (1.51 m)

NOTES: Anchor Pattern Guide can vary based on earth anchor and blanket selection.

Earth Anchor (~1/sy)

Staple/ Stake

(~1.3/sy)

2 in.-5 in.

(5-12.5 cm)

Load Bearing Plate

Anchor Head (Load-Locked

Position)

Tendon

Em be dm en t

(A s D es ig ned

Earth Anchor Detail

Anchor Detail (Shown for a 10 ft wide HP-TRM)

Percussion Earth Anchor Installation

Driving Anchor

Option B Manual

Drive

Loadlocking

Securing Plate Against the TERMS

Option A Crimping

Option B Self-Tension

Option A Pneumatic

Drive

Overlap Trench

Rod Removal

ANCHORING DETAIL

Consult the RollMax™ Turf and Earth Reinforced Mat Systems (TERMS) Installation Guide for details about using earth anchors with RollMax RECPs. The performance of ground anchoring devices is highly dependent on numerous site/ project specific variables. It is the responsibility of the project engineer and/or contractor to select the appropriate anchor.

1. Staples and/or stakes should be at least 6 in. (15 cm) in length and with sufficient ground penetration to resist pullout. Longer staples and/or stakes may be needed in looser soils.

2. The percussion earth anchor assembly includes an anchor head, a tendon, a faceplate, and an end-piece device.

Consult Earth Anchor specification for detailed informa-tion on assembly components and associated pull-out strength.

PERCUSSION EARTH ANCHOR INSTALLATION

1. Insert the drive rod into the assembly’s anchor head then use either a sledge hammer or a vibratory hammer to drive the anchor to the desired depth.

2. After the desired anchor depth is achieved, retract the drive rod.

3. Lock the anchor assembly by swiftly pulling the cable upwards until the anchor head rotates as signaled by sudden resistance to pulling. A hooked setting tool may be used to aid in this step.

4. Secure the faceplate to the HP-TRM surface by locking the end-piece. If using a copper or aluminum stop, crimp the ferrule to secure. If using a self-tensioning end-piece (grip or wedge grip) set by simply tightening the end-piece against the faceplate. If needed, cut the remaining cable to desired length.

SEEDING AND VEGETATING

When using a Composite Turf Reinforcement Mat (C-TRM) with fiber components:

1. Pre-seed prepared soils prior to the installation of the C-TRM. Install matting as directed. C-TRM does not require soil infill or a top dressing of seed. Overseeding may be done as a secondary form of seeding.

2. Sod may be installed in place of seeding on top of the C-TRM. Additional staking of sod is recommended in high-flow conditions. Sodded areas should be irrigated until rooting through the mat and into subgrade occurs.

When using a woven HP-TRM:

1. Install the HP-TRM as directed prior to seed and soil filling.

2. Place seed into the installed HP-TRM. After seeding, spread a layer of fine soil into the mat. Using the flat side of a rake, broom or other tool, completely fill the voids.

Smooth soil-fill in order to just expose the top of the HP-TRM matrix. Do not place excessive soil above the mat.

3. Additional seed, hydraulic mulching, or the use of a temporary Erosion Control Blanket (ECB) can be applied over the soil-filled mat for increased protection.

4. Sod may be installed in place of seeding. Install HP-TRM, and soil-fill as outlined above. Place sod directly onto the soil-filled HP-TRM. Additional staking of sod is recom-mended in high-flow conditions. Sodded areas should be irrigated until rooting through the mat and into subgrade occurs.

5. Consult with a manufacturer's technical representative for installation assistance if unique conditions apply.

EC_RMX_IG_1.16

©2016, Tensar International Corporation. North American Green is a registered trademark. Certain products and/or applications described or illustrated herein are protected under one or more U.S. patents. Other U.S. patents are pending, and certain foreign patents and patent applications may also exist. Trademark rights also apply as indicated here in. Final determination of the suitability of any information or material for the use contemplated, and its manner of use, is the sole responsibility of the user. Printed in the U.S.A.

Distributed by:

North American Green

5401 St. Wendel-Cynthiana Road

Poseyville, Indiana 47633 tensarnagreen.com 800-772-2040

ARTICULATED CONCRETE BLOCK INSTALLATION GUIDE

ArmorFlex® Installation Guide

ENGINEERED SOLUTIONS

ArmorFlex® Installation Guide The purpose of the ArmorFlex Installation Guide is to provide recommendations for the proper installation of Articulating Concrete Block (ACB) revetment systems. While this guide offers a set of instructions for performing those operations that are critical for the proper functioning of ACB revetment systems, final preparation and installation is the responsibility of the end user. Additional information is contained in ASTM D6884 Standard Practice for Installation of Articulating Concrete Block (ACB) Revetment Systems.

The proper installation of ACB revetment systems is important to achieving the intended hydraulic performance and maintaining stability against the erosive forces of flowing water. An ACB revetment system consists of a suitably prepared and compacted subgrade, a suitable site-specific filter fabric and properly sized ACB block mattresses placed in “intimate contact” with the filter fabric and subgrade. Each individual site will vary so it is important to follow the engineering project drawings as designed and sealed by a registered Professional Engineer; particularly as they relate to standard termination details. All illustrations and photographs used in this guide are examples of typical situations.

It is the Contractor’s responsibility to maintain safe work practices consistent with OSHA (Occupational Safety and Health Administration) regulations and other prevailing safe work practices. This guide is intended to be used in conjunction with all applicable safety regulations and safe work practices and is in no way a replacement thereof.

Site Planning & Preparation Foundation Preparation Areas on which filter fabric and ACB units are to be placed shall be constructed to the lines and grades shown on the contract drawings to the tolerances specified in the contract documents and approved by the engineer. All areas to receive the ACB shall be compacted and graded smooth to facilitate the installation of the articulated concrete block system and ensure that intimate contact (between the slope face, the filter fabric and the entire bottom surface of the ACB units) is maintained throughout the system.

Unsatisfactory soils (soils having excessive in-place moisture content, soils containing clods, roots, or other organic material that impair the local slope face) must be removed, replaced with approved material and compacted to a minimum 90% of Standard Proctor density (Test Method D698).

Holes, “pockmarks”, slope board teeth marks, footprints or other voids greater than 1 inch in depth normal to the local slope face shall not be permitted. No grooves or depressions greater than 0.5 inches in depth normal to the local slope face with a dimension exceeding 1 foot in any direction shall be permitted.

Where such areas are evident, they shall be brought to grade by placing compacted homogeneous material. The slope and slope face shall be uniformly compacted, and the Engineer shall determine the depth of layers, homogeneity of soil, and amount of compaction required. If differing block heights are used — the slope is to be prepared so that the tops of the blocks are flush.

Care shall be exercised so as not to excavate below the grades shown on the Engineer's Contract Drawings, unless directed by the Engineer to remove unsatisfactory materials. Excavation of subgrade shall not be more than 2 inches (50 mm) below specified grade. In such areas, placing and compacting approved material, in order to get up to specified grade, in layers not exceeding 6 inches (150 mm) is required. In such areas where subgrade is above specified grade, they shall be brought to grade by removing material or reworking existing material and compacting.

Proper excavation, grading and compaction is critical to the performance of the ACB system.

When working in an underwater application, it is the contractor’s responsibility to assess the jobsite conditions and the means of achieving proper subgrade preparation, per the Engineer’s Contract drawings, specifications, and tolerances.

Placement of Filter Fabric The subgrade shall be inspected immediately prior to filter fabric and ACB placement for proper preparation. The filter fabric shall be placed directly on the prepared subgrade, in intimate contact with the subgrade and free of folds, wrinkles or excess tension.

The filter fabric shall not be walked on or disturbed in a manner resulting in the loss of intimate contact between the filter frabric, the ArmorFlex block and subgrade soils.

The filter fabric shall be placed so that upstream sections overlap downstream sections and so that upslope sections overlap downslope sections (“shingle effect”). Overlaps shall be in the direction of flow wherever possible. The longitudinal and transverse joints shall be overlapped at least 3 feet (91 cm) for below-water installations and at least 2 feet (60 cm) for dry installations. The filter fabric shall extend at least 1 foot beyond the top, bottom, and flanking revetment termination points.

Product Delivery and Handling Deliveries are typically scheduled to accommodate the overall installation sequence requested though the stacking of mats on an individual load is limited to larger mats towards the bottom and smaller mats toward the top of the trailer.

Deliveries are typically made on 48’ flat beds with over-the-road tractors, so adequate truck access and turnaround room at the jobsite must be provided by the Contractor. The trucks and drivers are typically contract carriers (not CONTECH trucks).

The drivers are not expected to have any special certifications, jobsite training or equipment. In the case special requirements are needed, the terms and conditions will need to be negotiated and established at the time of the order. Drivers will untie their loads but are not qualified to help with any rigging, unloading or installation.

CONTECH requires at least a full 4 day notice to schedule trucks (Example: notification on Monday for Friday delivery).

For staging mats (offloading for installation later) allow approximately 30-45 minutes to offload each truck. Staging of mats on-site is highly recommended, especially if your company has never installed ArmorFlex in the past.

Timing is everything. Be prepared to unload the mats when the trucks arrive. If applicable, the first load will have the Spreader Bar and filter fabric, along with the first sequence of mats.

For installation off the truck, allow 45-60 minutes for direct installation off the truck. Additional time between loads should be considered for inexperienced crews.

CONTECH loads typically allow 2 hours for unloading time.

Detention may apply after this 2 hour period and will be charged to the contractor. Loads are typically pre-loaded the day before in order to arrive first thing in the morning.

Each load will have a Bill of Lading (BOL) that has the load number with unloading dates and times.

All mats will be marked on the side of each mat with one of the following descriptions:

1. Rectangle mats will be marked with the size

(Example: 8’ W x 20’ L).

2. Angle/Pie shape mats will be marked with the mat number per the Mat Layout Spreadsheet.

CONTECH requires notification of any changes or cancellation of scheduled deliveries during normal business hours the day prior to loading in order to avoid any cancellation charges.

Fabric shall have the proper overlap and be free of any holes or tears.

The use of a crane is optimal for fast and safe unloading and installation of the mats.

26' Min. Length

2 Part Line

Provided By Others Must match Mat length

Only one 2 part line to be used at a time.

The 2 part line shall be attached directly above the Hook Tube Assembly placement.

20' Min. Length

16' Min. Length

Hook Tube Assembly

Main Lifting Beam

*16'

* 20'

*26'

*See table 1 for the 2640 Series end bar increments.

Spreader Bar Overview This instruction content is for informational purposes and should not be considered to be used in lieu of consultation with a professional rigger. Distribute this guide as a procedure for rigging and handling CONTECH supplied Spreader Bars (See Detail A). Notwithstanding the instructions contained in this guide, it is the responsibility of the customer or customer’s agent to handle CONTECH products in a safe and efficient manner. For additional information, refer to safety standard ASME B30.20, Below-the- Hook Lifting Devices.

Inspection The operator or other designated personnel should visually inspect the unit before every lift, as well as during operation in the event that damage occurs during a lift. Connector Links, Eye Hooks with Snap Lock and Screw Pin Shackles should engage properly and be free of damage (see Detail B).

The unit shall be free of structural deformation, cracks or excessive wear of any part of the Main Lifting Beam and the Hook Tube Assemblies. The operator should check for loose or missing fasteners, including Connector Links (12), Eye Hooks with Snap Lock (12) and Screw Pin Shackles (2). Welds should also be inspected for signs of obvious cracking.

Spreader Bar Rigging Diagram

1626 Series

DETAIL A

Maintenance Any observed damage to the Connector Links, Eye Hooks with Snap Lock and Screw Pin Shackles or hazardous conditions found during an inspection shall be corrected before the Spreader Bar is put back into service. Adjustments and repairs shall only be done by a qualified person, and the following process shall be followed by the contractor or their designee:

1. Contact a CONTECH Project Manager before any repair work is performed.

2. The Spreader Bar shall be tagged “OUT OF SERVICE.”

3. Replacement parts shall be equal and/or exceed the original manufacturer’s specifications (see "Spreader Bar Parts List").

4. Personnel working on the device must be qualified to make the given repair.

When structural damage of the unit is noted or repairs are needed (except for Connector Link, Eye Hooks with Snap Lock, Screw Pin Shackle), the contractor shall halt use of the Spreader Bar, tag the bar "OUT OF SERVICE” and contact the CONTECH Project Manager for further instruction. No welding whatsoever shall be performed on the Spreader Bar unit.

Bar Increments

Spreader Bar Min. Med. Max.

1626 Series 16' 20' 26'

2640 Series 26' 32' 40' Table 1

Equipment Needs

Prior to delivery, review the heaviest lift and highest pick in order to properly size the equipment used for the offload and the installation of the mats.

Total pick weight will include the weight of each mat AND Spreader Bar. Estimated Spreader Bar weight is 2,600 lbs for 26’ bars and 3,500 lbs for 40’ bars.

Total vertical lift height typically ranges between 30’ - 65’ and is determined by the following variables:

Setting Mats with a Crane or Excavator

1. “Walking” mats with an excavator or using more than one piece of equipment to pick is not recommended and can result in unsafe working conditions and/or damage to the ACB mattresses.

2. Proper lifting with the Spreader Bar ensures the 5:1 working load factor of the cable is preserved.

3. Single end picks (picking up the mat from one end) are not allowed.

4. Identify and avoid obstructions that may hinder reach height (Example: Power lines).

Main Lifting Beam

Hook Tube Assembly

Supplied by CONTECH

Supplied by CONTECH

Eye Hook w/ Snap Lock

Connector Link

Supplied by CONTECH Screw Pin Shackle

DETAIL B

Spreader Bar Detail

At Hook Tube Assembly

Is the reach of your crane or excavator sufficient to set the mats?

CautIoN: Consult the load chart for the machine to verify its load rating is not exceeded.

Supplied by OTHERS Screw Pin Shackle

EquipmEnt pick HEigHt impact

Flatbed Trailer 5'

Sag of Mat 5'-20'

2-Part Line 15'-35'

Height of Spreader Bar 4'

Total Vertical Lift Range 30'-65'

SPrEadEr Bar PartS LISt

Qty. Description

1 Main Lifting Beam

2 Hook Tube Assembly

12 Connector Link, Lok-A-Loy 6-5/8", 16,500 lb Crosby #1014459

12 Eye Hook w/ Snap Lock - 2 ton S-320C Crosby #1022233

2 1" Screw Pin Shcackle 20,000 lb Columbus McKinnon #600-02515

Replacement Latch Kit - Crosby #1096468

Installation Instructions Placement of armorFlex units Care shall be taken while installing the system in order to avoid damage to the filter fabric or the underlying subgrade. The ArmorFlex units shall be placed on the filter fabric in such a manner as to produce a smooth plane surface in intimate contact with the filter fabric.

The preferred method is to start installation of the ACB system at the downstream end and proceed upstream, taking care to protect the leading edge against erosive forces. These erosive forces could potentially undermine the system if proper installation procedures are not followed.

No individual unit within the plane of the system shall exceed a

0.5 inch protrusion or greater protrusion than is specified in the contract drawings. The units shall be placed side by side so that the blocks abut. Termination trenches typically consist of a 2-block toe-in, including the top of slope, the toe of slope and flanks unless otherwise directed by the EOR. This design is typical of an ACB system to protect all sides from erosive factors.

Subgrade preparation, placement of filter fabric, placement of the concrete units and the final completed project shall be inspected and approved by the Contractor and EOR.

do Not: Exceed the rated load or lift loads not specified in this guide.

do Not: Operate a damaged or malfunctioning unit or a unit with missing parts.

do Not: Lift people.

do Not: Leave suspended loads unattended.

do Not: Remove or obscure warning labels.

do Not: Operate without having read and understood the operating guide.

do Not: Stand under or near suspended load.

do Not: Lift loads higher than necessary.

do Not: Make alterations or modifications to a Spreader Bar.

WarNINg NotES & SaFEty INStruCtIoNS Only trained and authorized equipment operators are to be permitted to use CONTECH supplied Spreader Bars. Failure to follow these instructions can result in serious injury or death and/or damage to the product.

Earth Anchors (if required):

1. Anchors shall be installed per the manufacturer's instructions.

2. Anchor penetrations through the filter fabric shall be grouted with approved material to prevent migration of subsoil through the penetration point.

To assist in aligning the unit being placed, use of a pry bar may be necessary.

FInISHInG grouting

4,000 psi non-shrinking grout or 4,000 psi concrete shall be placed where the loop ends of the mats meet, or wherever there is greater than a 2-inch gap between adjacent mats or structures.

Grout to the top of the block or slightly lower (not above).

Grouting of seams is meant to provide a hydraulic connection, not necessarily a structural connection between mats.

Backfill

Backfill of the block shall be specified by the Engineer of Record (EOR). Typical backfill is either suitable soil for revegatation or .375 to .750 inch (10 to 20 mm) diameter crushed stone. Backfilling should occur as early as possible to protect the filter fabric from UV damage. The exposed edges shall be backfilled until flush, ensuring the integrity of a soil backfill is maintained.

Termination trenches shall be backfilled as shown on the approved contract drawings. This backfill material shall be approved by the EOR. It is the recommendation by Armortec® that this non-erodible backfill be 4,000 psi non-shrinking grout or concrete.

repair of damaged units

In the event that a damaged concrete unit exists prior to the placement or after the mat has been installed, the concrete unit can be repaired in one of the following acceptable manners; unit to be completely removed and then backfilled with 4,000 psi grout/concrete or, replaced with a new block unit.

Depending on the size of the crack or chip, the perimeter and void areas of the block can be filled with grout up to or just below the top grade of the block.

Chipping resulting in a weight loss exceeding 10% of the average weight of a concrete unit shall be repaired. Surface chipping (i.e.

weight loss of less than 10%) resulting from customary handling methods generally do not require repair.

tool and Material Checklist

Two-part line for attachment to the Spreader Bar's Main Lifting Beam. Each leg of the two-part line needs to be equal to or greater than the longest mat to be picked to achieve an angle no less than 60 degrees between the bar and line. (See Detail A).

Supplied by others

Chokers or Straps for ease of Spreader Bar adjustment, recommend: 6 chokers each 2’, 5’, 8’ or 1-2 nylon straps each 2’, 5’, 8’. Supplied by others

Swivel Clevis for picking point of equipment Supplied by others

Three heavy duty rock bar or pry bars (5 feet length is optimal). Supplied by others

Upside down marking paint (for alignment markings on the mats or ground during installation). Supplied by others

100’ measuring tape. Supplied by others

Amortec's Mat Layout Plan Drawings and Mat Layout Spreadsheet with mat numbers and sizes. Have these documents on-site at ALL times for reference. Supplied by CoNtECH

Grout to the top of the block or slightly lower — not above.

Backfilling should occur as early as possible to protect the filter fabric from UV damage.

©2015 Contech Engineered Solutions LLC.

armorflex_install PDF 1/15

Notes: —————————————————————————————————————————————————————

Support If you need guidance please, call your local sales representative or our corporate headquarters at 1.800.338.1122 and ask for a representative.

• Drawings and specifications are available at www.ContechES.com.

• Site-specific design support is available from Contech representatives.

Contech Engineered Solutions LLC provides site solutions for the civil engineering industry. Contech’s portfolio includes bridges, drainage, sanitary sewer, stormwater and earth stabilization products.

Nothing in this catalog should be construed as an expressed warranty or an implied warranty of merchantability or fitness for any particular purpose. See the Contech standard quotation or acknowledgement for applicable warranties and other terms and conditions of sale.

For information on other Contech offerings, visit www.ContechES.com or call 800.338.1122

ArmorFlex® Tapered Installation Guide

ArmorFlex® Tapered Block Installation Guide The purpose of the ArmorFlex Tapered Block Installation Guide is to provide recommendations for the proper installation of Tapered Articulating Concrete Block (ACB) revetment systems. While this guide offers a set of instructions for performing those operations that are critical for the proper functioning of ACB revetment systems, final preparation and installation is the responsibility of the end user. Additional information is contained in ASTM D6884 Standard Practice for Installation of Articulating Concrete Block (ACB) Revetment Systems.

It is critical to emphasize that the ArmorFlex Tapered systems were developed for severe hydraulic applications and require proper unit/mattress orientation during installation that is in accordance with the anticipated flow paths.

The proper installation of tapered ACB revetment systems is important in achieving the intended hydraulic performance and maintaining stability against the erosive forces of flowing water. A tapered ACB revetment system consists of a suitably prepared and compacted subgrade, a soil-specific filter fabric, a layer of free draining stone, confining geogrid and properly sized ACB tapered block mattresses in “intimate contact” with the geogrid layer and drainage layer stone. Each individual site will vary so it is important to follow the engineering project drawings as designed and sealed by a registered Professional Engineer; particularly as they relate to standard termination details. All illustrations and photographs used in this guide are examples of typical situations.

It is the Contractor’s responsibility to maintain safe work practices consistent with OSHA (Occupational Safety and Health Administration) regulations and other prevailing safe work practices. This guide is intended to be used in conjunction with all applicable safety regulations and safe work practices and is in no way a replacement thereof.

Site Planning & Preparation Foundation Preparation Areas on which filter fabric and ACB system components are to be placed shall be constructed to the lines and grades shown on the contract drawings, to the tolerances specified in the contract documents and approved by the engineer. The ArmorFlex Tapered system is defined as subgrade, geotextile, stone layer, geogrid and ACB tapered unit. All areas to receive the ACB system shall be compacted and graded smooth to facilitate the installation of the articulated concrete block system and ensure that intimate contact (between the slope face, the filter fabric and the remaining ACB components) is maintained throughout the system.

Unsatisfactory soils (soils having excessive in-place moisture content, soils containing clods, roots, or other organic material that impair the local slope face) must be removed, replaced with approved material and compacted to a minimum 90% of Standard Proctor density (Test Method D698).

Holes, “pockmarks”, slope board teeth marks, footprints or other voids greater than 1 inch in depth normal to the local slope face shall not be permitted. No grooves or depressions greater than 0.5 inches in depth normal to the local slope face with a dimension exceeding 1 foot in any direction shall be permitted.

Where such areas are evident, they shall be brought to grade by placing compacted homogeneous material. The slope and slope face shall be uniformly compacted, and the Engineer shall determine the depth of layers, homogeneity of soil, and amount

ARMORFLEX TAPERED SYSTEM

FLOW

of compaction required. If differing block heights are used — the slope is to be prepared so that the tops of the blocks maintain their proper relationship with respect to easch other (i.e. no projection height). Care shall be exercised so as not to excavate below the grades shown on the Engineer's Contract Drawings, unless directed by the Engineer to remove unsatisfactory materials. Excavation of subgrade shall not be more than 2 inches (50 mm) below specified grade. In such areas, placing and compacting approved material, in order to get up to specified grade, in layers not exceeding 6 inches (150 mm) is required. In

Proper excavation, grading and compaction is critical to the performance of the ACB system.

such areas where subgrade is above specified grade, they shall be brought to grade by removing material or reworking existing material and compacting.

When working in an underwater application, it is the contractor’s responsibility to assess the jobsite conditions and the means of achieving proper subgrade preparation, per the Engineer’s Contract drawings, specifications, and tolerances.

Placement of Filter Fabric The subgrade shall be inspected and approved immediately prior to placement of the filter fabric to ensure proper preparation. The filter fabric shall be placed directly on the prepared subgrade, in intimate contact with the subgrade and free of folds, wrinkles or excess tension.

The filter fabric shall be placed so that upstream sections overlap downstream sections and so that upslope sections overlap downslope sections (“shingle effect”). Overlaps shall be in the direction of flow wherever possible. The longitudinal and transverse joints shall be overlapped at least 3 feet (91 cm) for below-water installations and at least 2 feet (60 cm) for dry installations. The filter fabric shall extend at least 1 foot beyond the top, bottom, and flanking revetment termination points.

Placement of Drainage Stone After installation of filter fabric, free draining stone shall be placed to the thickness shown on the Contract drawings (Contech recommends a 6” layer of stone). Contech strongly recomends that the contractor provide a gradation of the proposed stone to Contech for review to ensure compatibility to the system. Stone material containing fines shall not be allowed since clean free draining material is essential for the performance of the tapered system. The stone material shall be placed to ensure no damage will occur to the previously installed fabric using common stone backfilling techniques and placed to ensure a uniform thickness throughout the project ACB system. Thickness of the stone shall be in accordance with Contract documents.

Placement of Geogrid After installation of the drainage stone material, geogrid shall be placed as shown on the plans, as specified or as directed by the Engineer. Minimum overlaps of 1’-0” is standard and placed so that upstream sections overlap downstream sections and so that upslope sections overlap downslope sections (“shingle effect”).

Overlaps shall be in the direction of flow wherever possible.

Alternatives to overlapping geogrid material are possible but should be discussed with Contech prior to implementation.

Product Delivery and Handling Deliveries are typically scheduled to accommodate the overall installation sequence requested. Typically, the stacking of mats on an individual trailer load is limited to larger mats on the bottom and smaller mats on top.

Deliveries are typically made on 48’ flat beds with over-the-road tractors, so adequate truck access and turnaround room at the jobsite must be provided by the Contractor. The trucks and drivers are typically contract carriers (not Contech trucks).

The drivers are not expected to have any special certifications, jobsite training or equipment. In the event special requirements are needed, the terms and conditions will need to be negotiated and established at the time of the order. Drivers will untie their loads but are not qualified to help with any rigging, unloading or installation.

Contech requires at least a full 4 day notice to schedule trucks (Example: notification on Monday for Friday delivery).

Timing is everything. Be prepared to unload the mats when the trucks arrive.