SOW AND SITE MAP CONCRETE BLOCKS.pdf

SCOPE OF WORK

PRECAST CONCRETE BLOCK

PRODUCTION AND DELIVERY

CALUMET HARBOR CDF DIKE

TABLE OF CONTENTS

PART 1 GENERAL

1.1 Scope

1.2 Applicable Publications

1.3 Submittals

1.4 Material Production, Inspection And Testing

PART 2 PRODUCTS

2.1 Concrete Units

2.2 Concrete (High Performance Concrete)

2.3 Reinforcing

2.4 Concrete Curing

2.5 Form Materials

PART 3 EXECUTION

3.1 Manufacturing (General)

3.2 Forming, Casting and Handling Units

3.3 Delivery

3.4 Delivery Schedule

3.5 Period of Performance

3.6 Contract Minimum and Maximum Amounts

3.7 Formal Acceptance

3.8 Payment

PRECAST CONCRETE BLOCK

PRODUCTION AND DELIVERY

PART 1 GENERAL

1.1 SCOPE

1.1.1 This Section details the technical requirements for manufacturing and delivering precast concrete blocks to the dimensions listed that will be utilized by USACE for the repair and construction of breakwaters at various harbors on the Great Lakes.

1.1.2 The intent of this specification is defined below:

1.1.2.1 Precast one type of breakwater unit for use on breakwater reconstruction or rehabilitation. The unit shall be referred to as “Concrete Block Unit”

1.1.2.2 Deliver concrete units to the required locations at the required delivery rate as detailed in this Section. The units will be off-loaded from trucks at the delivery location by the Contractor and will be placed in four rows. Each row will be 2 blocks wide by 2 blocks high and between 270’ – 350’ long. The rows will be approximately 60’ apart.

1.2 APPLICABLE PUBLICATIONS

1.2.1 The following publications form a part of this specification to the extent indicated by the references provided. Publications are referred to hereafter by abbreviated designation only. Where similar requirements exist in multiple references, the most stringent requirement shall apply.

1.2.1.1 American Concrete Institute (ACI) Standards.

1.2.1.2 ACI 305R-77 (R 1982) Hot Weather Concreting.

1.2.1.3 ACI 306R-78 Cold Weather Concreting

1.2.1.4 ODOT Item 499 Concrete - General (CMS 2005)

1.2.1.5 IDOT Standard Specifications for Road and Bridge Construction (current edition)

Article 1020 – Portland Cement Concrete

1.2.1.6 American Society for Testing and Materials (ASTM) Standards With Corresponding

CRD Standard Indicated Where Available.

1.2.1.7 C 31-87 (CRD-C 11) Making and Curing Concrete Test Specimens in the Field.

1.2.1.8 C 33-86 (CRD-C 133) Concrete Aggregates

1.2.1.9 C 39-86 (CRD-C 14) Compressive Strength of Cylindrical Concrete Specimens

1.2.1.10 C 143-78 (CRD-C 5) Slump of Portland Cement Concrete

1.2.1.11 C 150-86 (CRD-C 201) Portland Cement

1.2.1.12 C 171-69 (R 1986) Sheet Materials for Curing Concrete (CRD-C 310)

1.2.1.13 C 172-82 (CRD-C 4) Sampling Freshly Mixed Concrete

1.2.1.14 C 231-82 (CRD-C 41) Air Content of Freshly Mixed Concrete by the Pressure

Method

1.2.1.15 C 260-86 (CRD-C 13) Air-Entraining Admixtures for Concrete

1.2.1.16 C 309-81 Liquid Membrane-Forming Compounds for Curing

Concrete

1.2.1.17 C 494-86 (CRD-C 87) Chemical Admixtures for Concrete

1.2.1.18 C1116-03 Fiber-Reinforced Concrete and Shot Crete

1.3 SUBMITTALS

1.3.1 All submittals described in this Section are provided with a “GA” or “FIO” designation.

Government approval is required for submittals with a prefix "GA" designation;

submittals having an "FIO" designation are for information only and are not subject to government approval. The Contractor shall provide all submittals to the government within 10 calendar days of the date of contract award.

1.3.2 Required Submittals

1.3.2.1 Shop Drawings (GA): The Contractor shall submit shop drawings showing complete information for the manufacture of the precast concrete units. Drawings shall show sufficient details including dimensions, cross sections, location of lifting devices for handling and any other details necessary to manufacture the units. Any revision to the units as designed shall be shown on the shop drawings and subject to the COR’s approval.

1.3.2.2 Aggregate Test Reports (GA): Aggregate will be accepted on the basis of test reports that show the material meeting the requirements of the specifications under which it is furnished. ODOT TE-24’s are acceptable. Alternatively, aggregates must be from an IDOT approved source(s).

1.3.2.3 Manufacturer's Literature (GA): Literature from suppliers which demonstrates compliance with applicable specifications for the following materials (as applicable):

1.3.2.3.1 Air-entraining agent

1.3.2.3.2 Accelerating agents

1.3.2.3.3 Retarding admixture

1.3.2.3.4 Water-reducing admixture

1.3.2.3.5 Curing materials

1.3.2.3.6 Fiber Reinforcement

1.3.2.4 Hot and Cold Weather Placement Procedures (GA): The Contractor shall meet this submittal requirement only if concrete products will be produced under hot or cold weather conditions as defined in Part 3 of this Specification. The submittal shall verify compliance with the hot and cold weather procedures specified.

1.3.2.5 Production Schedule (GA): The Contractor shall provide a production schedule that clearly demonstrates that the concrete block will be produced and cured to meet the specified deliveries. The schedule shall provide the milestones for: 25% production completion, 50% production completion, 75% production completion, and 100% production completion. The milestones shall be based on concrete unit production only and shall not include cure time. The schedule and milestone dates are critical to coordinating the milestone-inspections discussed elsewhere in this Section.

1.3.2.6 Independent Testing Service qualifications (GA).

1.3.2.7 National Precast Concrete Association Certification Document

1.4 MATERIAL PRODUCTION, INSPECTION, AND TESTING

1.4.1 Production:

1.4.1.1 Concrete unit blocks shall be manufactured in a National Precast Concrete

Association certified plant.

1.4.2 Inspections:

1.4.2.1 Defects: Blocks having voids or strata of segregated porous concrete, honeycombing, fracture, or other defects that, in the opinion of the Contracting Officer's Representative, would affect the structural quality of the concrete, will be cause for rejection of the unit. Rejected units shall become the property of the Contractor and shall be promptly removed from the point of final delivery of the work at no expense to the Government.

1.4.3 Testing:

1.4.3.1 The Contractor shall retain at his own expense an independent testing laboratory acceptable to the Contracting Officer to perform material evaluation tests and to design concrete mixes.

1.4.3.2 Test Procedures:

1.4.3.2.1 Concrete shall be sampled in accordance with ASTM C 172. If pumped concrete is used, samples for testing shall be obtained at the point of final placement.

1.4.3.2.2 Concrete shall be sampled and tested following the addition of all admixtures or additives.

1.4.3.2.3 Slump and air content shall be determined on a daily basis in accordance with ASTM

C 143 and ASTM C 231 respectively.

1.4.3.2.4 Compression test specimens shall be made and cured in accordance with ASTM C 31 and compression test specimens tested in accordance with ASTM C 39. Samples for strength tests shall be taken not less than once per day or for each 40 cubic yards of concrete used.

1.4.3.2.4.1 Three specimens shall be made from each sample, two shall be tested at 28 days for acceptance and one shall be tested at 7 days for information.

1.4.3.2.4.2 The acceptance test results shall be the average of the strengths of the two specimens tested at 28 days.

1.4.3.2.4.3 Concrete shall meet the requirements of ASTM C67 or ASTM C1262 for freeze-thaw durability.

1.4.3.3 The Army Corps of Engineers reserves the right to obtain third party independent testing in addition to the already specified QC testing.

2 PART 2 PRODUCTS

2.1 CONCRETE UNITS

2.1.1 Concrete precast unit shape: All blocks shall be rectangular in shape, with adjacent faces perpendicular and opposite faces parallel within 1/2 inch of the overall dimension. All blocks shall be formed with a 3” chamfer on all corners.

2.1.2 Concrete Block Unit Size:

Thickness: 4’0”, Width: 6’0”, Length: 6’0”

2.1.3 Lifting System:

2.1.3.1 The lifting system designed to handle the concrete units was based on commercially readily available under the trade name of the “Swift Lift System” as manufactured by the Dayton Superior Company. The components of the system are as follows:

2.1.3.1.1 The primary lifting attachment shall be the “P-50 Swift lift Universal Lifting Eye” with a rated load of 20 twenty tons. The load rating shall be based on a 5 to 1 factor of safety.

2.1.3.1.2 The portion of the lifting system embedded in the concrete units shall be the “P-53 Swift Lift Eye Anchor” with a rated load of 20 tons. The load rating shall be based on a 3 to 1 factor of safety in 2000-psi normal weight concrete. The P-53 Eye Anchor shall be used in conjunction with the “P-60 Tension Bar”.

2.1.3.1.3 The required tension bar shall be the “P-60 Swift Lift Tension Bar” (rebar style) with a rated load of 20 tons.

2.1.3.1.4 The lifting system shall be installed in strict compliance with manufacturer’s instructions. No exception will be made with respect to the manufacturer’s instructions.

2.1.3.1.5 Two sets (two pairs) of the lifting eyes shall be furnished and delivered to the unloading area for use by the government.

2.1.3.2 The lifting system defined in paragraph 2.1.3.1 is provided as a reference to a manufacturer that has commercially available units. Any other lifting system that provides an equivalent system shall be consider as an “or equal product”. Proper documentation by a registered structural engineer shall attest that the proposed unit is of equal or greater capacity than that defined above. Additionally, a drawing shall be submitted showing the end and edge distances that the embedded anchor will be installed.

2.1.3.3 All embedded items shall not protrude above the surface of the concrete units.

2.1.3.4 All embedded lifting items (P-53 Swift Lift Eye Anchor) shall be galvanized.

2.2 CONCRETE (High Performance Concrete)

2.2.1 Concrete Proportions: The proportions of the concrete materials for high performance shall be proportioned either per ODOT TABLE 499.03-4 Class HP or per IDOT Class SI.

2.2.2 The class of concrete shall be: ODOT Class HP2, or IDOT Class SI.

2.2.3 Concrete strength at 28 days shall be (f’c) 4000-psi minimum.

2.3 REINFORCING

2.3.1 Reinforcement shall be included through the use of ¾” nylon fibers. These fibers shall be

100% Virgin Nylon 66, Monofilament, have a tensile strength of 130-140 KSI (min), a Young’s Modulus of 750 KSI, and shall be added to the concrete at a rate of 1 lb per cubic yard.

2.4 CONCRETE CURING

2.4.1 Special curing methods for concrete will not be required if the Contractor avoids extreme conditions (dry/hot/cold);

2.4.2 If desired Contractor may apply a Membrane-Forming Curing Compound to surfaces of the unit when the formwork is removed.

2.4.3 Acceptable membrane forming curing compounds are ASTM C 309, Type 1-D or Type

2, Class A.

2.5 FORM MATERIALS

2.5.1 Forms

2.5.1.1 Forms shall be fabricated with facing materials that will produce a finish meeting the specified irregularities in formed surface requirements as defined in ACI 347R.

2.5.1.1.1 The class of finish that shall apply to all formed surfaces that is achieved from form facing material composed of tongue-and-groove or shiplap lumber, plywood conforming to PS-1, Grade B-B concrete form, tempered concrete form hard board or steel. Steel lining on wood sheathing will not be permitted.

2.5.2 Form Coating. Form coating shall be commercial formulation that will not bond with, stain, cause deterioration, or any other damage to concrete surfaces. The coating shall not impair subsequent treatment of concrete surfaces depending upon bond or adhesion nor impede the wetting of surfaces to be cured with water or curing compounds. If special form liners are to be used, the Contractor shall follow the recommendation of the form coating manufacturer.

3 PART 3 EXECUTION

3.1 MANUFACTURING (GENERAL)

3.1.1 The Contractor shall produce and cure concrete blocks within a schedule that will allow the material to be delivered by the Contractor to the specified locations, within the established time frame.

3.1.1.1 The Contractor shall develop this schedule in accordance with Part 1 of this Specification. The production schedule shall be documented and adhered to such that the blocks may be inspected and tentatively approved or rejected by the Contracting Officer.

3.2 FORMING, CASTING AND HANDLING UNITS

3.2.1 Each block shall be cast in one continuous operation. There shall be no cold joints.

3.2.2 Consolidation: Immediately after placing concrete, the plastic concrete shall be consolidated by internal or external formwork vibrating equipment. Vibrators shall not be used to transport concrete within the forms. The vibrating equipment shall be adequate in number of units and power to properly consolidate the concrete. Concrete shall be consolidated in horizontal layers 18 inches or less in thickness.

3.2.3 The Contractor shall be responsible for maintaining the soundness of castings: The contractor shall devise and adhere to schedules and procedures for manufacturing, handling and storing blocks in a manner that will not induce latent weakness in the units.

In the event the Contracting Officer's Representative finds cause to question the structural adequacy of any block for any reason of method or occurrence that is within the Contractor's control, it shall be the Contractor's responsibility to demonstrate the acceptability of the precast unit. Any block found structurally unsound, in the opinion of the Contracting Officer's Representative, will be rejected and shall be promptly removed from the point of final delivery at the Contractor at his expense.

3.2.4 Surface Requirements:

3.2.4.1 A magnesium trowel finish is required and after consolidation, screeding and floating of the concrete.

3.2.4.2 Maximum allowable surface irregularities shall not exceed ½ inch. Allowable irregularities for surface variations, displaced, misplaced or mismatched forms, form defects, warping, unevenness, curvature, shall be considered "gradual" irregularities will be acceptable provided that the irregularities do not exceed the ½ inch tolerance.

3.2.4.3 Lifting and Handling: The Contractor shall exercise caution when removing the concrete units from the formwork. The concrete must attain a minimum of 2000 psi (f’c) prior to handling the units by way of the lifting eye system. The handling or movement of the units shall not damage or otherwise adversely affect the structural qualities of the units. Any unit damaged due to early handling will not be accepted.

3.2.5 Hot Weather Concrete Placement: If concrete is proposed to be placed under hot weather conditions, the materials and methods will be provided in accordance with the requirements of ACI 305 and the Contractor’s submitted and approved procedures. The concrete placing temperature shall not exceed 90 degrees F. Cooling of the mixing water and/or aggregates will be required to obtain an adequate placing temperature. An approved retarding admixture may be used to facilitate placing and finishing.

3.2.6 Cold Weather Concrete Placement: If concrete is proposed to be placed under cold weather conditions, the materials and methods will be provided in accordance with the requirements of ACI 306 and the Contractor’s submitted and approved procedures.

Concrete shall not be subjected to freezing temperatures before it reaches minimum required compressive strength (4000 psi).

3.3 DELIVERY

3.3.1 General: The units shall be delivered to the destination set forth below with all transportation cost pre-paid. Any bid received on a basis other than FOB destination will be rejected as “non-responsive”.

3.3.2 The exact location at the respective harbor where the materials are to be delivered will be as specified under this contract. All associated land based transportation costs associated with the delivery of the material shall be FOB the specified site. The contractor will be provided a detailed location map or instructions to the delivery location listed in this contract. The precast units will be unloaded at the dock location by the Contractor. The contractor should expect to be directed to stack the blocks in multiple rows, two blocks in height.

3.3.3 The units shall be delivered to the harbors as indicated on the bid form, at the following locations (as applicable):

Chicago Combined Disposal Facility:

Illinois International Port District 3600 E. 95th Street Chicago, IL 60617-5193

3.3.4 Delivery Dates: The Contractor shall make delivery of the concrete block units between September 1, 2009 and May 31, 2010. Earlier delivery dates may be acceptable if agreed upon by both the Contractor and the Contracting Officer. Delivery may begin when concrete strength reaches 2000 psi..

3.3.5 Access to the Chicago Combined Disposal Facility is obtained via the Illinois International Port Gate, and therefore subject to USCG/ Dept. of Homeland Security Requirements. Any personnel wishing to gain access to the delivery site unescorted will require possession of a TWIX card. All other individuals accessing the site will require an escort, as well as a state or federal-issued photo ID, and a letter of introduction to the Port’s security officer. The contractor shall coordinate with the Technical POC to satisfy these requirements.

3.4 DELIVERY SCHEDULE

3.4.1 The basic delivery schedule shall follow the following format;

3.4.1.1 Materials shall be delivered to the respective sites during weekdays during scheduled time periods between 0700 and 1600 hours, Monday thru Friday (except federal holidays); other times may be available but all deliveries must be coordinated with the Technical Point of Contact (POC). The contractor shall notify the COR a minimum of 48 hours prior to any scheduled delivery.

3.5 PERIOD OF PERFORMANCE

3.5.1 Contract period of performance is 10 months following the date of the contract award.

3.5.2 The Technical Point of Contact for this project is Bob Ojala (312) 846-5488 robert.a.ojala@usace.army.mil. This person will be responsible for material acceptance and delivery coordination.

3.6 FORMAL ACCEPTANCE

3.6.1 Formal acceptance of the material will be made at the dock after the material has been inspected and found to conform to contract requirements. Any precast unit found to be unacceptable under these specifications shall be removed from the site at the expense of the Contractor.

3.6.2 Delivery tickets shall be accepted and signed by the Corps of Engineers representative or the derrick boat master at the time of delivery. A check will be performed to insure that the material loaded matches the number of tickets presented to the Corps Representative.

3.6.3 Delivery of material that cannot be verified by delivery tickets will not be accepted and signed for by the Corps representative and will not be accepted for payment. On delivery of each shipment, copies of bills of lading will be forwarded as follows:

Department of the Army U.S. Army Engineer District, Chicago 111 N. Canal Suite 600 Chicago, Illinois 60606-7206 ATTN: Mr. Bob Ojala

END OF SCOPE OF WORK

mailto:robert.a.ojala@usace.army.mil