AMENDMENT-0002-17-B-0010-CHICAGO_HARBOR_BREAKWATER_REPAIR_PROJECT_-_IFB-PKG.pdf

W81G6671708306

AMENDMENT OF SOLICITATION/MODIFICATION OF CONTRACT

Except as provided herein, all terms and conditions of the document referenced in Item 9A or 10A, as heretofore changed, remains unchanged and in full force and effect.

15A. NAME AND TITLE OF SIGNER (Type or print)

30-105-04EXCEPTION TO SF 30

APPROVED BY OIRM 11-84

STANDARD FORM 30 (Rev. 10-83) Prescribed by GSA

FAR (48 CFR) 53.243

SUBJECT: INVITATION FOR BIDS W912P6-17-B-0010, CHICAGO HARBOR BREAKWATER REPAIRS - CHICAGO, IL"

A. The Bid Opening Date & Time is extended from September 22, 2017 to September 25, 2017, the bid opening time remains unchanged at 2:00pm (CST) (bids must be submitted "prior" to 2:00p.m.). Further details on bid submission is located in Section 00100 of the Solicitation document.

B. CHANGES TO THE SPECIFICATIONS are as follow s: The Revised Section Pages are attached hereto.

1. Section 35 31 25.3.5.3 and Sheets C-102 and C-103 - revised as follow ing:

Sheets C-102 and C-103 w ere modif ied to call out the correct LWD (577.5) Specif ication 35 31 25.3.5.3 w as edited to identify only mix C to be used in row s B, C, and D.

-----SEE THE FOLLOWING PAGES-----

1. CONTRACT ID CODE PAGE OF PAGES

1 4

16A. NAME AND TITLE OF CONTRACTING OFFICER (Type or print)

16C. DATE SIGNED

BY 21-Sep-2017

16B. UNITED STATES OF AMERICA15C. DATE SIGNED15B. CONTRACTOR/OFFEROR

(Signature of Contracting Officer)(Signature of person authorized to sign)

8. NAME AND ADDRESS OF CONTRACTOR (No., Street, County, State and Zip Code) X W912P617B0010

X 9B. DATED (SEE ITEM 11)

22-Aug-2017

10B. DATED (SEE ITEM 13)

9A. AMENDMENT OF SOLICITATION NO.

11. THIS ITEM ONLY APPLIES TO AMENDMENTS OF SOLICITATIONS

X The above numbered solicitation is amended as set forth in Item 14. The hour and date specified for receipt of Offer X is extended, is not extended.

Offer must acknowledge receipt of this amendment prior to the hour and date specified in the solicitation or as amended by one of the following methods:

(a) By completing Items 8 and 15, and returning 1 copies of the amendment; (b) By acknowledging receipt of this amendment on each copy of the offer submitted;

or (c) By separate letter or telegram which includes a reference to the solicitation and amendment numbers. FAILURE OF YOUR ACKNOWLEDGMENT TO BE RECEIVED AT THE PLACE DESIGNATED FOR THE RECEIPT OF OFFERS PRIOR TO THE HOUR AND DATE SPECIFIED MAY RESULT IN REJECTION OF YOUR OFFER. If by virtue of this amendment you desire to change an offer already submitted, such change may be made by telegram or letter, provided each telegram or letter makes reference to the solicitation and this amendment, and is received prior to the opening hour and date specified.

12. ACCOUNTING AND APPROPRIATION DATA (If required)

13. THIS ITEM APPLIES ONLY TO MODIFICATIONS OF CONTRACTS/ORDERS.

IT MODIFIES THE CONTRACT/ORDER NO. AS DESCRIBED IN ITEM 14.

A. THIS CHANGE ORDER IS ISSUED PURSUANT TO: (Specify authority) THE CHANGES SET FORTH IN ITEM 14 ARE MADE IN THE

CONTRACT ORDER NO. IN ITEM 10A.

B. THE ABOVE NUMBERED CONTRACT/ORDER IS MODIFIED TO REFLECT THE ADMINISTRATIVE CHANGES (such as changes in paying office, appropriation date, etc.) SET FORTH IN ITEM 14, PURSUANT TO THE AUTHORITY OF FAR 43.103(B).

C. THIS SUPPLEMENTAL AGREEMENT IS ENTERED INTO PURSUANT TO AUTHORITY OF:

D. OTHER (Specify type of modification and authority)

E. IMPORTANT: Contractor is not, is required to sign this document and return copies to the issuing office.

14. DESCRIPTION OF AMENDMENT/MODIFICATION (Organized by UCF section headings, including solicitation/contract subject matter where feasible.)

10A. MOD. OF CONTRACT/ORDER NO.

2. AMENDMENT/MODIFICATION NO. 5. PROJECT NO.(If applicable)

6. ISSUED BY

3. EFFECTIVE DATE

21-Sep-2017

CODE

U.S. ARMY ENGINEER DISTRICT, CHICAGO

231 SOUTH LASALLE STREET SUITE 1500

CHICAGO IL 60604-1437

W912P6 7. ADMINISTERED BY (If other than item 6)

4. REQUISITION/PURCHASE REQ. NO.

CODE

See Item 6

FACILITY CODECODE

EMAIL:TEL:

W912P617B0010

SECTION SF 30 BLOCK 14 CONTINUATION PAGE

The following items are applicable to this modification:

AMENDMENT PARTICULARS

C. USACE RESPONSES TO CONTRACTOR’S QUESTIONS:

QUESTION 1. Based on the specifications 35 31 25 paragraph 1.2, the Contractor will be required to conduct a pre-grouting compatibility program on land. Amendment 0001 removed the compatibility test program mock-up section. What is the Government’s expectation for the pre-grouting compatibility test program? What bid item should the compatibility test program be included in?

A: The pre-grouting compatibility test is to confirm and validate the contractor's equipment, materials and proper silicate dosage for the prescribed set times for the barrier grout. It does not require a mock-up.

The program is incidental to those activities as stated in section 35 31 25.1.2 and there is no separate CLIN for the program. Costs should be attributed to the item most closely associated to the work in accordance with section 01 22 00.00 10.1.1.

QUESTION 2. Is the intent of the grouting program to fill existing voids and all of the void space in the stone fill within the timber cribs?

A: Yes.

QUESTION 3. The specifications for the consolidation grout to be used in Rows B, C and D requires that the grout have an average 28 day compressive strength of 5,000 psi.

a) What were the average 28 day compressive strengths of the consolidation grout that was used for the Northeast Breakwater Repair FY 2009 project?

A: The previous work in 2009 and 2014 required a 28-day strength of 5,000 psi.

b) Is there a reason for such a high compressive strength requirement?

A: This is required to insure long term durability and resistance to flowing water through the structure.

QUESTION 4. The Typical Sections of the structure shown on drawings C-102 and C-103 are different and have different elevations shown. Please clarify which typical section is correct.

A: Sheet C-103 has Low Water Datum for Lake Michigan Elevations at 577.5; the same noted on Sheet C-102.

QUESTION 5. Drawing C-103 How much of the existing 3/4” x 2’6” plate on the harbor and on the lake side is deteriorated?

A: The Section A-A detail on C-102 is provided to show approxiamte elevations. The elevation on Sheet C-103 pertaining to the Low Water Datum for Lake Michigan HAS been resvised to 577.5, WHICH NOW AGREES with the Low Water Datum (L.W.D. shown on Sheet C-102).

QUESTION 6. Drawing C-103 Does the existing 3/4” x 2’6” plate on the harbor and on the lake side exist across the entire work area?

A: It is assumed to have been installed along the entire work area per the As-builts available.

QUESTION 7. Drawing C-103. How much length of structure on the harbor side contains “failed timber areas”?

A: See note on sheet C-103: “Provide grout containment barrier along entire length,”

QUESTION 8. Drawing C-103. Which bid item is the grout containment barrier to be included in?

A: The barriers are incidental to the work and not paid for separately.

QUESTION 9. Please confirm that the contract does not require a Compatibility Test Program? The specification still contain reference to a Compatibility Test Program in specification sections 1.2 System Description, 1.7.1.a and 3.1.2.

A: Please refer to response for question #1.

QUESTION 10. Specification Section 1.7.1.d requires the intermediate holes to be redrilled if necessary. Which bid item will pay for the redrilled holes?

A: Redrilled holes will be paid for at the unit price for drilling.

QUESTION 11. Specification Section 1.7.1.e requires core holes after the initial 50-feet section of the work is completed for evaluation of the effectiveness of the grouting. Will a review period be required before the contractor may continue with the work?

A: No, the contract does not require a review period.

QUESTION 12. Specification Section 3.5.3 and 3.5.6 make note of two grout mixes for rows B, C and D. What are requirements of the second mix as only Mix C is listed?

A: Only Mix C is required per revised spec issued with amendment 0002.

QUESTION 13. SECTION 35 31 25 h. Any grout found to be in the existing relief holes in the concrete cap shall be flushed and/or drilled out.

The relief holes are 6x6 inches and are only the depth of the concrete cap which is around 4 feet.

New grout will fill the gap under the concrete cap and penetrate downward for some depth into the crib stone. We are assuming that this specification means use the same 3" grout hole drill to drill thru any grout in the 6x6 well opening, drill thru the grouted void beneath the cap, and continue drilling thru the grouted crib stone until reaching un-grouted crib stone to reconnect the relief hole to crib stone. By using the words flushed in the specification, it leads one to believe that only the 6x6 portion of the well is to be cleaned out and only in the concrete cap. Please clarify what is really expected.

A: The contractor shall remove grout that permeates into the existing relief wells by flushing or drilling per section 35 31 25.1.7.h.

C. Point of contact for this Amendment is Kim F. Hubbard at 312.846.5368 or kimberly.f.hubbard@usace.army.mil .

END OF AMENDMENT PARTICULARS

(REVISED SPECIFICATION SECTIONS FOLLOW)

mailto:kimberly.f.hubbard@usace.army.mil

Chicago Breakwater Repair FY17 CHICHRBRBRKWTR17

SECTION TABLE OF CONTENTS

DIVISION 35 - WATERWAY AND MARINE CONSTRUCTION

SECTION 35 31 25

TIMBER CRIB BREAKWATER REPAIR

PART 1 GENERAL

1.1 REFERENCES

1.2 SYSTEM DESCRIPTION

1.3 DEFINITIONS

1.3.1 General

1.3.1.1 Series

1.3.1.2 Section

1.3.1.3 Row

1.3.1.4 Cycle

1.3.1.5 Intermittent Grouting

1.3.1.6 Split Spacing

1.3.1.7 Closure

1.3.1.8 Refusal

1.3.1.9 Communication

1.3.1.10 Balanced Stable Grout

1.4 SUBMITTALS

1.5 MATERIALS DELIVERY, STORAGE, AND HANDLING

1.5.1 Grout Materials

1.6 PROJECT/SITE CONDITIONS

1.6.1 Field Conditions

1.6.2 Field Measurements

1.7 SEQUENCING AND SCHEDULING OF DRILLING AND GROUTING

1.7.1 General

1.8 Qualifications

1.8.1 Grouting Superintendent

PART 2 PRODUCTS

2.1 GROUTING MATERIAL

2.1.1 Water

2.1.2 Cement

2.1.3 Pozzolans

2.1.4 Admixtures

2.1.4.1 Water Reducer

2.1.4.2 Superplasticizer

2.1.4.3 Viscosity Modifier

2.1.5 Fluidifier

2.1.6 Anti Wash-out Agent

2.1.7 Bentonite

2.1.8 Sand

2.1.9 Sodium Silicate

2.2 CONTAINMENT BARRIERS

PART 3 EXECUTION

3.1 COMPATIBILITY TEST PROGRAM AND DRILLING AND GROUTING WORK PLANS

AND PREPARATORY ITEMS

SECTION 35 31 25 Page 1

AMD-0002 -09/20/17

3.1.1 General

3.1.2 Compatibilty Test Program Work Plan

3.1.3 Drilling and Grouting Work Plan

3.1.4 Grout Hole Layout

3.2 EQUIPMENT

3.2.1 General

3.2.2 Drilling Equipment

3.2.2.1 Drilling Conditions

3.2.3 Grouting Equipment

3.2.3.1 Grout Plant

3.3 GROUT CONTAINMENT

3.4 GROUT HOLE DRILLING

3.4.1 General

3.4.1.1 Drilling Log and Records

3.4.2 Location and Depth

3.4.3 Casing for Grout Holes

3.4.3.1 Casing

3.4.3.2 Casing Installation

3.4.3.3 Core Hole Drilling

3.4.3.4 Grout Data Logger

3.5 GROUTING PROCEDURES

3.5.1 Grouting

3.5.2 Grouting Lakeward and Harborside Rows

3.5.3 Grout Mixes

3.5.4 Communication

3.5.5 Grouting Pressures

3.5.6 Grout Mixes

3.5.7 Measurement Equipment

3.5.8 Mixing Procedure

3.5.9 3.5.9 Grout Injection

3.5.10 Backfilling of Holes

3.5.11 Equipment Arrangement and Operation

3.5.12 Protection to Work and Cleanup

3.5.13 Records

3.5.14 Communications

-- End of Section Table of Contents --

SECTION 35 31 25 Page 2

SECTION 35 31 25

TIMBER CRIB BREAKWATER REPAIR

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 in the text by basic designation only.

ASTM INTERNATIONAL (ASTM)

ASTM C 70 (2006) Standard Test Method for Surface Moisture in Fine Aggregate

ASTM C 136 (2006) Standard Test Method for Sieve Analysis of Fine and Coarse Aggregates

ASTM C 150 (2007) Standard Specification for Portland Cement

ASTM C 204 (2007) Standard Test Method for Fineness of Hydraulic Cement by Air Permeability Apparatus

ASTM C 243 (1995) Standard Test Method for Bleeding of Cement Pastes and Mortars

ASTM C 494 (2000) Chemical Admixtures for Concrete

ASTM C 618 (2008) Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in Concrete

ASTM C 937 (2002) Grout Fluidifier for Preplaced-Aggregate Concrete

U.S. ARMY CORPS OF ENGINEERS (USACE)

COE CRD-C 100 (1975) Method of Sampling Concrete Aggregate and Aggregate Sources, and Selection of Material for Testing

AMERICAN PETROLEUM INSTITUTE (API)

API RP 13B-1 (2003; Errata 2004) Standard Procedure for Field Testing Water-Based Drilling Fluids

1.2 SYSTEM DESCRIPTION

This section of the specifications covers construction of conducting pre-grouting compatibility program on land; installing grout containment barriers on both sides of the breakwater, drilling through concrete

SECTION 35 31 25 Page 3 breakwater cap, using either diamond rotary or percussion drilling equipment, making grout connections; furnishing, handling, transporting, storing, mixing and injecting the grouting materials; backfilling holes;

patching and backfilling the finished grout holes; clean up of the areas upon completion of the work and all other such operations as are incidental to the drilling and grouting. The work consists of constructing a grout curtain, the approximate locations, limits, and details which are indicated in the drawings using both quick-setting sodium silicate grouts and low-mobility consolidation grouts.

Drilling, grouting shall follow the sequence of work presented in the Contractor's Drilling and Grouting Work Plan and approved by the Contracting Officer Representative (COR). Adherence to the schedule and sequence directed by the COR will not be seen as cause for time extension or claims for additional costs beyond those specified herein.

1.3 DEFINITIONS

1.3.1 General

The drilling and grouting shall consist of a multi-line grout curtain.

The inner and outer single lines of the grout curtain shall be grouted using a fast-setting portland cement-sodium-silicate grout for containment of grout from the inner rows of grout holes. The three lines of the interior grout curtain shall be grouted using low/non-shrink balanced stabilized sanded portland cement grout with anti-washout characteristics. The drilling and grouting shall be performed on series of boreholes within sections, using the methods as described herein.

1.3.1.1 Series

A series of grout holes refers to a group of boreholes grouted simultaneously at one station aligned perpendicular to the breakwater structure within the inner three rows of the grout curtain.

1.3.1.2 Section

A section is a division along the grout curtain, not less than 50 feet up and down station from a hole being drilled or grouted within which grouting of successive series of holes shall be simultaneously grouted.

Insofar as practicable, the grout curtain shall be subdivided into sections in a manner to facilitate the Contractor's operations; however drilling within one section adjacent to a section that has yet to be grouted shall not be done except as directed by the COR.

1.3.1.3 Row

A row is defined as the line of holes parallel to the structure. There are 5 rows designed as shown on the Drawings:

Row A - the row of borings along the lake side of the structure;

Row B - the row of interior holes toward the lakeside;

Roc C - the Centerline row of interior holes;

Row D - the harbor side row of interior holes Row E - the row of holes nearest the harbor side of the structure.

SECTION 35 31 25 Page 4

1.3.1.4 Cycle

A cycle under these Specifications is defined as a period of continuous grouting of a hole from start to shut off of grout flow. Holes may be grouted for more than one cycle, following sufficient elapsed time between cycles for the grout to set, in cases where grouting was suspended prior to grout communicating with adjacent holes, or due to the appearance of grout outside of containment, or when interruption is directed by the COR.

1.3.1.5 Intermittent Grouting

Intermittent grouting under these Specifications is defined as grouting of more than one cycle applied to the same grout hole, each cycle separated by sufficient time for the grout to reach initial set.

1.3.1.6 Split Spacing

Split spacing is the procedure of locating an additional grout hole midway between two previously drilled and grouted holes.

1.3.1.7 Closure

Closure is defined as the acceptable level of void-filling of a section achieved by grouting. For this Contract, the closure criteria are:

1. Observed complete filling of voids in the stone fill within the timber crib to the designed extent, determined by the presence of grout filling or being clearly visible in adjacent holes; or

2. Cessation of grouting directed by the COR.

1.3.1.8 Refusal

Refusal is defined for this Contract as the condition where a hole accepts no grout under the pressure exerted by the grout pump.

1.3.1.9 Communication

Communication is the passage of water or grout from one hole to another or to any opening or exposed surface during the course of drilling and/or grouting.

1.3.1.10 Balanced Stable Grout

A grout mixture that exhibits minimal (less than 5 percent) bleed and retains the desired rheologic properties , viscosity, and cohesion throughout the pumping and placement processes regardless of pumping rate, turbulence or agitation.

1.4 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

SECTION 35 31 25 Page 5

Compatibility Test Program, Drilling and Grouting Work Plans,Grout Superintendent Qualifications ; G, DG

Submit Compatibility Test Program, Drilling and Grouting Work Plans not less than 30 Days prior to the commencement the respective portions of the work, the Contractor shall submit separate Compatibility Test Program Work Plan and Drilling and Grouting Work Plan that include but are not limited to detailed descriptions of conducting the compatibility test program, equipment, labor and staging operations for conducting overwater operations, installation of containment barriers, drilling and grouting, mobilization activities due to limited space at the lock, and overall sequence of work.

SD-02 Shop Drawings

Records ; G, DG

The Contractor shall submit complete, legible copies of DRILLING RECORDS and all photographs to the COR within 1 week after a hole is completed or at any time directed by the COR. Drill records will identify the hole number, total depth drill and the depth of the void space beneath the concrete cap.

Grouting Data Reports

The Contractor shall submit an example of the records produced by the Grouting Data Logger(s) not less than 30 days prior to the commencement of drilling and grouting holes.

Grout Production Records

The Contractor shall submit Grout Production Records from the Grouting Data Logger(s) on a daily basis.

The Contractor shall submit electronic records in Microstation and Excel Spreadsheet indicating the hole identification; type(s) and quantities of grout and grout components placed, date(s) and times of activities on a weekly basis.

Grout Hole Layout G, DG

The Contractor shall submit a layout in plan view illustrating the layout of grout hole lines of the grout curtain not less than 30 days prior to the commencement of drilling.

SD-03 Product Data

Drilling Equipment; G, DG

Grout Mixes ; G, DG

Details including, but not limited to all components, proportions, mixing procedures and sequence of additives, test results for sand gradation, grout viscosity/slump, density, set time, strength, bleed, shrinkage, and other testing as may be appropriate shall be submitted 7-days prior to commencement of use of the mixes.

Grouting Material; G, DG

SECTION 35 31 25 Page 6

The source of all grout components and a detailed list and manufacturers' descriptive literature of all components of grouts used in the work.

Grout Plant ; G, DG

Grouting Equipment G, DG

A detailed plan shall be submitted showing equipment floating plant and grout plant layout proposed for mixing and placing grout. A list, details, description and data on the grouting equipment and materials shall be submitted for conformance with the requirements of paragraph EQUIPMENT.

SD-06 Test Reports

System Calibration Reports

The Contractor shall provide calibration reports for calibration certificates for flow meters, pressure transducers, and any batch scales and/or admixture dispensing equipment, Grout Data Logger(s) and all related equipment not less than 7 days prior to the commencement using the equipment.

SD-06 Test Reports

Grout Property Tests

The Contractor shall provide laboratory testing results of grout materials properties not less than 7 days prior to the use of these materials. Field test data shall also be recorded on the daily QC reports and the daily grout reports.

SD-07 Certificates

Credentials ; G, DG

The Contractor shall submit the name and qualifications of the Grouting Superintendent(s) not less than 30 days prior to commencement of the Compatibility Test Program. Changes in personnel will require additional submittals for approval of these key personnel.

The Contractor or subcontractor performing the grouting shall have performed sodium silicate grouting on a scale comparable to this work on a minimum of 3 projects in the past 5 years, and shall have demonstrated proficiency with the materials and equipment to be used in this work. The Contractor shall submit the names and descriptions of previous projects indicating fulfillment of the experience requirement for this work with the Work Plan.

1.5 MATERIALS DELIVERY, STORAGE, AND HANDLING

1.5.1 Grout Materials

A sufficient quantity of cement, water and all other grout mix components shall be stored at or near the site of the work to insure that grouting

SECTION 35 31 25 Page 7 operations will not be delayed by shortage of grout materials or water.

In the event the cement is found to contain lumps or foreign matter of a nature and in amounts which, in the opinion of the COR, may be deleterious to the grouting operations, screening through a standard 100 mesh screen may be required. No payment will be made for such screening.

All materials are required to be adequately protected from inclement weather, including rain, snow and freezing conditions. Suitable enclosures to prevent the degradation of the various materials prior to use, will be required. Materials beyond the manufacturer's designated shelf life shall not be used in this work, and any such materials brought on site shall be disposed of at the Contractor's expense.

1.6 PROJECT/SITE CONDITIONS

1.6.1 Field Conditions

The program shown and described herein and in the Drawings is based on currently available information. Conditions encountered during construction may require additions or deletions. Grouting mixes, pressures, injection rate and the sequence in which the holes are drilled and grouted shall be submitted by the Contractor in accordance with the requirements indicated, but may be altered as field conditions dictate and approved by the COR.

1.6.2 Field Measurements

The Contractor shall produce a preliminary grout hole layout for the review and approval of the COR. The final drill hole locations will be as approved by the COR prior to the start of work. The locations of drill holes shall be surveyed by the Contractor to the nearest 0.1 ft on the NAD 83 coordinate system and elevations surveyed using the Chicago City Datum.

1.7 SEQUENCING AND SCHEDULING OF DRILLING AND GROUTING

1.7.1 General

The order in which the work is to be accomplished shall be as outlined in the Compatibility Test Program Work Plan and Drilling and Grouting Work Plans and as approved by the COR. The general requirements that shall apply are as follows:

a. Conduct an on-land Compatibility Test Program using the actual grouting equipment to develop the mix designs for the containment grout and low mobility grout. Base line rheologic and physical properties grout mixes shall be established.

b. Install the harbor side and lake side grout containment barriers for the first 100-feet to be grouted.

c. The Contractor shall verify the correct and approved location, orientation and alignment of the grout holes before drilling and installing any casings, should casings be deemed necessary. Casing may be used at the convenience of the Contractor, but no separate payment will be made for casing. Establish and layout sections of the grout curtain to be drilled and grouted in sequence and mark grout

SECTION 35 31 25 Page 8 holes and sections on the concrete breakwater cap accordingly with paint.

d. For each section of the grout curtain, drilling and grouting of the lakeward row (Row A) shall be completed before proceeding with drilling and grouting of the harborside holes (Row E) and the interior rows of the grout curtain. Monitor adjacent holes and the water lakeward and harborside of the breakwater during grouting for the presence of grout communicating. If grout appears beyond containment barrier, report this observation to the COR immediately, cease grouting and adjust grout flows, containment procedures, and/or mix to prevent recurrence before commencing grouting. Only after direction by the COR may the Contractor continue grouting a hole that has resulted in communication to the lake water. Grout each hole until:

1. Grout is detected in adjacent holes;

2. 8 cubic yards of grout has been injected, or;

3. The hole refuses to accept grout;

4. Directed by the COR to stop.

In the case of both the lakeward and harborside rows of grout holes, grouting shall be done using split-spacing on holes 8-feet apart, such that every other hole is grouted first, and then the intermediate holes are re-drilled (if necessary) and grouted, resulting in an array of holes on 4-foot spacing.

e. After both the lakeward and harborside rows of grout holes have been completely grouted, drill and grout the interior rows of holes.

Drill complete array of interior grout holes for a section prior to grouting within the section. Begin grouting at one end of the section, grouting the three holes at each station in Rows B, C and D simultaneously, and proceed across the first section in groups of threes from one end to the other. Monitor adjacent holes and the lakeward and harborside of the timber crib for the presence of grout.

If grout appears beyond containment barrier, report this observation to the COR immediately, cease grouting and adjust grout flows, containment procedures, or mix to prevent recurrence before commencing grouting. Stop grouting and move to the next three holes when a total of 8 cubic yards of grout has been pumped in each hole at a given station, or when grout is observed in adjacent holes, whichever occurs first, or when directed by the COR.

Following the complete grouting of the initial section of the work (50-feet), a set of 3 core holes shall be drilled to depth of 15 feet below the concrete: on each toe section and one in the crown of the breakwater, to evaluate the effectiveness of the grouting. If necessary, methods and mixes used in the remainder of the work shall be adjusted to improve effectiveness, based on observations of the core.

f. Grout holes within each row shall be spaced 4-feet apart in each line of the grout curtain. Drilling and grouting shall not be performed in sections adjoining an incompletely-grouted section of the grout curtain except as directed by the COR.

g. Remove any casings and top off grout holes to the surface of the breakwater cap by tremie grouting upon completion of each section of the grout curtain.

SECTION 35 31 25 Page 9

h. Any grout found to be in the existing relief holes in the concrete cap shall be flushed and/or drilled out.

1.8 Qualifications

1.8.1 Grouting Superintendent

The Contractor shall provide a qualified Grouting Superintendent, experienced in using the materials and equipment proposed for this work.

The Grouting Superintendent shall have a minimum of 5-years experience in marine construction, and 10-years experience in grouting projects, with at least 3 grouting projects involving sodium silicate grouts. The Grouting Superintendent shall be present during all drilling and grouting. This individual shall be responsible for the oversight of all drilling and grouting operations, mix formulations and the preparation of grouting records for each boring and series of borings.

The presence of a Government representative or the keeping of separate drilling records by the COR shall not relieve the Contractor of the responsibility for the work specified in this specification.

SECTION 35 31 25 Page 10

PART 2 PRODUCTS

2.1 GROUTING MATERIAL

Two grout types shall be used: a fast-setting sodium-silicate-based portland cement grout; and a low-mobility, balanced, stabilized portland cement and sand-based consolidation grout. The grouts shall be composed of water and cement, pozzolans, admixtures, anti washout additive, accelerant agent (sodium silicate) and aggregate - sand gravel, where appropriate and fillers in varying proportions. The grout mixes shall be proposed and demonstrated by the Contractor in accordance with the requirements of these specifications, and shall be varied to meet the characteristics of each hole as determined by conditions encountered. The various materials to be furnished by the Contractor shall conform to the specifications listed in paragraphs below.

2.1.1 Water

The Contractor is responsible for obtaining water for his operations and the use of his employees on-site. Lake water may be used in grout mixes;

however the Contractor shall be responsible for any permits associated with the use of water from Lake Michigan. The Contractor shall be solely responsible for furnishing water of suitable quantity and quality for use in the work. The Contractor shall be solely responsible for all pumps, supply lines, hoses, power and related equipment and materials necessary to provide water for the activities under this Contract. All water lines and pumps shall be sized appropriately to deliver sufficient quantity and quality of water for all concurrent activities on site. The cost of obtaining water and any cost for water quality testing and improvements shall be the responsibility of the Contractor and are considered incidental to the drilling and grouting activities.

2.1.2 Cement

Cement used in grout shall be Type II Portland cement that conforms to the requirements of ASTM C 150 , except that the cement shall have a Blaine fineness of 3,500 cm2/g as determined by ASTM C 204 . The use of bulk cement will be permitted, provided the Contractor employs methods of handling, transporting, and storage that are satisfactory to the Contracting Officer Representative, otherwise only cement furnished in cloth or paper bags will be accepted to use in the work.

2.1.3 Pozzolans

Pozzolans shall be Type F flyash conforming to ASTM C 618 . Sampling shall be done by the Contractor during mix design. Additional sampling and testing may be required at the direction of the COR to insure compliance with ASTM C 618 . All tests of pozzolans shall be made by the Contractor at no additional expense to the Government. Pozzolans may be furnished in paper sacks or in bulk, Materials shall be transported, handled, and stored so as to avoid damage, waste, or absorption of moisture.

The Contractor may use silica fume in conjunction with and/or in substitution for flyash. Silica fume shall be used in accordance with the manufacturer's recommendations and grout mix test results.

SECTION 35 31 25 Page 11

2.1.4 Admixtures

Admixtures shall be added to the grout immediately before or during its mixing and shall consist of an appropriate combination of one or more of the following: accelerators, retarders, water reducers, superplacticizers, aluminum powder, fluidifiers, anti wash-out additives and viscosity modifiers.

2.1.4.1 Water Reducer

A water reducer possessing characteristics that reduce the water demand by at least 5 percent shall be used. The quality of the materials shall meet the requirements of ASTM C 494 . The materials shall be shipped handled and stored in such a way as to prevent deterioration, contamination, damage or waste.

2.1.4.2 Superplasticizer

A high-range water reducer that decrease the water demand by at least 12 percent. Naphthalene sulphonate with the ability to coat grout particles in the suspension with a film having a negative charge may be used if compatible with the other components of the grout mixes without adversely affecting the desired grout properties of each mix. The materials shall be shipped, handled, and stored in such a way as to prevent deterioration, contamination, damage or waste. Alternatives may be proposed by the Contractor, contingent upon approval by the COR based on test results and review of available literature. No time extension will be allowed for the time required to review alternative materials.

2.1.4.3 Viscosity Modifier

Natural, soluble, bipolymer having a high molecular weight which enhances the stability of the grouts shall be used. The materials shall be shipped, handled, and stored in such a way as to prevent deterioration, contamination, damage or waste.

2.1.5 Fluidifier

Fluidifier shall be a compound possessing characteristics which will increase the flowability of the mixture, assist in dispersal of the cement grains, and neutralize the setting shrinkage of the grout. The quality of the material shall meet the requirements specified in ASTM C 937 .

Sampling of fluidifier shall be done by an authorized representative of the Contracting Officer. All tests will be made by and at the expense of the Government. Fluidifier shall be furnished in moisture-resistant paper sacks shipped in sealed containers and shall be handled and stored so as to avoid absorption of moisture, damage or waste. Material which has become caked due to moisture absorption will be rejected.

2.1.6 Anti Wash-out Agent

An anti-washout component such as Rheomac UW 450 or equal shall be used in grout used for the interior holes designed to maintain the grout mix in an aqueous environment.

2.1.7 Bentonite

Bentonite shall be sodium (Na) cation, powdered montmorillonite. It is anticipated that it shall be added to the cement grout at a ratio 2

SECTION 35 31 25 Page 12 percent to 8 percent by weight of cement. The percentage shall be adjusted as directed by the COR, based on the Contractor's mix design. A separate colloidal bentonite mixer shall be used to mix the bentonite and water to ensure fully dispensing and hydrating the bentonite before adding to the grout mixer. The bentonite slurry shall be prehydrated for at least 12 hours prior to use. The bentonite shall be handled and stored so as to avoid unintended absorption of moisture, damage, or waste.

Bentonite which has become caked due to moisture absorption will be rejected. A sufficient quantity of bentonite shall be stored at or near the site of the work to insure that grouting operations will not be delayed by shortage of bentonite. A sufficient quantity of bentonite slurry shall be on hand prior to commencement of grouting a hole to prevent interruption of supply, and under conditions that will not alter its properties.

2.1.8 Sand

a. Sand for grout shall be clean and consist of hard, tough, durable, uncoated particles with no more than 5 percent passing the #200 sieve. The shape of the particles shall be generally rounded or cubical. The sand shall be generally well graded from fine to coarse in accordance with ASTM C 136 with 100 percent passing the No. 16 sieve. Slag sand will not be accepted for this work..

b. The sand shall be subjected to such tests by the Contractor at no additional expense to the Government as are necessary to determine its acceptability. All sampling of sand shall be in accordance with the applicable sampling provisions contained in COE CRD-C 100 or as directed. The tests to which the sand will be subjected include specific gravity, absorption, soundness in magnesium sulfate, petrographic analyses, and any other tests that are necessary to demonstrate that grout of adequate durability can be produced.

c. The percentage of surface moisture in terms of the saturated surface-dried sand shall be determined in accordance with ASTM C 70 , or other method giving comparable results.

d. Sand shall be stored in such a manner as to avoid the inclusion of any foreign materials in the grout. All sand shall remain in free draining storage for at least 72 hours prior to use.

2.1.9 Sodium Silicate

Sodium Silicate additive shall be used in the lakeward and harborside rows of grout holes. Sodium Silicate additive shall be provided in a commercially-prepared and standardized liquid mixture. Sodium Silicate shall be compatible with the applicable grout mix(es) and compliant with applicable regulations, and shall be available in sufficient quantity such that grouting is not interrupted by lack of supply.

2.2 CONTAINMENT BARRIERS

The grout-containment barriers shall be of a material and design such that they will fit the timber crib surface and restrict the escape of grout from the timber crib. Forms shall be of sufficient strength and design to contain the grout materials. Barriers may be constructed of wood, steel, impermeable geotextile or other material accepted by the COR and may be single-use or reusable. Barriers shall be removed upon completion of the

SECTION 35 31 25 Page 13 work.

SECTION 35 31 25 Page 14

PART 3 EXECUTION

3.1 COMPATIBILITY TEST PROGRAM AND DRILLING AND GROUTING WORK PLANS AND

PREPARATORY ITEMS

3.1.1 General

The Work Plans shall include, but not be limited to a working schedule of activities; a personnel chart identifying key personnel, points of contact and their responsibilities; a detailed list of equipment and materials to be used; plan view, shop drawings, and sections identifying the features of the work area including floating plant, trailers, grout plants, storage areas, staging areas and the grout curtain details; proposed sequence of drilling, and grouting. The Work Plan shall include details of the sequence of: compatibility tests, mix designs, drilling, grouting grout holes, anticipated staffing and shifts, identification of key milestones and a list of assumptions and a discussion of their potential impacts on the course of work.

3.1.2 Compatibilty Test Program Work Plan

Not less than 30 days prior to the start of the applicable portion of the work, the Contractor shall prepare and submit a Compatibility Test Program Work Plan. The Compatibility Test Program shall be designed by the Contractor to develop and demonstrate the functionality and performance of the sodium silicate/portland cement-based grout to be used to contain the interior grout mixes within the breakwater, and determine the appropriate mixing and pumping procedures.

3.1.3 Drilling and Grouting Work Plan

The Drilling and Grouting Work Plan shall include descriptions and details of equipment, labor and material descriptions and the protocols to be followed in completion of the work. Equipment details shall include but not be limited to drilling equipment, packers, gages, Grout Data Logger(s), transducers, pumps, hoses, drills, drill bit size and type, stabilizers, and any equipment that will impact the quality of the work.

The mix designs for the sanded portland cement consolidation grouts shall also be included in the submittal. Included in the Work Plan shall be calibration methods for gages, flow meters, and head loss plots at various pressures and flow rates for the grouting system, and any additional equipment details requested by the COR. The general work sequences and procedures for all aspects of drilling, flushing, and grouting shall be included in the Work Plan. Also included in the Work Plan shall be general guidelines and procedures for identifying and isolating zones of grout take and procedures to be followed in thickening and thinning mixes, the means of providing thicker or thinner mixes expeditiously to the grout hole, and the procedures used to minimize wasted grout. The Work Plan shall include a detailed description of methods and materials the Contractor will use to prevent grout from seeping or spilling into the lake, including any containment materials or spill prevention. Grout entering the lake is considered a water quality violation, see section

01 57 20.01 03 ENVIRONMENTAL PROTECTION FOR ILLINOIS.

3.1.4 Grout Hole Layout

The Contractor shall submit not less than 30 days prior to the start of drilling, a grout hole layout in plan and section that shall present the recommended locations and depths of all grout and verification holes.

SECTION 35 31 25 Page 15

3.2 EQUIPMENT

3.2.1 General

All drilling and grouting equipment used shall be of a type, capacity and mechanical condition suitable for performing the work, as determined by the COR. The power and equipment and the layout thereof shall meet all applicable requirements of local, State, and Federal regulations and codes, both safety and otherwise.

3.2.2 Drilling Equipment

Drilling equipment shall be suitable for operation on the narrow breakwater cap surface and shall be operated using only air and/or water as drilling fluid. Standard pneumatic portable drills of the rotary percussion type or diamond rotary shall be used to perform the drilling as specified in paragraph GROUT HOLES. Diesel or gasoline operated equipment shall not be used on the breakwater; however diesel-powered air compressors located on the Contractor's floating plant are permitted. The Contractor shall prevent the discharge of oils, hydraulic fluid, or any other non-water liquids into the lake in the course of drilling and grouting. The drilling equipment shall be of configuration, size and weight that will not damage the breakwater structure.

Supplies shall include all bits, drill rods, hoses, tools, casing, piping, pumps, other equipment, compressed air, water, and power to accomplish the required drilling. All drilling rigs and pumps shall be equipped with pressure gages.

Coring equipment shall be capable of obtaining intact concrete and grouted riprap stone core to depths of at least 15-feet. Drilling for core shall be done using only water as a drilling fluid. Core shall be a minimum of 3-inches in diameter, and will be used to evaluate the breakwater condition and performance of grouting procedures. Coring shall be conducted after the first 100-feet of breakwater is grouted to completion, and the degree to which voids are filled with grout.

3.2.2.1 Drilling Conditions

The drilling equipment for the grout holes shall be capable of drilling through at least 12 feet of concrete. The logistics of the work area are such that the crown of the structure is rounded and uneven concrete that is over 50-years old, and the toe blocks are more narrow and weathered than the crown. The concrete includes steel reinforcement that is partially exposed, but is not always exposed enough to visually determine the location, nor is it spaced regularly enough to visually estimate locations to avoid encountering them during drilling. The Contractor may consider using a metal detector or magnetometer of some kind to determine final locations of grout holes, if drilling through reinforcement is likely to impede drilling progress.

3.2.3 Grouting Equipment

3.2.3.1 Grout Plant

Each grout plant shall be capable of supplying, mixing, stirring and pumping the grout and additives, to the satisfaction of the Contracting

SECTION 35 31 25 Page 16

Officer Representative. The plant shall have a minimum capacity of 30 cubic feet of grout injected at a pumping pressure not greater than 40 psi measured at the plant and shall have the capability of pumping at controlled and consistent rates from 1 to 10 cubic feet per minute. The grout plants shall be maintained at all times and any grout hole that is lost or damaged due to mechanical failure of equipment or inadequacy of grout supply shall be replaced by another hole, drilled by the Contractor at no additional cost to the Government. The amount of grouting equipment shall be as necessary to perform the work specified herein. The type to be furnished shall include, but need not be limited to the following:

a. A pump capable of generating pressures up to 40 psi measured at the plant while pumping from 1 up to 10 cubic feet per minute.

b. A mechanical type grout mixer having a minimum drum capacity of approximately 10 cubic feet . The grout mixers shall be capable of effectively mixing sanded pea gravel and portland cement grout having water to cement ratios of 0.5:1 to 2:1 measured by weight.

c. A separate colloidal mixer for mixing and hydrating bentonite. The bentonite shall be hydrated a minimum of 12 hours prior to use.

d. A mechanically agitated storage tanks capable of agitating and holding in suspension all solid matter contained in the grout.

e. A minimum of 3 (three) grout headers with control valves and a pressure gage with protector for each, if included in the Work Plan.

If included in the Work Plan, control valves shall be connected to the return line and header. The header shall be joined directly to the riser pipe or grout pipe at the hole by means of a quick connector union.

f. A separate water pump and/or storage tank or suitable source of clean auxiliary water for use in washing and flushing operations.

g. A water meter graduated in cubic feet and tenths having a direct reading totalizer and capable of conveniently being set back to zero.

h. Such valves, packers, pressure gages, pressure hose, supply lines, and small tools as may be necessary to provide a continuous supply of grout at accurately controlled pressures as specified. The inside diameter of the pressure hose and grout supply line shall be not less than 1 inch . An accurately calibrated, high precision master pressure gage shall be used to check the accuracy of all gages used in the grouting. Gages shall be checked at least every 24 hours, or more frequently if the COR so determines using the master gage. When defects are found, grouting operations will be stopped until calibration of gages has been obtained. The Contractor shall maintain a ready supply of packers and other accessories appropriate for the work. A sufficient supply of mechanical packers shall be provided for the purpose of preventing debris from entering or grout escaping the grout holes and to seal open holes awaiting grouting.

i. Means of verifying accurately and routinely that grout components have been mixed correctly and completely.

j. A means of measuring quantities of all materials used in grouting operations, including components of grout injected and wasted.

SECTION 35 31 25 Page 17

k. A means of recording the quantity and times of grouting.

3.3 GROUT CONTAINMENT

Grout containment shall be accomplished by a combination of the use of silicate-cement grout containment barriers installed along outer rows and a physical barrier of the contractor's design on both lakeward and harborsides of the breakwater. Additionally, the Contractor shall adjust the grout mixes and pump rates immediately if it is determined that the grout is too thin to be contained by the measures taken. Unless otherwise directed by the COR, a maximum injection of 8 cubic yards of grout per hole shall not be exceeded. Placement of the containment measures shall precede drilling and grouting by 50 feet.

3.4 GROUT HOLE DRILLING

3.4.1 General

The general sequence of drilling, shall proceed as approved in the Drilling and Grouting Work Plan, within the guidelines of the paragraphs of this Paragraphs of this Section entitled SEQUENCING AND SCHEDULING OF DRILLING AND GROUTING or as directed by the COR. Upon approval of the COR, the Contractor may drill both the lakeward and harborside rows of the grout holes. The grout holes in the outer rows (Rows A and E) shall be a minimum of 3 inches in diameter. Grout holes shall be drilled through the concrete cap, the thickness of which varies, but is not expected to be more than 12 feet. Whenever practical, the Contractor shall drill sufficient grout holes ahead of time such that there are enough grout holes remaining ungrouted to occupy the shift's grouting operations in a continuous manner.

Grout the entire lakeward row (Row A) of grout holes prior to the harborside (Row E)holes.

Once the lakeward and harborside grouting is complete, drill the inner rows of the grout curtain. Interior holes shall have a minimum diameter of 3 inches. Grouting shall begin at one end of the grout curtain and proceed along the breakwater in groups of three holes, until the entire section is completely grouted.

If necessary, split spaced holes shall be drilled at the locations and in the sequence directed by the COR.

3.4.1.1 Drilling Log and Records

The Contractor shall submit complete, legible records of the locations, depths and designations of all grout holes drilled on a weekly basis, or at any time directed by the COR. The updated tables on sheet C102 may be used for this purpose and also need to be maintained for As-Built documents.

3.4.2 Location and Depth

The Contractor shall drill grout holes at the locations and to the depths as directed by the COR. Grout holes shall be drilled through the concrete cap, which is believed to be no more than 12 feet; however the Contractor shall be prepared to drill to depths at least 15 feet, as a contingency.

The locations shall be within 0.25 foot (location of center of borehole) of the directed location. In the event that the Contractor drills beyond

SECTION 35 31 25 Page 18 the approved depth, he shall grout the hole as directed by the COR, and will not be paid for the costs of drilling or grouting of the hole.

3.4.3 Casing for Grout Holes

3.4.3.1 Casing

Casing may be used at the discretion of the Contractor as an incidental item and no separate payment will be made for casing. All casing shall be removed or cut off flush with the top of concrete at the end of the work.

3.4.3.2 Casing Installation

Casing pipe shall be installed through the concrete and shall be thoroughly grouted. Installation shall include all equipment, grout and casing materials.