Spec_35_31_19_A0002.pdf

REPAIRS TO STONE DIKE, PLYMOUTH LONG BEACH,

PLYMOUTH, MASSACHUSETTS

AMENDMENT 0002

AUGUST 2016

SECTION TABLE OF CONTENTS

DIVISION 35 - WATERWAY AND MARINE CONSTRUCTION

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STONE DIKE REPAIRS

PART 1 GENERAL

1.1 SUMMARY

1.2 REFERENCES

1.3 SUBMITTALS

1.4 WORK PLAN

1.5 QUALITY ASSURANCE

1.5.1 As-Built Cross-Sections

1.5.2 New Armor Stone

1.5.2.1 Quality of Stone

1.5.2.2 Source of Stone

1.5.2.3 Stone Samples

1.5.2.4 Evaluation Testing of Stone

1.5.2.5 Drop Test

1.6 CONSTRUCTION TOLERANCES

PART 2 PRODUCTS

2.1 NEW ARMOR STONE

2.1.1 Weight of New Armor Stone

2.1.2 Proportional Dimension Limitations

PART 3 EXECUTION

3.1 GENERAL

3.2 DEMONSTRATION SECTION

3.3 STOCKPILING OF ARMOR STONE

3.4 REHANDLING OF STONE

3.5 REUSE OF EXISTING STONE

3.5.1 Stones To Be Reused

3.5.2 Condition of Reused Stone

3.6 PLACEMENT OF ARMOR STONE

3.6.1 Existing Armor Stones in Non-Repair Areas

3.6.2 Chinking Of Void Spaces

3.6.3 Placement of Armor Stone at Major Repair Areas

3.6.4 Resetting of Existing Stones at Minor Repair Areas

3.6.5 Slides

3.7 TESTS AND INSPECTIONS

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SECTION 35 31 19

STONE DIKE REPAIRS

PART 1 GENERAL

1.1 SUMMARY

a. The work covered by this section of the specifications consists of providing all supervision, plant, labor, materials, tools and equipment, safety, quality control, and mobilization and demobilization necessary to perform all work required to repair the existing stone dike.

b. The work required to repair the existing stone dike shall be completed in accordance with the contract drawings and contract specifications.

The work includes the moving, handling and rehandling, retrieving, and resetting of existing stone, the filling of voids with existing displaced existing stone, and providing and setting new quarried armor stone. A substantial amount of rehandling of existing stones and new armor stone where applicable) will be required to satisfactorily place (to key-in and interlock) each repair stone within specified construction tolerances. The removal, readjustment, and rehandling of existing stone and the removal, setting, and resetting of new armor stone shall be done by foreman, crane operators and a spotter experienced in stone setting. Chinking of armor stone with small stone is prohibited as part of this work.

c. The Contractor shall work and make repairs from the landward (west) side of the existing stone dike. The Contractor will not be permitted to work along the top crest or on the seaward side of the existing stone dike.

d. The Contractor shall provide sufficient equipment to lift, move, adjust, reach, and/or set in place existing and new armor stone as specified on the contract drawings.

1.2 REFERENCES

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

ASTM INTERNATIONAL (ASTM)

ASTM C 127 (2012) Standard Test Method for Density, Relative Density (Specific Gravity), and Absorption of Coarse Aggregate

ASTM D 5312 (2013) Evaluation of Durability of Rock for Erosion Control Under Freezing and Thawing Conditions

INTERNATIONAL SOCIETY OF ROCK MECHANICS (ISRM)

ISRM Method 3 (2005) Unit Weight, Porosity and Specific

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Gravity of Rock

1.3 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

Source of Stone ; G, DO

The Contractor shall submit the source(s) for all stone proposed for use on the project.

Work Plan ; G, RO

SD-04 Samples

Stone Samples ; G, DO

The Contractor shall submit samples of all stone proposed for use on this project.

SD-06 Test Reports

Evaluation Testing of Stone ; G, DO

Demonstration Section ; G, DO

SD-07 Certificates

Qualifications ; G, RO

The Contractor shall submit resumes of the foreman and the crane operators who are to perform the stone handling and setting operation. The setting of stone shall be performed by a foreman and crane operator who have experience in the construction of massive stone structures such as dikes, breakwaters, and jetties;

the foreman shall have eight jobs and the crane operators shall have five jobs prior experience.

1.4 WORK PLAN

a. Prepare and submit a Work Plan to the Contracting Officer. The plan must be accepted and approved by the Contracting Officer prior to the start of any construction.

b. The plan shall include the names of all personnel working on site, their job title and job description, and the number of years of associated construction work experience on similar stone structures.

c. The plan shall detail how the work will be achieved to meet the requirements of the contract drawings and specifications. Details of the work shall include:

(1) The type of equipment to be used.

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(2) Where and how the equipment will be set up along the stone structures and how the areas of repairs will be accessed from.

(3) The methods used for stone removal, placement, adjustment, or resetting.

(4) The methods proposed for reworking portions of the stone structure found to be outside the construction tolerances.

(5) The name of the company establishing control points and performing the as-built surveys, the name of the registered land surveyor, the names of the personnel performing the surveys, and their job title and job description.

(6) The frequency of both the as-built survey efforts and the submittal of data to the Contracting Officer.

d. As part of the plan, provide detail on work methods, procedures, and materials to be used to protect the integrity of existing stones along the stone structures that are not part of the repair work or are not to be disturbed as part of this contract, but which may be impacted or damaged by construction operations.

1.5 QUALITY ASSURANCE

1.5.1 As-Built Cross-Sections

The Contractor shall provide as-built cross-sections in accordance with Section 01 71 23 FIELD ENGINEERING.

1.5.2 New Armor Stone

1.5.2.1 Quality of Stone

All stone shall be durable material as approved by the Contracting Officer. Stone shall be of a suitable quality and be limited to fine to coarse grained metamorphic or igneous rocks to ensure permanence in the structure and in the climate in which it is to be used. Slabs and rounded stones will be rejected. The stone shall be of irregular and angular shape. It shall be free from cracks, blast fractures, bedding, seams, fissures, solution cavities or other defects that would tend to increase its deterioration from natural causes. Inspections for cracks, fractures, seams and defects shall be made by visual examination during the stone selection process at the stone source. If, by visual examination, it is determined that 20 percent or more of the stone produced contains hairline cracks, then all stone produced at that source by the means and measures which caused the fractures shall be rejected. A hairline crack that is defined as being detrimental is visible to the naked eye (aperture of approximately 4 mils) and continuous for one-third the dimension of at least two sides of the stone. The stone shall be clean and adequately free from all foreign matter. Any foreign material adhering to or combined with the stone as a result of stockpiling shall be removed prior to placement.

1.5.2.2 Source of Stone

a. Selection of Source. The Contractor shall submit the source for all stone materials used in the project. The Contractor shall designate

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in writing only one source or one combination of sources from which stone is proposed to be furnished. It is the Contractor's responsibility to determine that the stone source or combination of sources selected is capable of providing the quality, quantities and gradation needed and at the rate needed to maintain the scheduled progress of the work. Samples for acceptance testing shall be provided in accordance with paragraph EVALUATION TESTING below. If a source for stone so designated by the Contractor is not accepted for use by the Contracting Officer, the Contractor shall propose other sources.

b. Acceptance of Materials. Acceptance of a source of stone is not to be construed as acceptance of all material from that source. The right is reserved to reject materials from certain localized areas, zones, strata, or channels, within the approved source when, in the opinion of the Contracting Officer, the stone is disintegrated, badly weathered, or otherwise unsatisfactory for use in the work. The Contracting Officer also reserves the right to reject individual units of produced specified materials in stockpiles at the quarry, all transfer points, and at the project construction site when such materials are determined to be unsuitable. Materials produced shall meet all the requirements herein. During the contract period, both prior to and after materials are delivered to the job site, visual inspections and measurements of the stone materials may be performed by the Contracting Officer. If the Contracting Officer, during the inspections, finds that the stone quality, gradation or weights of stone being furnished are not as specified or are questionable, re-sampling and re-testing are required. Sampling of the delivered stone for testing and the manner in which the testing is to be performed shall be as directed by the Contracting Officer. This additional sampling and testing shall be performed at the Contractor's expense when test results indicate that the materials do not meet specified requirements. When test results indicate that materials meet specified requirements, an equitable adjustment in the contract price will be made for the sampling and testing. Any material rejected on site shall be removed from the site by the CONTRACTOR and returned to the quarry named and weighed with a weight slip, and disposed of as specified and at the CONTRACTOR's expense.

1.5.2.3 Stone Samples

a. Suitable stone samples shall be submitted for approval to the Contracting Officer prior to delivery of any such material to the worksite. Samples shall be composed of approximately 25 pound pieces of representative rock, one piece for each type of rock and each stone source planned for use.

b. The samples shall be suitably identified by number and quarry name.

Submitted samples shall be accompanied by letter, in triplicate, setting forth sample designations, name of quarry, ownership of quarry, location of samples from within the quarry, method of sampling, and, if available, record and method of tests, geologic descriptions, and history of use in marine construction. The Contractor shall provide photographs of the quarried stone stockpile.

c. In the event that the Contractor proposes to furnish stone from an undeveloped source, or a source open by minor quarrying or prospecting, the area proposed for development shall be adequately explored to the satisfaction of the Contracting Officer by means of

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"NX" (3 inch) size core drilling to the limits and full depths of expected production. The Contractor shall locate the borings by surveys, and the entire footage of recovered cores shall constitute the samples and shall be suitably boxed and marked as to elevations, depths, and core losses. Submittal of core samples shall be accompanied by three copies of a plan showing locations and elevations of borings together with detailed logs of boring operations.

Drilling, blasting, and sampling of stripped or naturally exposed areas of the bedrock surface which present prominent faces suitable for trial quarrying may serve as a partial alternative to the core drilling method of exploration and sampling, as approved by the Contracting Officer.

1.5.2.4 Evaluation Testing of Stone

a. The acceptability of the stone shall be determined from existing test reports available from the stone supplier, or by tests performed at the Contractor's expense, and by geologic examination of samples from the quarry. Tests performed shall be at the Contractor's expense for proposed sources of stone which do not have suitable existing test reports, such as newly opened, or long abandoned quarries and undeveloped sources, and for existing tests that are more than 2 years old. Existing test report results, or new tests to which the stone shall be subjected, shall include specific gravity, unit weight, absorption, and freezing and thawing. The tests shall be conducted in accordance with ISRM Method 3 (or ASTM C 127 and ASTM D 5312 ). The Contractor shall submit a copy of the required test reports, which shall be approved by the Contracting Officer prior to delivery of such material to the worksite.

b. Samples of stone for evaluation testing shall be taken by a representative of the Contractor under the supervision of the Contracting Officer for testing and acceptance prior to delivery of any stone from this source to the site of the work. Samples shall consist of at least three pieces of stone, roughly cubical in shape and weighing not more than 25 pounds each from each unit that will be used in the production of the required stone. The Contractor shall confirm the sample quantity and size required by the testing laboratory as their sample requirements may differ from that shown in the specifications. If the source is an undeveloped quarry, or if the operation has been dormant for more than one year such that fresh samples are not available, expose fresh rock for 20 feet horizontally and for the full height of the face proposed for production, prior to the field evaluation. The Contracting Officer may also require documentation of subsurface exploration of an undeveloped quarry in order to determine whether or not sufficient reserves are available.

Stone from an existing stockpile may also used as long as fresh stone samples can be obtained for geotechnical testing. The samples shall be shipped at the Contractor's expense to a local Geotechnical Testing Laboratory for analysis.

c. As noted above, the COR will not accept existing test reports that are more than 2 years old.

1.5.2.5 Drop Test

A drop test shall be performed for each type and source of stone proposed for use. This test shall be performed under the supervision and observation of the Contracting Officer. This test provides an immediate

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evaluation of the durability of very large stones during handling, including placement into a structure. For comparability, the test stone(s) shall be dropped from a bucket or by other means from a height of not less than half the average diameter of the stone onto a hard rigid surface or second stone of comparable size. Dumping from a truck is not acceptable. The stone shall be examined carefully before as well as after the completion of the test. Failure criteria is the development of new cracks, opening of old cracks, and the loss of larger pieces from the surface (i.e., flaking and spalling) of the stone. Each test stone shall be dropped a total of five times for evaluation purposes with examination after each drop. Provide all necessary equipment and operating personnel to perform the testing. Flaking and spalling of the stone can occur and are acceptable as long as they do not significantly affect the final weight of the stone. The COR shall have final determination.

1.6 CONSTRUCTION TOLERANCES

a. The finished surfaces (top of crest and side slopes) of the armor stone shall not deviate from the lines and grades shown by more than the tolerances listed below. Tolerances are measured perpendicular to the indicated neatlines. Extreme limits of the tolerances given shall not be continuous in any direction for more than five times the nominal stone dimension nor for an area greater than 100 square feet of the structure surface, unless otherwise noted on the contract drawings or approved by the Contracting Officer.

NEATLINE TOLERANCES:

MATERIAL ABOVE NEATLINE (INCHES) BELOW NEATLINE

(INCHES)

Crest Armor Stone 6 6

Side Slope Armor Stone 12 6

b. The intention is that the work shall be built generally to the required elevations, slope and grade as shown or specified on the contract drawings, and with a slightly irregular, not flat or smooth, surface. Placed material not meeting these limits shall be removed or reworked as directed by the Contracting Officer.

c. Allowable construction tolerances shall not be used to expand the footprint of work beyond the limits required to establish the finished grade shown on the contract drawings. Tolerances will be used as a means to provide minor flexibility with the construction without the need for the Contracting Officer to reject the work at each repair area over the possibility of a few select armor stones occasionally projecting above or below the finished grade noted on the contract drawings.

PART 2 PRODUCTS

2.1 NEW ARMOR STONE

2.1.1 Weight of New Armor Stone

The stones furnished for new armor stone shall weigh between 3 tons and 5 tons each, and shall be free of fines and any attached debris. 50 percent of the stones shall weigh greater than 4 tons each. New armor stones

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shall have a density of more than 162 pounds per cubic foot.

2.1.2 Proportional Dimension Limitations

The maximum aspect ratio (greatest dimension:least dimension) of any piece of new armor stone for size ranges shall be not greater than 3H:1V when measured across mutually perpendicular axis. Not more than 25 percent of the new armor stones shall have an aspect ratio greater than 2.5H:1V. The new armor stone shall be of irregular and angular shape; however, not more than 25 percent may be roughly rectangular.

PART 3 EXECUTION

3.1 GENERAL

a. Prior to the placement of any material, the Contractor shall establish construction control markers, clearly visible and understandable to the workers placing the material. The surface areas upon which armor stone materials are to be placed shall be trimmed and dressed to conform to the lines, grades, and cross-sections specified in the contract documents, or as modified, to within the tolerances specified herein. Immediately prior to the placement of armor stone material, the surface upon which it is to be placed will be inspected and no material shall be placed thereon until the surface has been approved.

b. Previously accepted areas which are subsequently damaged by the Contractor's operations shall be repaired at the Contractor's expense.

c. The Contractor shall remove any sand that has been blown or washed onto the armor stones. Armor stones shall not be placed on sand.

Sand which has been removed shall be placed along the toe on the landward side of the existing stone dike. Sand shall not be placed on the seaward side of the existing stone dike.

3.2 DEMONSTRATION SECTION

a. The Contractor shall construct a demonstration section for approval by the Contracting Officer. The demonstration section shall be approved by the Contracting Officer prior to the start of any other work or repairs to the existing stone dike.

b. The most northerly major repair area shall be used as the demonstration section. The demonstration section shall meet the requirements of the contract documents and be within acceptable tolerances. Prior to inspection of the completed demonstration section by the Contracting Officer, the Contractor shall notify the Contracting Officer in writing and submit as-built cross-sections of the completed demonstration section.

c. Deficiencies noted in the inspection shall be corrected, at no additional cost to the Government, by the Contractor until the demonstration section has been successfully completed and approved.

Additional time will not be granted for any reconstruction work required to correct deficiencies. The Contracting Officer shall be the sole judge as to the acceptability of the demonstration section.

After acceptance of the demonstration section by the Contracting Officer, construction may proceed on the remaining work along the existing stone dike using the demonstration section as a baseline

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3.3 STOCKPILING OF ARMOR STONE

a. New armor stone delivered to the work site that requires temporary storage shall be placed within the Contractor's temporary staging and storage areas.

b. Existing armor stones that are to be removed and stockpiled prior to rebuilding the stone dike, shall be stockpiled on the landward side of the existing stone dike and be kept separate from new armor stones.

c. Upon completion of the work and after the armor stone has been removed, armor stone storage areas shall be cleaned of all storage residues and restored to the condition that existed prior to construction. The Contractor will be required to repair any damages to the pavement or other features of the site at no additional cost to the Government.

d. Storage of armor stone at the worksite is not to be confused with off-site stockpiling of stone. If the Contractor elects to provide off-site stockpiling areas, the Contracting Officer shall be notified of all such areas.

e. Armor stones shall not be stockpiled on any pavement or concrete areas.

3.4 REHANDLING OF STONE

The Contractor shall shift, or remove and reset, a large number of new and existing armor stones adjacent to, underneath, and within each repair area to ensure the best possible interlocking and firm embedment of the repair (new or reused) stone. The costs for rehandling of stone are considered incidental and shall be included in the appropriate line item in the bid schedule.

3.5 REUSE OF EXISTING STONE

a. The Contractor shall reuse all existing armor stones within the repair areas to include all those displaced along the landward and seaward side slopes of the existing stone dike. The reused existing stones shall be reset ensuring the best possible interlocking and firm embedment to achieve minimum void spaces and the required construction tolerances at the repair area. The Contractor shall incorporate new armor stones as needed to replace either existing stones that are deemed not reusable or displaced stones that are no longer within the repair areas.

b. (AMENDMENT 0002) The existing armor stones may vary in size from approximately 1 ton to 10 tons.

3.5.1 Stones To Be Reused

a. The Contractor shall utilize all existing suitable stones for reuse even if the existing stones are not in the size range noted above under paragraph titled "Reuse of Existing Stone".

b. Existing stones do not need to meet the requirements of new armor stone as noted above in Part 2 under paragraph titled "New Armor Stone".

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3.5.2 Condition of Reused Stone

a. Existing suitable stones shall be free from open cracks, seams and fissures, and from porous structure, solution cavities, structural planes of weakness and from component minerals and cementing or bonding materials that might contribute to spalling or breakdown from handling and placing. The COR will make the final determination as to whether an existing stone is not suitable for reuse. The COR's determination will be final.

b. Existing armor stones that are deemed unsatisfactory for reuse shall be placed along the toe on the landward side of the existing stone dike. Stones shall not be placed on the seaward side of the existing stone dike.

3.6 PLACEMENT OF ARMOR STONE

The Contractor shall employ the services of a spotter at the site of the armor stone placement to ensure that each armor stone is placed in accordance with the contract documents.

3.6.1 Existing Armor Stones in Non-Repair Areas

Existing armor stone in adjacent non-repair areas shall be removed as necessary to incorporate the repaired areas and shall be reset as part of the work to ensure interlocking of all stones; refer to General Repair Notes on contract drawing sheet C-303. Existing stones that are to be reused and reset shall meet the requirements as noted above under the paragraph titled STONE TO BE REUSED otherwise the existing stone shall be rejected. All reworked existing armor stone shall be interlocked and placed within the limits and elevations as specified in the contract documents, including allowance for tolerances.

3.6.2 Chinking Of Void Spaces

Chinking of void spaces using smaller stones or other material is not allowed at either the major or minor repair areas.

3.6.3 Placement of Armor Stone at Major Repair Areas

a. Refer to Major Repair Area Notes on contract drawing sheet C-303.

b. Armor stones shall be:

(1) Selected with care as to size and shape and key-in, meaning that the armor stones selected are able to provide for the required minimum interlocking. New armor stones (reusable existing armor stones are excluded) shall be generally rectangular in cross section, the least dimension of any stone not being less than one-third its greatest dimension.

(2) Placed individually keyed and fitted into the structure by equipment suitable for handling, lifting, manipulating, rotating, and placing stone of the size specified to the lines and grades as specified in the contract documents, including allowance for tolerances. The equipment used in placing the armor stones shall also have the ability to hydraulically rotate the armor stone 360 degrees in one motion while suspended, place the stone, and if necessary pick up and reposition the stone. Dragline buckets and

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skips shall not be used in placement. Moving stone by drifting or manipulating down the slope will not be permitted. Unless otherwise specified, armor stone shall not be dropped from a height greater than 12 inches.

(3) Placed such all vertical joints are staggered and not continuous from the lower stone layers to the upper stone layers.

(4) Placed such that the surface of armor stone at the crest shall be set to provide a reasonably flat and level top surface with no individual armor stone surface to vary more than 12 inches from the top surface of any new or existing adjacent interlocking armor stones comprising the crest.

c. The minimum interlocking of stone shall be that all major faces of the set stone will be touching adjacent stones including the bottom face (face closest to the structure with no bridging of gaps). Each set stone shall not move or rock in place. The maximum dimension for void space between adjacent stones shall be 12 inches, unless otherwise accepted by Contracting Officer.

d. In general, the long axis of each stone shall be placed perpendicular to the axis of the structure and slope downward toward the center of the structure. The Contractor shall begin placement at the bottom of the slope. The heaviest stones shall be placed as toe stones.

e. New and reset existing armor stones shall be placed on a prepared stable surface using equipment suitable for handling the sizes of armor stone indicated without damage to either new or existing armor stones.

f. Any new armor stone that is deposited outside the lines and grades as specified in the contract documents or elsewhere other than in places designated or approved by the Contracting Officer will not be paid for, and the Contractor will be required to remove the misplaced armor stone and reinstall as required at no additional cost to the Government.

g. Avoid creating flat final surfaces by using smaller stones, as the smaller stones will eventually be moved out of the structure creating degradation and movement of the larger stones.

h. Avoid placing the largest face of the outermost stones parallel to the design lines and grades of the structure.

i. The Contractor shall interlock armor stone placement with the existing construction that is not a part of the repair work of this contract.

j. The Contractor shall anticipate that re-handling of individual armor stones after initial placement will be required to achieve the requirements of subparagraph titled "Placement of Armor Stone."

k. The finished work shall be a well-distributed mass, free of pockets of either smaller or larger stones, having a minimum of voids, and with a maximum of interlocking stones. The mass of stone shall follow the lines and grades as specified on the contract drawings.

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3.6.4 Resetting of Existing Stones at Minor Repair Areas

a. The work also consists of moving and resetting existing armor stones at minor repair areas along the existing stone dike. Existing stone shall be moved and reset to achieve minimum void spaces and the required minimum interlocking with adjacent existing armor stone and, if required, any newly placed armor stone. Removing, resetting, and interlocking of existing armor stone shall be in accordance with applicable portions of the paragraph above titled "Placement of Armor Stone at Major Repair Areas" and as specified on the contract drawings. Temporary storage may be necessary between lifting and final placing.

b. Refer to Minor Repair Area Notes on contract drawing sheet C-303.

3.6.5 Slides

In the event of the sliding or failure of any part of the repaired areas during its construction, or after its completion, but prior to its acceptance, the Contractor shall cut out and remove the slide from the structure and then rebuild that portion of the structure with new materials or reuse the displaced materials for rebuilding if deemed appropriate. The COR will determine the nature and cause of the slide.

In case the slide is caused through fault of the Contractor, the foregoing operations shall be performed at no additional cost to the Government.

3.7 TESTS AND INSPECTIONS

Establish and maintain quality control for all work performed at the job site under this section to ensure compliance with contract requirements.

Maintain records of the quality control tests, inspections and corrective actions. Quality control measures shall cover all construction operations including, but not limited to, the placement of all materials to the slope and grade lines shown on the contract drawings and in accordance with this section.

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