ML20090J595
| ML20090J595 | |
| Person / Time | |
|---|---|
| Site: | Midland |
| Issue date: | 08/02/1979 |
| From: | BECHTEL GROUP, INC. |
| To: | |
| Shared Package | |
| ML17198A223 | List:
|
| References | |
| CON-BOX-05, CON-BOX-5, FOIA-84-96 7220-C-95(Q), NUDOCS 8405230049 | |
| Download: ML20090J595 (66) | |
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E CHTEL ASSOCIATES PRCTESSIONAL CORPORATION EXHIBIT D
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TECHNICAL SPECIFICATION
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UNDERPINNING, EXCAVATION, AND PLACING OF CONCRETE
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DATE REv SIONS f BY CHK'D AFD NO.
DATE REVISIONS SY CH K'D AFD FACING SHEET UNDERFINNING, EXCAVATION, AND PLACING 0F
,, y, CONCRETE CONSUMERS POWER COMPANY C-95(Q) 0 HIDLAND POWER PLU.T UNITS 1 AND 2 l
MIDLAND, MICHICAN
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Spscification 7220-C-95 (0) f. Rev 0 TECHNICAL SPECIFICATION FOR
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- UNDERPINNING, EXCAVATION, AND PLACING OF CONCRETE CONTENTS
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1.0 SCOPE 1
2.0 ABBREVIATIONS 3
3.0 CODES, STANDARDS, AND REFERENCES 3
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4.0 DOCUMENTATION REQUIREMENTS 4
5.0 MATERIAL REQUIREMENTS S
6.0 DESIGN PARAMETERS 5
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7.0 PILE AND CAI? SON LOAD TESTING 9
8.0 UNDERPINNING AND SUPPORT OF STRUCTURES 11 9.0 WELDING 22
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10.0 EXCAVATION 22 11.0 CCNCRETING 26 12.0 CLEANING AND RESTORATION 27 13.0 QUALITY ASSURANCE REQUIREMENTS 28
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14.0 MEASUREMENT OF PAYMENT 28 APPECICS
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A QUALITY ASSU1WG REQUIRDEMS FOR Q-LISIID IHMS AND NORK g
B SPECIFICATICN 7220 C-231' (Q) *FtEMING, PIACING FINISRING Alt CIRING T CCNCRE:E" PAGES 22, 23, 24, 25,
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Spscifi. cation 7220-C-95(Q), Rav 0 i
1.0 SCOPE 1.1 ITEMS INCLUDED The following work to be performed in accordance with this subcontract is located at Midland Plant Units 1 and 2.
This specification includes Q-listed work where specifically noted and is to be performed in accordance with Subcontractor's QA program:
1.1.1 Underpinning the auxiliary building penetration rooms with caissons in the area indicated in the drawings 1.1.2 Removal of all unsuitable material as determined by Contractor and replacement of all removed material with concrete from under the feedwater valve pits 1.1.3 In addition, the following items are j
included under the scope of this i
I subcontract:
a.
Submit all drawings, calculations, and detailed procedures for a proposed type and method of underpinning which is best suited for the intended purpose and, as a minimum, meets all of the applicable criteria specified herein.
b.
Furnish all lEbor, material, tools, equipment, supervision, design, and procedures to perform all operations and incidentals necessary to complete the work to the satisfaction cf Contractor.
c.
Provide (design, furnish, and install) local dewatering to remove and control all water which could cause soil movement.
d.
Provide (design, furnish. and 4
install) permanent support under the auxiliary building penetration rooms capable of withstanding approximately 4,000 kips vertical load at locations shown in the drawings without exceeding a 1/2-inch settlement (movement) of 1
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Specification 7220-C-95(Q), Rev 0 l
the structure at points indicated in the drawings.
e.
Provide (design, furnish, and install) permanent support under the turbine building along the K line to support the column and i
slab loads at columns 1
2.0,2.5, and 3.0 for Unit 1 and 10.0, 10.5, and 11.0 for Unit 2, resulting from and including the temporary support of the valve pits as indicated in the drawings.
f.
Provide hydraalic jacking capacity sufficient to simultaneously lift approximately 4,000 kips of structural load utilizing the permanent support as a reaction point.
1 g.
Provide lateral support for the soil in the zone of influence resulting from excavation made during underpinning to prevent soil movement.
h.
Place and cure lean concrete backfill under the designated buildings including encasement of the permanent caissons.
i.
Provide positive contact between the underside of the building foundation and the lean concrete backfill by methods acceptable to contractor.
j.
Install styrofoam or similar material as indicated on the drawings.
k.
Monitor the buildings for settlement.
1.2 ITEMS NOT INCLUDED BUT PERFORMED BY OTHERS 4
1.2.1 Area dewatering prior to underpinning and excavation 2
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Specification 7220-C-95(Q), Rev 0 1.2.2 Temporary support (above the ground) of the feedwater valve pit for Units 1 and 2 as indicated in the drawings.
1.2.3 Disposing of the waste material from a stock pile to be located at the ground surface near subcontractor's access shaft.
1.2.4 Furnishing and testing of lean concrete backfill 1.2.5 Furnishing and testing structural concrete
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1.2.6 Furnishing reinforcing steel 1.2.7 Furnishing styrofoam 1.2.8 Soil testing 1.2.9 Monitoring the auxiliary building for cracks 2.0 ABBREVIATIONS ACI American Concrete Institute AISC American Institute of Steel Construction ASTM American Society of Testing Materials AWS American Welding Society 3.0 CODES, STANDARDS, AND REFERENCES BuildingCodeRequirementsforReinfobced ACI 318-77 Concrete ACI 543-74 Recommendation for Design, Manufacture, and Installation of Concrete Piles AISC Manual of Steel Construction, 7th Edition ASTM A 36-77a Specification for Structural Steel ASTM A 53-77a Specification for Steel, Black and Hot-I Dipped, Zinc-Coated, Welded, and Seamless Pipe ASTM A 252-Specification for Welded and Seamless 77a Steel Pipe Piles 3
Specification 7220-C-95(Q), Rev 0 AWS Dl.1-74 Structural Welding Code Reference 1 Soft Ground Tunneling with Steel Supports, Commercial Shearing Inc., Proctor and White, Youngstown, Ohio, 1977 (used for definition of state and behavioral characteristics of soil) 4.0 DOCUMENTATION REQUIREMENTS 4.1 Engineering and quality verification documents shall be submitted to contractor by the underpinning Subcontractor.
Permission to proceed, based upon Contractor's review of the procedures, does not constitute acceptance or approval of design details, calculations, analyses, test methods, or materials developed or selected by Subcontractor and does not relieve Subcontractor from full compliance with contractual obligations.
The submittal requirements are summarized in Form G-321-D attached.
These requirements are augmented by detailed ~ requirements in this specification.
4.2 As a minimum, Subcontractor shall submit the following procedures (in detail, including hold points and inspection points) to Contractor's satisfaction:
4.2.1 General Underpinning Precedure - This procedure shall include the overall concept.of the work involved, including the interface of-all the operations listed below.
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I 4.2.2 Detection and Monitoring of Structural Movement Procedure 4.2.3 Local Dewatering Procedure 4.2.4 Support of Excavation, Bracing, and Lagging Procedure 4.2.5 Installation of Access Shafts Procedure 4.2.6 Permanent Support Procedure for.
g approximately 4,000-Kip Caisson capacity Installed Under Each Electrical Penetration Room s
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s Specification 7220-C-95(Q), Rev 0 4.2.7 Pile and/or Caisson Installation, Cleaning, Concreting, and Testing Procedure 4.2.8 Lifting Procedure 'for Raising Ends of the Electrical Penetration Rooms Utilizing Approximately 4,000 Kips of Hydraulic Jacking Force 4.2.9 Mass Excavation and Removal of the Material Under the Structures Procedure 4.2.10 Installation of Styrofoam Procedure 4.2.11 Mass Concreting Procedure 4.2.12 Dry Packing / Pressure Grouting Precedure 4.2.13 Soil Grouting Procedure (Chemical and Cement) 4.2.14 Pump Tremie Procedure 4.2.15 Final Cleanup Procedure 4.2.16 Welding Procedures and Qualifications 5.0 MATERIAL REQUIREMENTS Materials shall conform to the above standard specifications, and Subcontractor shall submit to Contractor certified copies of mill test reports of all material used as specified by the applicable ASTM specifications.
5.1 ASTM A 36:
For structural steel and bearing plates 5.2 ASTM A 53:
Types E or.S, Grade B for piles and caissons 5.3 ASTM A 252:
Grade 2 seamless for piles and caissons 6.0 DESIGN PARAMETERS 6.1 PILE AND CAISSON DESIGN Piles or caissons may be used to underpin the turbine building along the K line adjacent to the valve pit structure.
Only caissons shall~
be used to underpin the auxiliary building penetration rooms.
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Specification 7220-C-95(Q), Rev 0 6.1.1 Piles shall be located at a minimum center-to-center spacing of 3.0 feet for 80-ton piles and 3.5 feet for 100-ton piles.
The pile center to the edge of concrete shall be l'3" for 80-ton piles and l'6" for 100-ton piles.
6.1.2 Combination bearing / soldier piles shall penetrate a minimum of 5 feet into the till or natural dense sand strata as determined by the soil removed from the interior of the pile and the jacking resistance.
6.1.3 Maximum calculated soldier pile lateral deflection shall be limited to 0.25 inch due to bending under the combined axial and lateral loading.
6.1.4 Maximum calculated lagging member deflection due to bending shall be limited to 0.25 inch.
6.1.5 The lateral pressure diagram for soil pressure shall be trapezoidal with break points at 0.2 of the full excavated depth.
6.1.6 Bending stress reduction of lateral loads due to arching shall not be allowed.
6.1.7 Pile and caisson locations shall be taken into account in the support of the mudmat to prevent separation from the foundation.
6.1.8 A full water head shall be considered for lateral support from el 627' to the-bottom of mass excavation under the structures.
6.1.9 Caissons shall extend at least 4.0 feet into the till or natural dense sand strata as evidenced by inspection of in y
situ material.
The design bearing capacity shall be 20 ksf times the 2
diameter squared (ft ) of the caisson.
If the caisson is belled, the capacity
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shall be calculated at 17.7 ksf times the plan area of the bell.
No increase in capacity is allowed for additional embedment of the caisson in the bearing 6
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o Specification 7220-C-95(Q), Rev 0 strata.. Caissons acting as combination soldier and bearing elements are governed by the stress and deflection i
criteria from Sections 6.1.3 through 6.1.7.
6.1.10 The access shaft from el 634' to el 607' need not conform to Sections 6.1.3 to 6.1.8 but must be in accordance with acceptable industry practice.
6.1.11 For bearing plate design, the allowable bearing stress for concrete shall be 750 psi.
Bearing stress for steel
'shall be 27,000 psi.
6.1.12 The design stresses shall not be greater than the allowable stress presented in AISC, ACI, or as specified herein.
In the event of conflict, notify Contractor, who will determine the governing criteria.
6.2 DESIGN LOADS 6.2.1 Structure Loads The load of each auxiliary building penetration room is equal to 8,300 kips (vertical).
The center of gravity of the load is shown in the drawing.
The allowable eccentricity of the underpinning support system during construction with respect to the east-west centroidal axis of the penetration room load is 3 feet.
Foundation pressure as well as local column loads for structures in the vicinity are shown in the drawings.
6.2.2 Soil Conditions
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1 Soil conditions and interpretation of soil properties encountered are discussed below.
In general, the g
backfill consists of heterogeneous mix of very loose to dense sand and very soft to hard clay fill.
Details of
, soil information and boring logs are given in the' foundation engineering sections of the PSAR and FSAR and are available from contractor.
The interpreted engineering properties of 7
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Specification 7220-C-95(Q), Rev 0 l
backfill presented below are based upon the laboratory and field investigations l
performed in the vicinity of the diesel generator building.
a.
Soft to stiff, silty, sandy clay fill (CL)
Total unit weight vt = 110 - 130 pcf Dry unit weight Td = 98 - 116 pcf Undrained shear strength = 150 -
3,000 psf b.
Loose to dense, silty, fine to medium sand (sm-sp)
Total unit weight vt = 110 - 130 pcf Dry unit weight Td = 94 - 116 pcf Angle of internal friction 28 -
32 degrees c.
In-Situ Fill Total unit weight it = 130 pcf Average undrained shear strength El 580-560' 6,000 psf Below 560' 8,000 psf 6.2.3 The permanent support for each auxiliary building penetration room provided by underpinning shall have a vertical resistance capacity sufficient to produce a moment equal to or greater than 325,000 foot kips at column rows 5.3 and 7.8, respectively.
This moment capacity is the major design criterion and shall be met by subcontractor.
The approximate value of 4,000 kips of g
installed capacity as referenced throughout this specification is an estimate of the actual caisson capacity.
The exact capacity required
,'is to be determined by Subcontractor.
All pumps, jacks, gages, equipment, and other hardware shall be of sufficient capacity and number to install and 8
t Specification 7220-C-95(Q), Rev 0 test, in accordance with this specification, the caissons that will I
produce a moment equal to or greater i
than 325,000 foot kips.
6.2.4 The permanent underpinning support for
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the turbine building shall be capable l
of safely resisting the column loads indicated in the drawings plus half the base slab pressure within the zone of i
influence.
The zone of influence is defined by a slope of one horizontal to l
one vertical from the bottom of the excavation required for removal of the unsuitable material from under the valve pit structure.
The permanent underpinning support for the turbine i
building shall take into account the i
1,300 kips of force anticipated due to support of the valve pit structure.
7.0 PILE AND CAISSON LOAD TESTING 7.1 The vertical factor of safety established by in-place testing shall be not less than 1.5 for piles and caissons.
7.2 Test Method 7.2.1 The first caisson installed under each auxiliary building penetration room shall be load tested for 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> at 1.5 times the design load and 12 hours1.388889e-4 days <br />0.00333 hours <br />1.984127e-5 weeks <br />4.566e-6 months <br /> at 2.0 times the design load.
The test
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load shall be applied in increments 6T.
50%, 20%, 10%, 10%, and 10% of l
1.5 times the design load at 1-hour intervals which are not included in the 24-hour period.
At the completion of the 24-hour test at 1.5 times the
._. design load, the load shall be
/ increased to 2.0 times the design load
-- 6.'- d in increments of 10% of.the design load
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per hour.
The load shall be maintained at 2.0 times the design load for
'e N 30 hours3.472222e-4 days <br />0.00833 hours <br />4.960317e-5 weeks <br />1.1415e-5 months <br /> and then removed in decrements of 20% per hour to 80% of design load, I
then removed in decrements of 30%, and
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.. ' jgW finally 50% at 1-hour intervals.
This ' ' '
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/.iv.a J,"'."..' ///., caisson selected for testing shall be
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C representative of the majority of
,W caissons to be installed.
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Specification 7220-C-95(Q), Rev 0 7.2.2 All remaining caissons shall be loaded to 1.0 times the design load prior to l
concreting.
This loading shall be i
referred to as the Empty Shell Test (EST).
A satisfactory EST is defined as causing a caisson movement of less than 0.10 inch in a 5-minute period under a load equal to 1.0 times the design. load.
l 7.2.3 After the EST and concreting of the caisson, the caisson shall be subjected l
to a Full Test Load (FTL).
A satisfactory FTL is defined as causing a caisson movement of less than 0.05 inch in a continuous 1-hour period under a load equal to 1.5 times the design load.
Extensometers (AMES) dial gages shall be calibrated to 0.001 inch per revolution and used to measure the movement of the caisson relative to the structure.
7.2.4 After installation of a group of caissons which constitute 500 design tons of underpinning resistance and prior to the completion of the caissons of the next group, one caisson in the previous group shall be chosen by contractor for retesting.
The caisson shall be tested for a period of 5 minutes at 1.5 times the design load.
A satisfactory test shall be one where less than 0.010 inch of settlement occurs from the start of the test to the end of the test.
If the test is satisfactory, the work on the next i
group may continue.
If the test is not satisfactory, the caisson being tested shall be unloaded and ratested in accordance with the requirements of FLT (Section 7.2.3).
Then one more caisson in the group shall be subjected to the 5-minute and 0.01-inch settlement test.
If the second caisson retested is satisfactory, the work on the next group may continue. -If it is not I
satisfactory, repeat the procedure o.n caissons selected by contractor until a satisfactory 5-minute and 0.01-inch settlement test is achieved before l
proceeding with the work.
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4 Specification 7220-C-95(Q), Rev 0 After completion'of the FLT (Section 7.3.2) or 5-minute retest, the caissons shall be locked off (wedged tight) at 1.5 times the design load.
7.2.5 During the period of the test performed in Section 7.2.1, neither jacking against the structure nor any work which causes vibrations or may otherwise affect the test results shall be permitted.
7.3 The test method for the piles and/or caissons under the turbine building adjacent to the valve pit structure shall be in accordance with Section 7.2.
8.0 UNDERPINNING AND SUPPORT OF STRUCTURES 8.1 GENERAL i
Subcontractor shall provide the necessary underpinning and permanent support for the auxiliary building penetration rooms for Units 1 and 2 in accordance with the requirement of this specification and as shown in the drawings.
In addition to the underpinning work shown in the subcontract drawings, Subcontractor shall take all other action necessary to. maintain
- the integrity of these buildings.
Subcontractor shall be responsible for supporting structures and taking all necessary precautions to prevent the settlement (movement) greater than specified in this specification or cracking of the buildings, including slabs on grade, supported slabs, i
appendages, interior partitions, and other columns and walls.
8.2 RESPONSIBILITY Subcontractor shall conform to the following.
8.2.1 Assume full responsibility for all i
g underpinning and related operations.
Take necessary precautions for protection of persons, and preclude damage to property,-including structures which are underpinned or i
affected by underpinning work.
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o Specification 7220-C-95(Q), Rev 0 J
8.2.2 All underpinning operations shall conform to applicable codes and also meet requirements of other authorities having jurisdiction over the work involved.
8.2.3 The maximum settlement (movement) of the auxiliary building penetration rooms and the turbine building along the K line for Units 1 and 2 shall not exceed 1/2 inch.
8.3 TEMPORARY SUPPORT Prior to underpinning for Unit 1 and 2 operations, the feedwater valve pits will be temporarily supported by Contractor as shown in the drawings.
The feedwater valve pits shall not be subjected to any additional vertical loads or external forces by Subcontractor during the underpinning operation.
8.4 PILE AND CAISSON INSTALLATION 8.4.1 General The piling or caisson shall consist of a concrete-filled steel pipe.
The steel pipe shall be installed by jacking against the existing structure.
The pipe shall be precut to a convenient length for jacking.
The pipe segments shall be joined together by full penetration welds around the circumference as the pipes are advanced into the subsurface.
The pipe shall be installed open-ended to the depths specified.
The pipe shall then be subjected to the EST -
(Section 7.2.2), cleaned, inspected, concreted, subjected to the FLT (Section 7.2.3), and wedged tight to the structure under a load equal to 1.5 times the design load.
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Specification 7220-C-95(Q), Rev 0 8.4.2 Materials Steel _ pipe shall conform to ASTM A 252, Grade 2 seamless or ASTM A 53, Types E or S, Grade B.
It shall have a minimum wall thickness sufficient to sustain the design load of the pile or caisson calculated at fa = 18,000 psi.
All cutting of the pipe shall be done in such a manner that the cut edge shall be perpendicular to the longitudinal axis of the pipe.
Flame cutting is permitted.
Beveling of edges for welding shall be done in such a manner to ensure a true cut.
Internal or 1
I external pipe couplings, whether mechanical or welded, are not permitted.
The pipe tip shall be reinforced by a steel shoe or by increasing the wall thickness of the lowermost section of pipe.
The reinforcement shall be sufficiently strong to sustain a static point load equal to the maximum jacking force without permanent deformation of the lowermost pipe section.
The shoe diameter or outside diameter of the lowermost pipe section shall not exceed the diameter of the remaining pipe section by more than 1/4 inch.
Steel friction breakers may be installed on the outside of the pipe by welding.
Friction breakers will not extend more than 1/8 inch beyond the outside of the pipe.
8.4.3 Pile Installation a.
The plan location shall be established at the bottom of the concrete slab at el 607'+.
The tolerance for the plan location i
shall be +5 inches, but the algebraic aggregate of the deviations shall not exceed
+5 inches.
i b.
The' allowable top-to-bottom plumbness of the pile shall be not more than 2% out over the entire
. length.
If the plumbness is more than 2% over the entire length, Subcontractor shall reduce the 13 j
i
i Specification 7220-C-95(Q), Rev 0 design load on the pile accordingly.
c.
The maximum deviation for pile straightness shall be 1/2 inch in 10 feet and 1/2 inch in 20 feet.
d.
If any criteria specified in Items a, b, or e of Section 8.4.3 are not satisfied, Subcontractor shall calculate the allowable reduced design capacity of the pile in accordance'with generally acceptabic methods.
Calculations shall be submitted to Contractor for review.
Subcontractor shall not be permitted to increase the load on other piles to compensate for the reduction caused by failure to achieve the requirements stated in Items a, b, or c of Section 8.4.3.
All additional piles which shall be installed to compensate the loss of capacity shall be at the l
expense of Subcontractor.
J e.
The maximum jacking force shall be 1.50 times the design pile load or 0.85 fy prior to the reduction for L/r ratio or 0.70 fy as indicated in the certified material test report prior to reduction for L/r ratio.
A commercial grade bentonite slurry may be injected between the pipe and the soil.to minimize side wall friction.
f.
Maintain a minimum of a 1-foot i
(vertical measurements) soil plug in the pile at all times unless an 1
obstruction is encountered.
If an obstruction is encountered, then maintain a liquid level inside the pile to within 5 feet of the bottom of the jacking pit, and limit the removal of material y
beyond the existing tip of the pile to less than 1 foot except by specific written instructions by Contractor.
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Specification 7220-C-95(Q), Rev 0 g.
No water jetting, slurry jetting, or air jetting for loosening or removal of material inside or in advance of the pile is permitted except by written permission from contractor.
h.
No airlifting or venturi principle lifting of the material in the pile or in advance of the pile is permitted within 5 feet of the pile tip except after final seating of the pile in the till.
If air or venturi lifting is employed, Subcontractor shall maintain a liquid level in the pile at the bottom of the jacking pit during the entire operation.
Contractor shall be notified in advance and in writing each time Subcontractor employs this procedure.
i.
No impact or vibratory forces may be used for advancing the pile.
j.
Inspection of piles prior to concreting shall be accomplished by visual inspection and measurements inside the pile.
Subcontractor shall make a final cleaning of the pile and remove all water and deleterious matter from inside the pile.
The pile will then be inspected by Contractor, who will give written permission to Subcontractor to place concrete in the pile.
The maximum length of earth plug at the pile tip prior to concreting is l'-6" of compact material.
k.
The concrete for the pile shall be placed in such a manner that the concrete drops vertically from the top of the pile.
Subcontractor shall take necessary measures to g
prevent segregation and voids in the concrete during placing.
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e Specification 7220-C-95(Q), Rev 0 1.
Contractor reserves the right to direct Subcontractor to use the pumped tremie method for concreting the piles without employing the grout plug.
8.4.4 Caisson Installation a.
The plan location shall be established at the bottom of the concrete slab at elevation 607'+.
The allowable deviation from the plan location shall be 15 inches, but the algebraic aggregate of the deviation shall not exceed
- +5 inches.
b.
The allowable top-to-bottom plumbness of the caisson shall be not more than 2% out over the entire length.
If the plumbness is more than 2% over the entire length, subcontractor shall reduce the design load on the caisson l
accordingly.
c.
The maximum deviation for caisson straightness shall be 1 inch in 10 feet and 1 inch in 20 feet.
d.
If any criteria specified in Items a, b, or c of Section 8.4.4 are not satisfied, Subcontractor shall calculate the reduced allowable design capacity of the caisson in accordance with generally acceptable methods.
Calculations will be submitted to 4
contractor.
Subcontractor shall not be permitted to increase the load on other caissons to compensate for the reduction l
caused by failure to achieve the requirements stated in Items a, b, and c of Section 8.4.4.
All additional caissons shall be at the expense of Subcontractor, p
e.
The maximun jacking force shall be 0.85 fy prior.to the reduction for the L/r ratio or 0.70 fy as indicated in the certified material test report for the steel shall (prior to reduction for L/r 16
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Specification 7220-C-95(Q), Rev 0 ratio /)Acommercialgradeor 800 kips, whichever is less.
bentonite slurry may be injected between the pipe and the soil to minimize side wall friction.
f.
No water jetting, slurry jetting, or air jetting for loosening or removal of material inside or in advance of the caisson is permitted except by written
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permission from Contractor.
' g.
No airlifting or venturi principle lifting of the material in the caisson or in advance of the caisson is permitted within 5 feet of the caisson tip except after final seating of the caisson in. :
the till.
If air or venturi lifting is employed, subcontractor shall obtain written permission from Contractor, and then maintain a liquid level in the caisson at j
the bottom of the jacking pit during the entire operation.
h.
Caisson linings shall be of adequate thickness to ensure safe working conditions within the i
t caissons.
)
1.
The straight-shafted portion of-the metal-lined caissons shall be limited in plan area to 16 square feet.
j.
Metal-lined caissons with belled-4 or wedge-shaped bottoms shall not
.have the top bell started until the shaft has penetrated only into the clay till a minimum of 2 feet.
..t k.
The bell angle shall be a minimum, of 60 degrees from the horizontal.
The bell shall be lined for depths i
g in excess of 4 feet below the straignt shaft.
The annulus (void) between the straight shaft:-
liner and the ground shall be. f:.-
grouted and cured for 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> prior to starting excavation of the bell.
s i
17 l
Specification 7220-C-95(Q), Rev 0 1.
If squeezing ground (as defined in Soft Ground Tunneling with Steel Supports by Proctor and Wnite) is encountered, Subcontractor shall proceed in such a manner that no ground is lost.
Methods acceptable for this operation are as follows:
1.
Jacking the lining past the squeezing zone without removal of material 2.
Drilling under bentonite slurry and jacking (Drilling cannot proceed in excess of 1 foot beyond end of lining.)
If running ground (as defined in m.
Soft Ground Tunneline with Steel l
Supports by Proctor and White) is encountered, the following methods for advancing are acceptable.
1.
Jacking the lining past the running zone wit!xmt reeval of a
material 2.
Drilling under bentonite slurry and jacking (Drilling cannot proceed in excess of 1 foot beyond end of lining.)
3.
Grouting i
n.
If flowing ground (as defined in Soft Ground Tunneling with Steel, Supports oy Proctor and White) is encountered, stop excavation, fill caisson with water or slurry, give written notice of the condition to Contractor, and await written direction from Contractor prior to-proceeding.
o.
Concreting shall not be performed until Contractor has inspected the g
botten and bell of the caisson and made measurements for plumbness, l
straightness, and location.
t 18 l
i
~.-_
o Specification 7220-C-95(Q), Rev 0 p.
Tha concrete for the caisson shall be placed in such a manner that the concrete drops vertically from the top of the caisson.
Subcontractor shall take necessary measures to prevent segregation and voids in the concrete during placing.
q.
Contractor reserves the right to direct Subcontractor to use the pumped tremie method for concreting.
8.5 JACKING AND TESTING EQUIPMENT 8.5.1 The jacking and testing apparatus is to be actuated by hydraulic pressure generated by electrically or mechanically driven pumps.
All high-pressure hydraulic apparatus shall be kept in a state of good maintenance.
8.5.2 All jacking and testing apparatus shall be equipped with two hydraulic pressure gages.
The pressure gages for the production jacking equipment shall have a minimum face diameter of 2 inches.
Testing equipment for the 24-hour load test (Section 7.2.1) shall have gages with a minimum 6-inch diameter face calibrated so that 270 degrees of dial movement covers the operating range of the equipment.
Test equipment for the FLT (Section 7.2.3) shall have 4-inch diameter gage faces and be calibrated so the 270 degrees of dial movement cover the operating range of the equipment.
8.5.3 Subcontractor shall have the following hydraulic pressure gages at the job:
i three 8-inch face, three 6-inch face, and three 4-inch face gages calibrated with the specific rams intended to be used with each set of gages.
The g
calibration shall be performed and certified by an independent laboratory which specializes in that type of work i
.no earlier than 1 month prior to load testing.
The calibration certificates shall be submitted to contractor.
O 19
i Specification 7220-C-95(Q), Rev 0 8.5.4 The gages and rams referred to in Section 8.5.3 shall hereafter be referred to as the master set.
The master set shall not be used in the field operations except for the 24-hour load test.
The master set shall be kept in a place suitable to contractor and shall be used for calibrating all 1
gages used in the field.
8.5.5 Subcontractor shall furnish a test i
manifold and test stand which will enable Subcontractor to field-calibrate four field gages simultaneously in the same hydraulic circuit as the respective three master gages and ram.
Subcontractor shall notify Contractor :
in writing when field calibrating of gages will be done.
Contractor will have a representative present during-field calibration.
The field gages.
shall be calibrated against a master set having a larger gage face.
The results of the field calibration shall'.
be forwarded to Contractor following..
the calibration.
.: :s 8.5.6 Each field and master gage shall be assigned a unique identification a
number, and that number shall be engraved on the gage cover and also be painted on the gage back.
In addition, a suitable calibration curve or f
1 tabulation for the particular gage shall be afixed to the back of the gage by means of a clear, sticky, celluloid cover.
If gage face overlays are used, this is equally satisfactory.
I 8.5.7 Recalibration of the master sets is required at a minimum of every 3 months.
This should be scheduled so i
l there is at least one set of 6-inch or l
larger master gages on the project at.
all times.
In' addition, the master.
gages shall be recalibrated any time i
that one master ga e varies by more I
I than 5% of its cal brated rating as. :
established by the other two master.:.
l
. gages in the same master set.
Field.
I gages shall be recalibrated monthly or at any time when one gage is broken or damaged or when one gage varies by more 20 i
Specification 7220-C-95(U), nov 0 thnn 10% f rom its calibrated rating as established by its coi.:panion gage.
8.5.8 The field testing apparatus shall contain a snubber valve in the hydraulic circuit.
The snubber valve shall be located on the high-pressure side between the tandem gages and the pu:ap, and immediately behind tne gages.
For the FLT (Section 7.2.3), the snubber valves shall be closed when the ram attains the test load and shall stay closed until either the move,aent of the pile execcus 0.05 inch, or when the' FLT (Section 7.2.3) witn less than 0.05 inch has occurred.
hovement (not aage pressure) is the testing criterion for the FLT (Section 7.2.3).
- However, if the 9 age pressure drops by more than 10% during the FLT (Section 7.2.3), the test shall be restarted.
For the 24-hour load test, the gage pressure required shall be maintained tnroughout the test period.
8.5.9 During the underpinning operation, Subcontractor shall have available at the site all rac.s, gages, pur.ips, hose, and fittings required to simultaneouly lif t the auxiliary building penetration area at the location of the permanent support.
The total lifting capacity required is approxic ately 4,000 hips, which is to be distributed equally as specified in Section 6.2.3.
8.6 DCTECTIOD OF MOVCMCUT 8.6.1 General Sub ;ntractor shall submit and l
implement to the satisfaction of
- ?.
i Contractor a procedure to monitor each
.1 ~
l structure which might be affected by the underpinning operations.
8.6.2 I
llorizontal movement detection points shall be located at or near the top and at the ground level of the structures.
l Vertical moveuent detection points j
shall be located near the ground level
[ ~.
of 'the structures.
-, j.,
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I i
l 21 l
A O
Specification 7220-C-95(Q), Rev 0 8.6.3 Measurements shall be to the nearest 1/16 inch based upon survey observation.
8.6.4 Measurements shall be made daily during the underpinning operation, and Contractor shall be informed in writing if any movement is detected in excess of 1/16 inch of the previous reading or accumulated value of 1/8 inch.
9.0 WELDING 9.1 All welding shall be performed in accordance with AWS Dl.l.
Contractor shall approve all welding procedures.
9.2 All welders shall be qualified to the applicable welding procedures in accordance with AWS Dl.l.
10.0 EXCAVATION 10.1 GENERAL Subcontractor shall submit prior to excavation a detailed procedure describing the method of excavation.
This procedure shall be to the satisfaction of Contractor and shall indicate coordination of the installation of lagging and bracing.
The procedure shall also indicate the maximum amount of excavation below any previously installed lagging or structure.
As a mininum, the excavation procedure shall include the following.
10.1.1 The location and dimension of each jacking pit 10.1.2 A flow diagram showing the excavation of all pits and the sequence of installation, testing, and locking off vertical support elements (caisson er jacked pile).
10.1.3 A table relating the information g
provided in Item 10.1.2 showing the following data with respect to each vertical support element:
s 22 j
Spccification 7220-C-95(Q), Rsv 0 a.
Pile or caisson number i
b.
Pit number c.
Sequence number d.
Vertical capacity installed (kips) e.
Area undermined times 5.5 kips /ft (Note:
The area undermined includes the disturbed but not excavated soil (influence zone) determined by a 1 horizontal to 3 vertical slope subtended from the bottom of the excavation prior to the installation of the lagging.
Thus, a pit which is opened up to a depth of 6 feet prior to the installation of the lagging would have an influence zone which extended 2 feet beyond the edge of the excavation.
If this same pit was subsequently (after installation of lagging) excavated i
to a greater depth, and lagging was installed as frequently as required by this specification, the influence zone would remain at 2 feet.)
f.
Net overload (Item e) minus (Item d) (kips)
Percent net overload (Item f) ips g.
times (100) divided by 8,300 k 10.1.4 Sequence Control and Limits In general, the objective is to install approximately 4,000 kips of underpinning resistance as close to the extreme end of the wings as possible.
Subcontractor's plan shall be governed accordingly.
a.
Piles which are adjacent to one y
another may be worked simultaneously provided the area i
of undermine is within allowable l
limits 23 l
1
.A
' Specification 7220-C-95(Q), Rev 0 b.
Caissons which are adjacent to one another cannot be worked simultaneously.
Where there are adjacent caissons, one must be excavated, concreted, tested, and stressed before work on any adjacent caisson can start.
However, the first 7 feet below el 607' may be excavated in advance (if the space is required) for access to a nonadjacent caisson or pit.
10.2 Once an excavation is started, it must be worked continuously and without cessation until the lagging is in place and the lateral ground support restored.
10.3 Explosives shall not be used to dislocate and/or remove hardened material during excavation.
Conventional tools, such as rock splitters and demolition tools, are acceptable.
10.4 Subcontractor shall submit the following procedure that is satisfactory to Contractor.
This procedure shall describe in detail the measures, including hold points and inspection points, taken by Subcontractor to ensure slope stability and to prevent any movement of foundation material outside the excavation area.
10.5 Prior to excavation of material from under or within 7 feet from the foundations of the auxiliary or turbine buildings, the sand material shall be grouted.
The pregrouted zone shall extend vertically from the underside of the existing foundation or mudmat to a depth of approximately 1 foot below the access excavation, or approximately 7 feet beyond the farthect lateral ' extant of the excavation.
10.6 The initial excavation below the bottom of the 31ab at el 607'+ shall not exceed 7 feet in g
depth.
In: addition, in no case shall the jacking pit exceed 7-feet in depth.
10.7 The percent net' overload as established by Section 10.1.3 shall not exceed 10% during i
installation cf apprcximately 4,000 kips of permanent support capacity under each electrical penetration roca.
l 24
d.
Specification 7220-C-95(Q), Rev 0 10.8 Subcontractor shall advance the mass excavation under the valve pit structures to
)
the depth determined by Contractor.
The j
bottom surface shall then be prepared for concreting as follows.
10.8.1 The surface shall be flat but sloped to a minimum of 1/4 inch per foot draining toward a sump located in one corner.
10.8.2 Subcontractor shall dispose of all water in the sump to the satisfaction of Contractor.
10.9 LAGGING INSTAI.LATION 10.9.1 All lagging material that will remain in the ground shall be metal or concrete.
Any wooden lagging used for jacking pit lining or any other purpose must be removed.
If removal of the lagging exposes earth, which will not be excavated, then the unremoved soil l
shall be grouted prior to removal of j
the lagging.
The object of the j
grouting is to ensure intimate contact
^
between the soil and the structure, and where granular soil is involved, to ensure the material in the zone of influence is self-supporting.
i 10.9.2 The initial excavation, where the earth is not supported, shall not exceed a depth of 4 feet if it is within 6 feet of the K line.
Otherwise, a maximum depth of 7 feet shall be used.
10.9.3 After initial excavation, the lagging shall be installed and back packed or grouted.
The lagging along the K line l
located below el 600.0' shall be grouted.
10.9.4 The excavation shall not proceed to a depth greater than 3 feet below the previously grouted lagging.
4 10.9.5 The procedure for installation of the lagging below el 600' along the K line shall indicate the maximum vertical
' distance between unpacked lagging and
~
the bottom of the excavation.
This distance shall not exceed 16 inches.
25 I
...e
\\
-Specification 7220-C-95(Q), Rav 0 5
10.9.6 If sque,ezing ground (as defined in Soft Ground Tunneling with Steel Supports by Proctor and White) is enccuntered below el.600',
Subcontractor shall employ a Chicago lagging system-(near vertical-driven lagging) for advancing.
The advance shall be limited to a maximum of one-half tho length of the lag.
After advancing one-half a lag, the lower breasting member shall be installed and the lagging wedged.
10.9.7. 'If running ground (as defined in Soft Ground Tunneling with Steel Supports by Proctor-and White) is encountered below'el 600', the zone shall be grouted'in advance of excavation.
Spieling is not a satisfactory procedure for running ground.
10.9.6 If-f, lowing ground (as defined 'in Soft Ground Tunneline with Steel Sundo'rts by Proctor and White) is encountered,- Subcontractor shall immediately close the opening from which ground is. flowing, dewater the area to the: extent that the ground-
, behavior is changed to a running
' condition, and then proceed in
- accordance with Section 10.9.7.
11.0
- CONCRETING 11.1 CENERAL Subcontractor shall submit to the satisfaction of Contractor a detaile procedure, including hold points and inspection' points', des.cribing the
- placing of cencretelunder the structure.
As a' minimum, the placing and' consolidating of the concrete shall be in accordance with Articles 11.0 and 12.0 of Specification
- 7220-C-231, unless otherwise specified herein.
4
~
Pile, pit and caisson procedures are 11.2 specified elsewhere,
~
11.3 Mass concrete shall first be placed in the corner opposite the sump such that any water t
shall be triven'to the sump as the concrete is placed -
t te s
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Specification 7220-C-95(Q), Rev 0 11.4 The first lift shall not exceed 2 feet in thickness; all subsequent lifts shall not exceed 5 feet in thickness.
11.5 Successive lifts shall be doseled into the preceding lift by using #8 bars on is -inch
')
centers on a grit pattern.
Dowels shall be located such that a minimum of 24 inches shall be embedded in both lifts.
Reinforcing steel will be furnished by contractor.
i 11.6 The surface of the concrete lifts shall be horizontal within +3 inches for the entire area.
11.7 The top lift shall be placed to within 6 inches of the bottom of the existing slab.
The remaining void between the lean concrete backfill and the foundation slab shall be either dry pack grouted or pressure grouted using a nonshrink grout.
Subcontractor, shall submit a procedure to the satisfaction of Contractor, including hold points and witness points, describing in detail the method of dry pack grouting or pressure grouting.
11.8 Each lift of concrete shall be water cured for a minimum of 48 hours5.555556e-4 days <br />0.0133 hours <br />7.936508e-5 weeks <br />1.8264e-5 months <br /> in accordance with ACI 318-1977 before continuing the placement.
11.9 Contractor will perform slump, percent air content, temperature, unit weight, and compressive strength cylinders on the lean concrete placed, and perform a compressive strength test on the grout used.
Subcontractor shall assist contractor when performing all grout,and concrete testing.
11.10 Preceding the placing of concrete, Subcontractor shall install 2-inch styrofoam along the containment structure. and 3-inch styrofoam between the containment and auxiliary buildings.
Subcontractor shall submit a procedure for installing the g
styrofoam to the satisfaction of Contractor.
(
12.0 CLEANING AND RESTORATION Subcontractor shall' restore the work area to the same condition that existed prior to the start of operation and to the satisfaction of Contractor.
27
Specification 7220-C-95(Q), Rev 0 Subcontractor shall also submit a procedure on final cleaning.
13.0 QUALITY ASSURANCE REQUIREMENTS 13.1 CENERAL The following operations are to be controlled in accordance with Subcontractor's approved QA program (Subcontractor's QA program shall be in accordance with Specification 7220-G-23, Appendix A, Attachnent 2):
13.1.1,The design, materials, installation, testing, concreting, grouting, and all other incidentals for the permanent underpinning (caissons) of the auxiliary building penetration rooms 13.1.2 The excavation, mass concreting, and grouting under the valve pit structures 13.1.3 As a minimum, the following sections of this specification are under the scope j
of subcontractor's QA program: 50,
6.1.4, 6.1.5, 6.1.6, 6.1.7, 6.1.8, 6.1.9, 6.1.11, 6.1.12, 6.2.1, 6.2.2, 6.2.3, 7.1, 7.2, 8.1, 8.2, 8.4.1, 8.4.2, 8.4.4, 8.5, 8.6, 9.'0, 10.1, 10.4, 10.5, 10.6, 10.7, 10.9, and 11.0.
These sections are applicable only with the work defined in Sections 13.1.1 and 13.1.2.
13.2 Because of the nature of the work, an independent overlay inspection will be performed by Contractor in accordance with this specification and subcontractor's procedures.
14.0 MEASUREMENT Of PAYMENT The measure of payment for this subcontract shall be in accordance with the pricing structure of the contract.
e 28-
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Specification 7220 C-95(Q)
Rev. 0 APPENDIX A QUALITY ASSURANCE REQUIREMENTS FOR Q-LISTED ITDiS AND WORK 1.0 Subcontractor shall establish and maintain an effective quality assurance program which will meet the applicable requirements of Specification G-23 to ensure that all materials and workmanship furnished hereunder for Class I structures conform to the sp'ecifications.
2.0 Contract.or shall have free access to all work and shall have the authority to stop work or reject shipment if the specification requirements, including those for documentation, have not been
, fulfilled.
3.0 Subcontractor shall furnish documentation in accordance with the I
specifications as summarized and directed by Form G-321-D.
To co=plete Form G-321-D, Subcontractor shall check in colu=n 8 which documents are being transmitted, and shall sign line 21.
Subcontractor shall fill in lines 13 through 20 as applicable.
Entries such as N/A or NA (not applicable) and "see attached sheets" are permissible. Form G321-D completed is then used for a cover sheet as directed on the back of the form.
Attach:nents:
1.
Fonn G-321-D, Engineering and Quality Verificaticrr Wmt Requi.wts.
Rev. 0
+
2.
Specification 7220 G 23, General Requriertents for Supplier Quality-Assurance P.ws, Rev. 7 3.
Data Sheet 1, Quality Assurance Program Elements, Rev. O M1
1 Apptndix A Attaclunent 1 l af AO INSTRUCTIONS ON BACK BEFORE FiltlNG IN FORM l
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1A StemeC OATA StPORT Ill ifA tesseess peessser aseseu E l Insmaammspfene la ASALYSIE Ae9 Ott:64 HPORT MI' 10 0 C00t C0ePLIAstCt M E2 tauseasteem SA ACOUBTet GAT A REPORT WI ISA b7 WLTRA80mtC ERAme#Afl04 P90-g33 PenYflTTPE TEST RGPORT tt & VI me sAmetts al Ct00 ass Ml. Ane VieiriCAfica At-mA Personnel Qualification (E) te.1 f,s 0
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rents M 29.0YuppY1ershippingprepara-tion procedure (E) l
i Sp2cification 7220 C-95(Q)
AppandiX A Page 3 of 4 DOCUMENT CATEGORY DEFINITIONS (E) Eng.neenno Documents Tras term comoreses procedures crewegs. soecdcations. OA pians. prototype ouwitcation test procecures reoorts ano other sar utar occu ents that reow.re Becntee perm ssen to proceed prior to f aDrcat.cn or prer to use of tne docu ent e the ces.gn. faoncat.on m
m estamaton. or other work process urvess otherwee mecated The term is wso apphed to orce sats. and estrw.one! cocuments for nandteng.
esorage. rnemtenance etc. that are of rWormatenal eterest orvy to proyect engmeenng (V)- QualW venicaten Documents. Ths term compnses merenenest reports. heet treatment enarts. wesong recores NDE resu es. pedormance test r
reports. etc., w uch comonstrate or certay conformance to tne tecnncal or especbon recurements of tne procurement cocuments.
r 1.0 DRAWINGS (E) 1.1 Outime Denensions. Sonnees and Foundaten/ Mounting Deteds Drawegs prowong extemel ementope. metudog sucs. center kne(s).
tocaton and we for octrcas cacae. concurt. nuid. and otner servce connecsons, sometncs, and oetads rotated to founostions and mountegs.
1.2 Assemeey Dramngs Dotaded crewegs mecaeng sufhcient eformenon to facetate assemefy of the component parts of an ocuoment nem 1.3 Shop Detail Drawegs Drewegs whch pronoe suffesent decad to facetate the teencaton or manufacture of the eauioment tem Thrs m-cavoes but rs not leuted to, spool drawegs. heat esenanger miemas estads, mesmes pong anJ wmng, cross-secton dotads and ar-chtectural cetaas.
1.4 weng Degrams Dramngs wruch snow the schemate weng and connecten mformebon for e6ectnces items.
1.5 Control Log c Degrams Dra* cgs wnch show the petns when input signais must fosow to accomp%sh the : soured responses.
1.6 PUDS Pong and instrumentaten Degrams wttch show poing system estada and the beac control eiements.
2.0 PARTS UST AND COST (El Explooed new mtn eenefied parts and recommended apare parts for one year's operaten eth urwt cost.
3 0 COMPLETED BECHTEL DATA SHEETS (E) Informaten pronced by a supplier on esta sheets fumeshed by Becntei *tucn states serei numoers. operateg ranges. etc., of ecuoment that the supot.or etenas to coisver to setsty tne specafcaten reouvements.
4 0 INSTRUCTIONS (El 4.1 Erectorvinstartaton Detaded wntten procedures mstructens. and orawegs recured to erect or estes matened or ecu oment.
4.2 Operateg Detaded wntten matruenons descreeg how an nem or system shouse ne operated 4.3 Mactenance DetaJed wntten es*ruenons recured to disassemese reassemees and memten items or systems e en operating condi-ton.
4a Site Storage end Handico Detailed wntten estructens which defee the recurements and ame pened, for bbncabon. rotet:en, heateg.
etteg or omer hanctng recurements to prevent camege or detenorsoon ounne storage and hanoi.ng at potste. This inctuces return shopeg estructons S C SCHEDULES ENGINEERING AND FABRICATION ERECTION (E) Bar enarts, entcal path methods etc., wruen enronologca'ty detad the se-ovence of actmtes 8.0 CUAUTY ASSURANCE MANUAUPROCEDURES (E) The oocument(s) when descreetsi tne pianned ano systemaec measures tnat are us-ed to aneure that structures, systems. and cwoonents we meet the recurements of the procurement occuments.
7.0 SEtSMIC DATA REPORT (E) The ana#ytcal or test data whch procees physcal reasonw eWormaten on an nom, metener, component or eyesem m relaton to the conotens encased by the sisted seeme arttena.
8.0 ANALYSIS AND DESIGN REPORT (E) The anefynces assa. (seees. sesemcelloseng. shed cynsvues, etc.). when assures inat en ite n sansties spec.hed recurements.
9.0 ACOUSTIC DATA REPORT (E) The nome, sound and omer weremon asia recured by speunesson wach is a the oudete range and accve the seems frecuency 10.0 SAMi%ES(E) 10.1 A repre cose pectinge when we to submntes for tpe items puremened as recured vi the mamanaaman 10.2 A representoewe exemple of me medened to be used.
l l
11.0 MATMAL DESCftePTION (E) The tecnrucal asse esecreng a masenst wnich a suppear progenes to use Ier a specitc oroer. This usuesy ep-pass to arcnnectures noms, e.g.. motes enang. oscenne, esers. pomes. ec. wigs i
12.0 WELDesG PROCEDURES ANO QUAUFICATIONS(E). AND VE7tPICATION REPORTS (V) The weseng procedures specificamon and suppor-eng ousticaton recores recured for weseng, here fecmg. overtey. treams and songenng. A venaceton report of weens performed actueng De scenehcanon of me aushhee weseertel, one the proceeare(s) used. ens cercheeben met me weeper (s) were oushfed AAG-020279 G3214 SUP A i
l m.
' t 3'O MATERIAL CONTROL PROCEDUIES (E) The procedures for conrosing rsouanct hendung. storego. and traciaosty of matenel such as weld rod 1 a O REPA8R PROCEDUPES (E). AND M AJOR REP AIR VER#iCAT ON REPORTS M. The procedures for contro.ng matenal removal and replace.
m ment by *eideg travng etc. sunsecuent ineemas tresiments ano final acceptance esoection venficehon reports may metude weed repair locabor's (macst. marenas test reports for t.aer metaa. pre-and post. wee heat treaitnent recoros. NDE recoros. etc. The resosut on of whetner a repair rs maeor or not is a Bechtet respons.ohty 15 0 CLEANAG AND CO ATING PROCEDURES (E). AND VER$1 CATION REPORTS M. The procedures for removal of ert. grease or otner sur.
face contammatior and cciuoes apokcat.on of protectwo coatogs venfcation reports ecsuoe corbicahon of visuar examination for sur' ace preparahon. surface prolde, matenais, etc.. nummery anta. temoerature data ano coatmg tracemens casa as recured by the procurement occuments 16 0 NEAT TREATMENT PROCEDURES (E). AND VER$8CAh0N REPORTS M The procedures for controang temperature, trne at temperature as a funcbon of thcaress. fumace atmosonore. coonno rate and mornod, etc. Venicauon reports normasy mesvoe furnace cnarts or smiar recores wnch ioenbfy and certif y tne elemt si treated. the procoeure useo fumece atmospriere, ame at temperature, cochng rete. etc venica.
Son Oata may be a either narrateve or taDunar form 17.0 CERTIFIED MATERIAL PROPERTY REPORTS M 17.1 MTR (Cert.f.ec Matenal Test Reportsi. These reports metude ali enemeal. onyscal. mechen c.d.sid electncas prooerty test cata re.
oured by tne malenal specification and appicabie codes. This is amphcacle to ce<wert. concrete. n. tais, cacae packet matenais. recar, recar Schces. etc The certfied MTR smals ecluce a statement of conformance that the metenal meets the specifcahon recurements.
17.2 enpect Test Data Results of mit Charcy or droo weight tests ancludeg specanon conigsabon test temperasure and fracture data 17.3 Femte Data. Report of the femte percentage for stamiesa stoet matenets used. eclueng cashngs & vasideg fdier metals as cepoested.
17.4 Maierial CertACste of Corr'ot;ance. Venficahon Oocument which certfits conformance lo the recurements of the appbcaDie matenal soecificahon 17.S Electncal Property Reports. Report of e+ectrcal charactensbcs, e g. dielectnc. rnoeoance, resistance, flame test, corona, etc 18 0 CODE CCMPLIANCE M. Venfyeg cocuments tsuen as cata Forms U.1, N 2. State, etc.). wtuch are prepared by the manufacturer or estalier and cert.r.eo ey me Autnanteo Code inspector.
1g 0 UT ULTRASOMC EXAMINATION PROCEDURES (E). AND VER#lCAT!ON REPORTS (V). Metnod of detection and esammetron results of presence and certain cnaractenshcs of escontarsabes and eclussons vi metenais Dy the use of high frecuency acousbc energy-20 0 RT. A ADIOGRApHic EXAMINATION PROCEDURES (El. AND VERIFICATION REPORTS M.Mefnod of detection and erammation results of presence arid certain charactenstics of esconhnushes and inclus#ons an eratenals Oy a-ray or gamme<ay exposure of photograohic tiim.
21.0 MT. MAGNETIC PARTICLE EXAMINATION PROCEDURES (E). AND VERFICATION REPORTS M Method of detectoi and enammebon resufts of surface (or near surface) escontmuities e magnebc matenais By distorbon of an acched magnetc field.
22 O PT UOuiO PENETR ANT EXAMINATlON PROCEDURES (E). AND VERIFICATION AEPORTS(V). Method of detection and examination of our.
fece esconbnuses e matennis cy application of a penetratng housd m conluncbon with suitante development techtneues.
23 0 EDDY CURRENT EXAMINATIO*1 PROCEDURES (E), AND VERWICATION REPORTS M. Method for detecnon and enemmation resurts of escontrut.es e matenal by estortion of an apphed etectromagnebe fie44.
24 0 PRESSURE TEST. HYDRO. AIR. LEAK. SUBBLE OR VACUUM TEST PROCEDURE (E). AND VERWICATION REPORTS M Metnod for evaluateg the structural and mecnarwcal adecuacy or esegnty by apphcaton of dettecent.at pressures, and report of the test resutts 2S 0 INSPECTION PROCEDURE (El. AND VER$1 CATION REPORTS M Organized process fonowed for the purpose of determeng tnat soecified recurements Io mensons. properties, portormance results, etc.) are met. Documented frongs reauetog from an especbon are included ri the venfication report 26 0 PERFORMANCE TEST PROCEDURES (E). AND VERfFICAT'ON REPORTS M Teste performed to demonstrate that functional oesign and opershonal parameters are met by each item produced and the report of the test results. Test results performed as venication of comohance to cuai.ficat on recurements shan De subtrutted as enqpneereg documents.
26 1 Mechancel Test. e g.. pteno curves, vesve stroneg load, tonnegresurt noe. omstraton enveonmental, etc.
26.2 Electical Tests, e g., load. knpulse, overload, contnuiey, voltage, temp 6 tous ree, cettroton. seweton, losa, etc.
27.0 PROTOTYPE'OUAUFICATION TEST PROCEDURES AND TEST REPORTS (E). Rooert of a test whch to performed on a standard or tyocal of equement. mecenal or item, and is not respuesd for each stern groeuced m oreer to nuessantase the naam of equal rtoms. This metuose tests which moy, or could be==ameme ig, r,eult m demoge to ete dem(s) totted.
i 26.0 PERSONNEL QUAufrlCATION PROCEDURES (E). Procesares for cuentyme weteers. Winoseners and odier seccial process personnel 29.0 SUPPUER SHIPPING PREP AR ATION PROCEDURE (E). The procedure used by a suponer to prepare finished mesonais or essement for she.
j ment from his fecery to the fonerte.
MQ Specification g M (Q) 324 (OPEN) 33 0 (OPEN) i l
34.0 (OPEN)
Page 4 of 4 l
l G32104UP A AAfM7027'l
Appendix A 1;.. Li c i Assor i. iter. Prof car.lottal Corporation "j
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[,g GENERAL REQUIRDiciTS ji."
FOR I X SUPPLIER QUALITY ASSURANCE PROGRAMS T.,
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!e UNITS 1 AND 2 EI FOR E7 CONSUMERS POWER COMPANY
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..;,..,9 CC E! AL REQUIRDICITS FOR.9OPPLIERS QUAI.ITY l
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l yJ ASSulW;CE PROCP.f.".3 Specification i
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GENERAL REQUIREMENTS FOR SUPPLIER QUALITY ASSURANCE' PROG."A"5 FOR THE MIDLAND PLANT
. UNITS 1 & 2
.FOR CONSUMERS POWER COMPANY
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TABLE OF CONTENTS
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1.0
. SCOPE 1
2.O GENERAL PROGRAM REQUIREMENTS l l&
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3.O ADDITILJAL REQUIREMENTS lb 3
4.O QUALITY SURVEILLANCE
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APPENDIX I
- PROPOSAL
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APPENDIX II SDDR INSTRUCTION EXHIBIT A SAMPLE DATA SHEET 1 EXHIBIT B SDDR FORM D
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1.0 scori; 1.1 This specification providos the quality assurance requirements for the equipment, material, or forvices as specified in the purchase order, specifications, or material requisitions.
1.2 This specification does not delete or revise
/2\\
(but is in addition to) those requirements defined by the procurement documents.
If a supplier believes that an inconsistency exists between this specification and the procurement documents and referenced codes and standards, he shall immediately notify Bechtel for resolution.
e 1.3 Definitions used herein are derived from ANSI l
N45.2.10-1973.
If the supplier needs clarifica-g tion, requests departure, or feels an inconsis-tency exists between this specification and the procurement documents, he shall immediately notify Bechtel for resolution.
1.4 For all activities within the scope of the l
ASME B&PV Code, the supplier shall maintain a quality program that is in compliance with current Code requirements.
All revisions jg necessary to meet these requirements shall be submitted to the buyer within seven days after the supplier receives written acce the authorized inspection agency. ptance by Evidence of Code acceptance shall accompany the submittal.
2.O GENERAL PROGRA*1 REQUIRE 51ENTS 2.1 The term supplier, as used herein, includes seller, vendor, contractor, and subcontractor.
2.2 The project quality assurance program is governed by NRC Regulation 10 CFR 50, Appendix B, " Quality Assurance Criteria for Nuclear Power Plants."
To satisfy this requirement, the supplier shall establish and implement a quality assurance program that conforms to the g
applicable provisions of ANSI N45.2-1971,
" Quality Assurance Program Requirements for Nuclear Power Plants" as delineated on Data Sheet 1 (Exhibit A) and to the other codes and 4
standards as cited in the contract documents, Eor commodities within the scope of the ASME 1
.c.tiun /..: n -. ;.: ;,,
3.. v. 7 g
BCPV Code, the Code shall govern; for those items not within the scope of the Code, ANSI N45.2-1971 QA program requirements _shall be applicable.
These quality assurance requirements shall apply to all aspects of the work necessary for carrying out this contract, including design, procurement, fabrication, inspection, installation, and testing.
(Data Sheet 1 is attached to this specification for reference i
only.
This completed form is attached to the gji material requisition package.)
2.3 In the event a supplier does have a quality assurance program in accordance with Paragraph 2.2 and if the supplier's function is limited.
i to placing the order with the actual manufacturer, the supplier shall be responsible for providing i
a controlled copy of the manufacturer's quality assurance program documents to Bechtel within 30 days after the award.
The manufacturer's and supplier's quality assurance program documents must meet the requirements as outlined in this specification-that pertain to the activities he performs.
In no case will the supplier. start activities without prior approval i
e, of the portions of the program applicable to jpg i
the respective operation.
l 2.4 When audits are required the supplier shall implement a system of internal and external
'I audits consistent with the requirements of ANSI N45.2.12, Draft 4, Rev.
1, dated November 1, 1974, " Requirements for Auditing of Quality Assurance Programs for Nuclear Power Plants."
l 2.5 When it becomes necessary for the supplier to procure materials, components, or services from a subsupplier(s), it is the suppliers e
responsibility to establish and implement a procurement control process consistent with the requirements and guidelines of ANSI N45.2.13,..
Draft 3 Rev. 3 dated June 1975, " Quality Assurance Requirements for Control of Procurement of Items and Services for Nuclear Power Plants."
2.6 g
Definitions utilized in the Supplier's Quality Assurance Program shall be consistent with
- 1.,-
2
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3.3 In order to comply with Subsection 50.55 (e) of 10 CFR 50 Appendix B, the supplier, in less gpg than 12 hours1.388889e-4 days <br />0.00333 hours <br />1.984127e-5 weeks <br />4.566e-6 months <br /> after detection, shall report to Bechtel Project Engineering each deficiency found in design, manufacturing, and/or construc-tion, which, were it to have remained uncorrected, could have affected adversely the safety of operations of the nuclear power plant at any time throughout the expected lifetime of the plant, and which represents:
a.
A significant breakdown in any portion of the quality assurance program conducted in accordance with the requirements of ANSI N45.2 b.
A significant deficiency in final design as approved and released for manufacturing and/or construction such that the design does not conform to the criteria and bases stated in the specifica-j{g tions A significant deficiency in manufacturing, c.
and/or construction of/or significant damage to a structure, system, or component which will require extensive evaluation, extensive redesign, or extensive repair to meet the criteria and bases stated in this specification s'
or to otherwise establish the adequacy of the structure, sy. stem, or component to perform its intended safety functions d.
A significant deviation from performance specifications which will require extensive evaluation, extensive redesign, or extensive repair to establish the adequacy of a structure, system, or component to meet the criteria and bases stated in the specifications or to otherwise establish the adequacy of the structure, system, or component to perform its intended safety function.
e.
Notification of reportable deficiencies 4
as delineated above shall be by. telephone gkg or TWX, followed up by a completed SDDR form per instructions in Appendix II.
1 l
I
3.4 Any dopnrture from thd requirements of the procuring documents or Bechtel approved supplier technical documents which the supplier intends to incorporate in the completed item or service i
provided must be documented on a Supplier Deviation Disposition Request (SDDR).
Deviation requests shall be submitted to the Bechtel project engineer with a copy to the Bechtel supplier quality representative if one is assigned within five working days after detection.
Specific instructions are contained in Appendix i
II.
The signature of the suppliers authorized representative in block number 17 of the SDDR form, signifies compliance with Paragraph 3.3.
In addition, the supplier shall also maintain a status list of all nonconformances.
{
3.4.1 Definitions i
a)
Rework is defined as the process by which a nonconforming item is made to conform to a prior specified requirement b reassembling,y completion, remachining, or other corrective means.
Items classified as rework
/kL do not require submittal of the SDDR.
b)
See sheet 2 of SDDR for difinition of repair.
'I l
3.5 Engineering and quality verification documents shall be submitted to Bechtel in accordance with the provisions of Form G-321-D.
While in i
the supplier's facilities these and other records required by applicable codes and~
standards which are necessary to verify activities l
affecting quality,-shall be maintained in facilities to protect contents from possible destruction by causes such as fire, flooding, tornadoes, insects, rodents, and from possible deterioration by a combination of extreme variations in temperature and humidity conditions.
Storage systems shall provide for the accurate retrieval of information without undue delay.
(Compliance to ANSI N45.2.9-1974, " Requirements for Collection, Storage, and Maintenance of i
Quality Assurance Records for Nuclear Power Plants" fulfills these requirements.)
Quality assurance records are those records which -
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furnish documentary evidence of the quality of items and of activities affecting quality.
Records become quality assurance records upon issuance for use.
3.5.1 Records shall not be stored loosely.
They shall be firmly attached in binders or placed in folders or envelopes for storage on shelving in containers.
Steel file cabinets are preferred.
3.5.2 An audit system shall be established to assure that the quality assurance records' storage system is effective.
The following shall be performed as a minimum:
a.
Periodic surveys to assure that
,A records logged in are available
'm
. and have been placed in their proper location within the files
- and to assure that the control
. system is adequate b.
Periodic audits to assure that the facilities are in good condition and that the temperature / humidity controls and protective devices are functioning properly c.
Periodic audits of the records to assure that the documents are not deteriorating due to improper storage practices or rough handling d.
The frequency of surveys and
. audits delineated above shall be determined by the supplier and addressed in the quality assurance program documents 3.6 All quality related records, procedures, and qualifications shall be available for examination by Bechtel or Bechtel's authorized agents.
3.7 The applicabic quality assurance records shall
[
be considered valid only if stamped, initialed, A
l
' signed, or otherwise authenticated and dated R*,
by authorized personnel.
These may be either the original or a high quality reproducible copy.
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,y, 3.0 No quality related record shall be destroyed or otherwise discosed of without written permission of Dechtel (or their designee).
3.9 QUALIFICATIONS OF INSPECTION, EXAMINATION, AND TESTING PERSONNEL 3.9.1 The supplier's quality assurance program shall provide measures to assure that personnel performing safety-related inspections, examinations, and tests are qualified to perform these activities.
Such measures include procedures for qualifications of personnel describing the minimum experience, training, and proficiency testing required for qualifica-tion.
The measures shall also include requirements for records documenting qualifications for each of the suppliers' inspection, examination, and testing personnel.
(Compliance to ANSI N45.2.6,
" Qualifications of Inspection, Examination, and Testing Personnel for the Construction Phase of Nuclear Power Plants" fulfills these requirements.)
3.9.2 Nondestructive examination performed according to the quality requirements of Section III of the ASME Boiler and Pressure Vessel Code shall be performed by supplier personnel certified to SNT-TC-1A 3.9.3 Personnel qualification procedures will be reviewed by Bechtel, prier to initiation of inspections, examinations, or tests.
4.0 QUALITY SURVEILLANCE 4.1 All designing, procuring, manufacturing, processing, assembling, testing, examination, and inspection operations performed by the l
supplier and his lower-tier suppliers are subject to surveillance by Bechtel or Bechtel's authorized agents.
This surveillance shall in l
no way relieve the supplier of any contractual I
responsibilities.
NOTE:
The term surveillance, here, may include inspection, survey, and/or audit.
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!(e v. 7 g e.j, 4.2 The Dcchtel supplier quality represchtative kh\\
shall be given free access to the supplier's and his subsupplicr's facilities to perform
[([
the necessary surveillance and report on the work in all phases of design, manufacturing, and testing.
4.3 The supplier shall give the Bechtel supplier db Ab quality representative at least five working days prior notice of all tests, and other check points in the manufacturing proyram specifically requested by the representative,
/.
af ter a joint review of supplier's wor 1. plan (s) and this specification.
4.4 If the requirements of this specification have not been fulfilled, the Bechtel supplier kk'_
quality representative has the authority to refuse release for shipment.
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...ition 7220-C-2; l
A v.
o APPCt3 DIX I PROPOSAL (This sheet applies to the bid stage)
With his proposal, each bidder shall submit a summary description of the quality assurance program to be implemented in the parformance of the work, or an uncontrolled copy of his quality assurance manual or procedure.
This shall include information on the organization of the bidder, including the cuthority and responsibility of personnel performing QA/QC functions.
It shall also explain administrative policies and procedures to be used in carrying out the program.
j Tho bidder shall provide an adequate statement of justification if his quality assurance program does not need to contain c11 of the elements or portions thereof called for in Data gp Shtet 1 (Exhibit A).
Any modifications agreed to by Bechtel will be identified in the procurament documents.
D;chtel will evaluate the description of the quality assurance program to determine its acceptability.
An acceptable gunlity assurance program is a mandatory requirement for plecing an order.
If a bidder is currently performing to or has completed a B chtel order which invokes the requirements of this specifica-tion, he may, in lieu of submitting a copy of his manual, cubmit a letter listing the date of Bechtel acceptance, the 4
controlled manual to be used and the revision that is currently j(g in effect or was in effect, and a statement that it will cpply for this proposed effort.
4 Ccchtel reserves the right to survey / audit the bidder / supplier to determine the adequacy of his quality program as he preposed or is executing.
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, APPENDIX II SDDR INSTRUCTIONS DEVIATION - any departure from the requirements of the procuring documents, which the supplier intends to incorpoaate in the completed item or service provided.
1.0 The supplier shall be required to submit deviation requests to the Bechtel project engineer with a copy g
to the Bechtal supplier quality representative within five working days after detection.
When this time limit car.not be met, notification by telephone, TWX, etc is acceptable; at that time, a revised submittal date shall be established.
Any deviation is considered unacceptable until approval from Bechtel in writing is obtained.
2.0 SDDRs must be supported by technically valid information that is sufficient for project engineering evaluation.
When necessary, the supplier shall attach supporting technical documents (of reproducible quality) to the SDDR.
One copy of each attachment must also be j{
supplied to the Bechtel (supplier quality representative),
if assigned.
3.0 Detailed instructions for completion of the SDDR are shown on the attached form and instruction sheet, Exhibit B.
It is required that all portions of the SDDR applicable to the supplier be completed prior to d$s1 submittal to Bechtel including Block No. 10.
If the entries are not completed, the SDDR will be returned to the supplier for inclusion of the pertinent informa-tion.
4.0 A copy of the SDDR, with the applicable attachment (s), is ih returned to the supplier after completion of Bechtel engineering actions.
5.0 For approved SDDRs, suppliers may be required by project engineering to change their engineering documents to reflect the "as-built" condition without extra cost to the Buyer.
A copy of the completed SDDR (including attachments) 4shall be included by the supplier in the QC data package for tho item (s) to which it applies.
The SDDR is considered complete when all entries are made including the appropriate verification signatures by the supplier and Bechtel supplier quality representativo.
jg If no representativo is assigned for the order, d
1
Sl +ue IseiLion 7.!.' U - i :.f.;
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s arrangements will be made by Dechtel enginacring for verification of impicmentation.
6.0 A copy of the SDDR form shall be maintained as a QA record by the supplier after all entries have been completed.
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- . I 1i 7220-C-23 d lite IOLLUlilt.L /.... I t.
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- 1b/1 (N ALITY ACT,UR ANCE Rev. 7 PitOGn A?a L LETAL.J 5 Ali'LY lO llitS :,PL CIFICATION.
TO CC CC*dLETED TO CE CDP..rLCT:D CY Tlic SU:'PLICG UY CL';l TE L SUPPLit:1 OOCUf.1*.NT AND PARAGRAPit REFERENCl;S
- .lCAE' E 9
OUALITY AS*,URAt:CE PACGRAM OR GAN12ATICN OES;GN CCNT3OL
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PROCUREf TENT OCC:.l?.:CNT CONTROL
]
INSTRUCTION
S. PROCEDURE
S Af!D ORAVilNGS
']
OCCU!.:EP.T CCB. TROL CO'; TROL CF PURCHASED MATL., EQUIP..& SERVICES
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ID* il. 6.;U.*. TROL OF MATLS., PARTS, COT.'.PONENTS
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,l 5 Cor.TRCL C.: SPECIAL PROCESSES g
1.M92CT:CN W
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TEST COS.TRCL CCNTRCL OF f.*EASURif;G AND TEST EQUIPfiENT
}
HAP.DLINC, STORAGE AND SHIPPING
{
INSPECT:C :. TEST AtJO CPERATitJG STATUS
)
NONCCNFC.7.. SNG 17 EMS
{
CORdECTiVE ACTION l
QUALITY ASSU"RANCE RECORDS
{
AU0iTS
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OTHERS v
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OA1 E REVISIONS CY CHECKEO APPGOVCD JOR110.
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220-C-23 i$
OOCurt.ENT NO.
REV.
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- . c a.... i..in.ica Di. posiuca Request jy P.w e~ i of :
(Q tunutie 4.5L h0ll Ih' '"e'5e S'Ce C' Fut for"(onl.ns tne 4
$i,ppl.er 59;d t.a 04tt %utm.t:,0 IOR f tCHfTL UM "t
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eletniel 5D;8 tes
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St.ooner shall corsicte sie Lcces Iinr:.n 15...tn Lia; int or toe.riter. Use..A la t.ct Ar,Gute,le.
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Address CW & Sta'e 2;p _
L $i,gpfier's Croct f.a
}. Su;;h,e's part no.
A $w;pner's Parit.4me S. Cr.e Cessabon Cetarmened
- 4. Prevevs $CCR c.o & C4:e.
J. Snhtti P Q..' o.
L 8echte Par.No
- 9. enruei #4ti t.4rae la gernwiinspecur Noches iL parites (ng, t.ot,tive
- 12. Off of 58tial 74 i i) Oevedkon CelCr 21.on edifJta estra v' tref t. PCl3;r#3Rs.18elCnet, e"c. as MetellerYD 14 Suppt.er's D.sans.tes Classification:
C use As is O neneir O aiaitir sanie'aeeu rea'ai r
e 11 Precewe 0.t: nit en sat ?'en* Cat Justi can:
f 9
eatracn vitra tree's sse': Pet etc. as nMestarv8 16 Auxireo ss:sner exu ent ceaate ist,
- 17. Cest Effem-11 Socobert AL.tnorered Recresentatne S' nature:
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Titiet Dat-319. Secn:elInirl Actson n
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[ngrg. ISUO4-90:
O o s caanse einer Desm.t.en oisemition O acceeteo O atiecr a
.. O sea m enda1e e
OoiaerSies'+rsatrates 70 seenres o.oeg.t.on sta se,siinciueine Just.hcat.on iAttxn estra sneets, sattenes. etc. as entstarvi f
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l 221. santes acetya,ce paie ve,.s. canon 5 ywswee C5 Date pg __
??. $verliet -
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'2) BecNel 560ssier 1
064td, tepresentathe i
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E'.'ll-G.' J lif.;f fiUCllO.T.i I Oil CO*.*Pl.CT ING *.;UWI TOIC.1 itev. 7 E
U th.. tren. i. v...: 4., a surt.ii.e in:
t Isii ril ofit ins un from arrevied ibhnkat requnements and dusument the surphet's recrosed dorotation.anJ A Notet h
mish it.
e.. hn al justois48.on b)
R..weJ 14.ht.Li J..v..anm i.e sing blaDit.
A deniasian is any it.posues frone the tu;hnmal esquiren:ents of the reet'seier Jormnients mhicts the wayber Prutsnes to incorporals in the ennickteJ sessia i.e we e6e remnJeJ. lieviaanon Ja.coution 6an bc classitivJ as Rvpais. L'w Apit.os \\ludify Requircui nt.
Itepair is defined at ths pAst. of rettorins a nonsonformier characternric to a rendstron such that the carabdity of an lican to fuection relubl) a d wf.ly it uneing.orsJ. tien though that eteni stJ8 may ans contgem to the ireagenalleftunernent. IterJu in.luJss alteratiom to n
the reoretties of the piatsrul rhtough hvas.frestemr. aufJang. metal Jepoeirion, chemical processmg. tre.This tosin is not to be ut.a ior cases w here Deshirl has resu..udy proeiJed vushorwatma to prues.J uung an acespfsJ tspant presedure govering a s,weilic type us repair; 1 se eist. re.orJ. me.s N mentams J tor eac's icesites seraer, techtvl's enginnring action and Jitposition statement does not refwwe the Suppher from responsibihte for the esewracy. aJsquagy, or swit.
abthey of the i:em ur servme bemg rtovsJud as defensd in the precurm; docunwnts. net does it constituar maint of the right to tsnegotiate late terms of the procurm; Jorunwnts.
NOTE: 1: ems marked by an astetisit (*) are for Bechtel use only.
steek No.
Enter infeesmation 1.
Suppt.er's name and address, t.ist lower.tiet Suppher's nasne and levation (City and Statel 6f appt sable.
3.
Enter the Suppt.es's ordet numbee if one has been asesned.
Enter Suppher's Part No. as septentie from the drawine, estate
);
3.
appi.n to su parts and sed.iaenas space e. neeeed,a anat et paeis se.s. Intes.as speetnestien, ete. If the Denation Reevest nish sne request appi.es me, no estaened.
4.
tener Supphet's Part Name.
6.
Enset the Jane and tie methed ($ pet.tenew. NDE. dielectric test.etc.) werd to dise4ees the deviation.
6.
List 48F pfeM8us $DDR*s aPd their datet that han been tubenitted fes 4tetagens requnted en this pWretase Ordet.
7.
Enter the Beehlet Purchase Order Numbee.
8.
Entet the Bechnet Requisiden item. Part, top or code Jimmber at is appears in the requiaiuda. If addimenal space is needed. e trperate theet mer be seu.hed.
9.
Enter the Beentel PC. Name if one has been asa sned.
30 Intet the date and the method (TWX.lettet.etc.) sted to nenfy the enttel 5.rriwt %I.ry Receewstaein, ll.
later the date and the method (TM letter.ete. inned to nuury Bechist EntL*eertes' i
13.
As apetstable, enter quantetees et settet numbere of the elems le whlek the destation appises. If not senaissed.teeeed tet.
batch, beat ce other applicable identatring infeemauen.
33.
Desertbe the denstant charsetesis46es and define the essent of the evt-of stseelhestion tenditiese fee eseh Idevitlhed piece ofreetes. leentity the toesteen of the senating charsetenstie by pnat speedenates er speesias terauen.as aspheatle. Att.aen e stra sheets, phetearo phs, skets fu. ele., as necesener.
14.
Mentier disposinen einsatt.e ii.e.
n.
Driente the pressied dape$inea sad pennde tes'iancal heitificatiea for teentel's e'aiveiiea, if the deeistina is correciatte by repast, submit a detaded sepalt receedare er reference the procedute preneutit setepted fleeel 1)by Bedtel fos use in senaler sisustseat. Nude Seentel contret number suppiner eenvoi number and procedure title.
1 14 Identify the nature of ebenses that snaf fetepet en aesseisted adppiste detumenta(df=W4Sta.gpeoG p eefdures.Insthllatsen 1
inattue 66ena, e te.).
~
17.
Lates the vest impact of the subject Joistioet.
18.
l'ates the name it) ped et PrinteJ). tiyaatste and title of tihr supplid tertrientative methuriding the Ji.pswition resguest anJ 1
iface s%neJ.
- l9.
boet an X in the applivalde buses.
'20.
Provide arrtorriste jutil#*eestian (w the Beshiel actionist IndicateJ in Block 19. Men sbanprs to dramlapt. trethfions.
tenteisilian. nt other lieshiel Joeunients aev insolivJ. ed.h iloewment =aineld lie klentit*wJ anJ the amiatcJ chan.;e hewth 5
deseteheJ. It'nthet weptiste a#e atten ted. inificate o h.iihey see anil the Joeusnent that inetiatcJ tvi.duteen ut that ins.Jicment.
"Other" tiil.nn.wp sin.n tv.ir.. Ilie need tise 41.sei.n,I ise6tstel calculateien.. liisteestal iles.inys ese sket.hss.in svetnin by a a
.. Pteket I agtnett ng tertewntaine.etc.)ihvelal alw liv miesteenrJ bere.
'21.
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GS = $444teste of lied teoriansettle lasicipline Ceuwp Surettlost anverting time Lapisevrier actiism anel the date sipned.
Pli - Sipoetsee of the livshiel rtwiret I apinelrt and the date =ipmeJ.
22.
$3 nature of eine wprlws's in.rectne or wher terrewnfaene aestinorited in serify that the anwrtvJ Ji.gwisbn mas vestestly
/
eminerhJiv.t.
- 23.
1,pnature of time itechtel %eerrlies Qiselet) ltereewetatiev ese wh.t evyweestasse sveit) hip final t8st anwptsJ Ji.e nalion #44 *
=
tveresti; as.imiph.h.J.
SOTl.
A nors 4the to'nr4<l J S18tiltl' nne i8helll'c innl=JeJ 14 t8hr
- Prince in the Lat*Jata railare for e hisins to lei le it arrem mee
i Appendix A Attachme.at 3 QUALITY ASSURANCE PROGRAM ELEMENTS
~
(DATA SHEET !)
THE FOLLOW 8NG ANSI N45.2-1971 ouALITY AssUR ANCE PnoGR AM E LK MENTS APPLY To THIS SPCCIFICATioN.
TO BE COMPLETED TO BE COMPLETED RY THE SUPPLIER SY SECHTEL SUPPLIER DOCUMENT AND PARAGRAPM REFERENCES APPLICABLE 3
OVALITY ASSURANCE PROGRAM ORGANIZATION C
x
. DESIGN CONTROL y
PROCUREMENT DCCUMENT CONTROL INSTRUCTIONS,PROCEDURCS AND DRAWINGS
=
x 00CUMENT CONTRCL 7
CONTROL OF PURCHASED MATL.ECUIP.C SERV!CES 3
IDENT.C CONTROL OF MATLS. PARTS. COMPONENTS C
CONTROL OF SPECIAL PROCESTES C
X INSPECTION Z
x TEST CONTROL T
CONTROL OF MEASURING AND TEST EQUIPMENT C
HANDLING. STORAGE AND SHIPPING 4
INSPECTION. TEST AND CPERATING STATUS
=
NONCONFORMING ITEMS y
CORRECT!VE ACTION g
C y
QUALITY ASSURANCE RECURD3 g
AUDITS C
OTgERS ANSI N45.2.1; N45.2.2; N45.2.10; N45.2.11; 1
N45.2.12; N45.2.13; ( As defined in th. r.---.--s J.- - oom O
JVf/79 ISSUID FOR BIDS JPi
/
' ddg'OJS NO DATE REVISIONS d SY CHECK'ED APPROVED JOB NO 7220 CONSt2fERS POWER CC:!!' m BAFC MIDI.AND POUER FLANT ITJITS 1&2 DOCUMENT NO REV HIDLA :D, MIQIICAN C-95 (Q) 0
l Speci fication 7220-C-231Q Appendix B Rev. 0 T~
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APPE!OII B Specification 7220 C-95(Q)
. 11.0 CONVEYI::G A:0 Pl.ACII:G Conveying and depesiting of concrete shall be in accordance with ACI 301, ACI 318, ACI Committee 304 Report "*1 acing Concrete by Pu= ping Methods"3 ACI 614, ASnt C-94 and as follous: An adequate communication system will be provided.
No aluminum pipe or other conycying equipeent containing aluminc.,
that will be in contact with the frcsh concrete, shall be used for conveying concreto to point of placement. Steel pipe shall be used for concretc inem.
cr pneumatic placers. A piping arrangteent utilizing a "Y" will be perritted pro-vided a valve is installed at the branch point which will direct the flow into only one branch at any one time. The equipment shall be cleaned at the end of each operation.
e/h,_
i 11.1 C1can-up Preparation Before depositing concrete, all placing equipment shall be cle ned.
Debris, mud, snow, standing puddles of water, and ice shall be rerrved---
from spaces to receive concrete, and the reinforcement and other metal I
to be embedded shall be thoroughly cleaned of all coatings which efght-impair the bond. All compacted soil, rock or concrete surfaces to reccTVc concrete shall be thoroughly saturated before placement.
11.2 Deposition critical structural concrete as derignated on the drawings, shal1 be.,,
deposited in accordance with an approved schedulo showing the nu,m,b,or,,.slau,__._.
i and sequence of concrete placements. Slabs shall be placed in,a c;as,..-.
board pattern unless otherwise approved. A concrete placement.chccl.c#t.. -.-
card shall be completed prior to concrete deposition. See Sect, ion 11 ?_.
for procedures for Inrge placements.
l
Appendix B Rev. 0
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..,. a na..mu Specificstion No. 7220.C-231 Q l
oman C (,
11.3 Time totaicen Adjscent Pisec=ents Unicas shown on the drawinr 3 or directed by Projcet Engincering a minismm of 3 days shall clapsc between the placinr, of concretc of 1
adjacent horizontal scetions of mass pours greater than 2-1/2 feet in the least dimencion.
11.4 Adequate provisions shs11 he made to protect the concrete from rain or snou durin; pisec=ent, und the exposed surfaces of fresh concrete after placensnc.
11.5 Segregstion Concrete shall not be dropped through dense reinforcing steel uhich might causo sesrea,stion of the coarse sgy,re:;ste. In such cases spouts, ficxible drop chutes. or other suitr.ble r.asns shall be used.
.t any event, concrete shall not be dropped free through a height of core than 6 feet, a:: cept as other.:ise approved by Engineering.
'On the botten of fo'r=ed beans and slabs, where the congestion of steci near the forms takes placing difficult, a layer of mortsr, not to exceed one inch in depth shall be first deposited. The
/;
acttar shs11 have, as'a minieun, the same cement-send ratio as
- 4 used in the concrete. !!ortars of higher eenent-ssnd ratios approved by Project. Engineering tray be used.
~*
11.6 Placins Li=itations-Cone):etc shall be deposited in hori:ontal layers of not greater
' depth then 24 inches so.that notisf actory consolidation can be achieved ~vich vitrctors. Concrete shall not be allowed or caused to flow a distsner. vithin the mass of more.than 5 feet from point of depositio%,.
'11.7 Substitution of )!ixes -
With' th( enception of the t.ontaire, ant exterior, non-pozzolan sixas cay.be, substituted for mixes containing pozzolans, provided
[..o
'.he cotu. rete is 3 feet or less in the least dimension.
11.t, Additional Water
^
Concretes for Cints ;% structures shall be rejected when the established watet/ cement ratio-is exceeded. Water shall not be I
added to the (Jnerate alter it hi been dischstged from the batch
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plant.
,11.9 Requirenants foi 'Plantdn's Procediates for Large Placements (single itos er.ceeding 600 cubie; yard.Q.
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'C The propoced procedarcishsH br subpitted t.1 the Project Ent.incer at least two weeks in cdvance c? the pinsment, and shall contain consideration of the fr.11oving itens:
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Apperdix B Rev. 0
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[ 'i SpeciGcation No. 7220-C-231 C 11.9.1 The anticipsted size and duration of'the p1sec ncne including both the car.imum and sverage piscing rates.
11.9.2 The proposed staffing over the anticipsted duration of the placement, including curing, including a brcskdown of the number of supervisory personnel, vibrator operstors, finishers and laborers pisnned per shift.
11.9.3 The proposed conveyance system (i.e. the number of transit-mix trucks, the conveyor system, pumperete system and/or crane and buchet assemblics, chutes, and tremies) planned to accomplish the pour at the anticipated placing race.
11.9.4 The planned sequence of the pour to achieve a monolithic slab and to insure assinst cold joints and the planned movements of the conveyance system (s) to accomplish this.
11.9.5 The checklist fo'r approval of the pour including embed ents.
11.9.6 The ueather protection facilities proposed to prevent damage in the event of the inclenent westher and in the case of planned cold weather placements the enclosure to accomplish the heating requirements for the necessary 7 days.
Include the specifics on the heaters. '
11.9.7 The procedures to,follou in the case of emergencies (i.e. batch plant breakdown with a resultant requirement for an unplanned construction joint).
12.0 CONS 01,IDATION OF CONCRETE l
Hechods for consolidating concrete shall conforn with the recon = ended practices of ACI 309. Concrete shall be consolidated, thoroughly worked around the reinforcement and embedded fixtures, and into corners of the forms by mechanical vibrating equipment. The vibrating equipment shall be of the internal type and shall at all times be adequate in nu.ber of units and power of each unit to properly consolidate all concrete. The frequency vibration shall be not less than 7000 cycles per minute. The duration of vibration shall be limited to the necessary ties to produce satisfactory consolidation without causing objectionable segregation. In consolidsting each layer of concrete, the vibrator shall be operated in a near vertical position, and the vibrating head shall be allowed to penetrato under the action of its own weight 8
and revibrate the, concrete in the upper portion of the underlying layer.
Surface vibrators. hall not be used unless specifically
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approved by Project Engineering.
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- peedix 3 Rev. O
."'}!-l%.to.nu.ain:ssow~
Specificstion No. 7220-C-231 C.
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V Forn vihrators may be used in areas of extreme con;;cstion as approved lf by the ricId Ent;f ncer. The form vibration sha11' conform with the recommended pr.tetice of ACI-309.
librators shall not be used to move or spread concrete., _
Sufficient spare vibrators shall be kept avaliabic for insnediato use at the point ois.desposition.
(Pecommend one cpare vibrator for each three in use.)
Provisions r.hsll be made for auxiliary power to provide continuity of vibratic.
in case ol ;/over failure frcn the principal sourec. D:pe rienced and competent operators shall be proviled for each vibrator being us..l. and chall have received instrue: ions in proper vibration procedures.
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4 Form of Proposal 7220-C-95(Q), Rev 0 FORM OF PROPOSAL SUBCONTRACT FOR UNDERPINNING, EXCAVATION, AND PLACING OF CONCRETE FOR CONSUMERS POWER COMPANY MIDLAND PLANT UNITS 1 AND 2 Name of Bidder The following summary of pricing and other information is offered to Bechtel Associates Professional Corporation in response to the bid request covering the material requisition identified above.
By execution of this form of proposal, the bidder agrees to furnish all items described in the bid request in compliance with the material requisition and general conditions without deviation or exception (except as may be specifically noted below) in accordance with the following.
1.0 MEASUREMENT OF PAYMENT The payment for the work performed as described below shall be on a lump sum basis.
A separate lump sum price shall be submitted for each of the items listed below.
1.1 MOBILIZATION Mobilization includes payment as compensation for the work and expense of importing labor, equipment, materials, supplies, supervision, and setting up onsite utilities.
1.2 AUXILIARY BUILDING This includes payment as compensation for the work and expense of designing, furnishing, installing, and testing of the underpinning for the auxiliary building penetration rooms for Units 1 and 2.
Work includes, but is not limited to, caissons from the underside of the I
existing foundation or mudmat to el 575',
excavation of the material which is required s
to install the caissons, placing concrete backfill in,the area of excavation, and dry packing.
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e Form of Proposal 7220-C-95(Q), Rev 0 1.3 TURBINE BUILDING This includes payment as compensation for the work and expense of designing, furnishing, installing, and testing of the underpinning for the turbine building for Units 1 and 2.
Work includes, but is not limited to, caissons and/or piles for support of the turbine building and the temporary load from the valve pit structure from the underside of the existing concrete foundation or mudmat to el 575', excavation of the material which is required to install the caissons, placing concrete backfill in the area of excavation and dry packing.
1.4 VALVE PIT STRUCTURE This includes payment a; compensation for the work and expense of excavation of all material underlying the entire plan area of the valve pit structure for Units 1 and 2.
It extends from the elevation of the underside of the existing concrete foundation or the mudmat to el 580', support of the excavation from the elevation of the underside of the existing concrete foundation or mudmat to the top of the ccess shaft foundation, or el 580',
whichever occurs first, foundation preparation, concrete backfill, and dry packing.
1.5 ACCESS SHAFTS FOR UNITS 1 AND 2 Included is payment as compensation for the work and expense of designing, furnishing, and installing shafts to provide access to the work itemized in Sections 1.2, 1.3, and 1.4 above.
This work includes, but is not limited to, support of excavation and backfill of the two access shafts from the ground surface to 7 feet below the elevation of the underside of the existing concrete foundation or mudmat of the isolation valve pit.
If Subcontractor elects to salvage the support of excavation material, such savings shall be included herein.
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1.6 MONITORING Included is payment as compensation for the work and expense of monitoring the buildings for movement.
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Form of Proposal 7220-C-95(Q), Rev 0 1.7 DEMOBILIZATION AFD CLEANUP Included is payment as compensation for the work and expense of demobilization, cleanup, and any such work and expense necessary for the complete performance of the work but not included in any other of the payments listed herein.
2.0 ADJUSTMEFIS The payment for the lump sum price work shall be adjusted for added and deleted work according to the following schedule of unit prices.
2.1 Additional or deleted piles and caissons as ordered by contractor shall include, but not be limited to, designing, furnishing, installing, testing of piles and/or caissons from the elevation of the underside of the existing concrete foundation or mudmat to el 575', bearing plates, stub columns, excavation, support of excavation, and support of excavation and concrete backfill of the necessary work space.
Design Price Description Capacity per Each (type)
(kips)
Unit (S)
Caisson Pile 2.2 The leagth of the caisson and/or pile deducted above or added below el 575' is as follows:
Design Price Description Capacity per Each (type)
.(kips)
Unit (S)
Caisson Pile 2.3 Mass excavation, deducted above or added below i
el 580' (price per cubic yard in the bank g
measure) i 2.4 Mass concrete, deducted above or added below l
el 580' (price per cubic yard)
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Form of Proposal 7220-C-95(Q), Rev 0 l
2.5 Support of mass excavation, deducted above or added below el 580' (price per square foot of expoced area) 3.0 ITEMS NOT INCLUDED E LUMP SUM Payment for the work listed below is specifically excluded from the lump sum items or the lump sum unit price adjustment items.
3.1 Installation of styrofoam (price per contact square foot of area covered) 3.2 Placing and inspecting Q-listed dry packing (price per square foot) 3.3 Placing of reinforcing steel (price per pound) 3.4 Placing pumped tremie concret; (price per cubic yard) 3.5 SOIL STABILIZATION - Grouting (excluding grouting indicated in Section 4.2 above), as in the following:
3.5.1 Cement grouting (price per 94-pound sack of cement) 3.5.2 Chemical grouting (price per gallon) 3.6 OBSTRUCTIONS 3.6.1 Jacked Piling - Crew cost per hour, including all special equiptent for removing obstruction - An obstruction for jacked piling is defined hs follows.
a.
The pile fails to.sdvance while subjected to the maximum jacking force when there is no plug at the tip (provided there is adequate lubrication between the pipe and the ground as evidenced by the jacking force just prior to encountering the obstruction).
The material removed from within I
or in advance of the pipe contains rocks or concrete fragments greater than 2 inches in any
. flat plane dimension.
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t Form of Proposal 7220-C-95(Q), Rev 0 b.
Wood or steel is considered an obstruction by definition.
(Material cost per linear foot of pile is to be added to the above crew cost for lengths of pile installed while passing or removing an obstruction.
The price per linear foot is to be deducted from section 13.2 for lengths of pile installed while passing or removing an obstruction.)
3.6.2 Caissons - Crew cost per hour, including all special equipment for removing obstruction - An obstruction for caissons is defined as follows.
a.
The caisson fails to advance while subjected to the maximum jacking force when there is no plug at the tip (provided there is adequate lubrication between the pipe and ground as evidenced by the jacking force' just prior to encountering the obstruction).
The material removed from within or in advance of the pipe contains rock or concrete fragments greater than 2 inches in any flat plane dimension.
b.
Wood.or steel is considered an obstruction by definition.
(Material cost per linear foot of caisson is to be added to the above crew cost for lengths of pile installed while passing or removing an obstruction.
The price per linear foot is to be deducted from section 13.2 for lengths of pile installed while passing or removing an obstruction).
3.6.3 Mass Excavation - The demolition of k
obstructions to a size suitable for efficient handling will be paid on a cost plus basis.
All other costs for l
removal of obstructions shall be paid in the unit price for mass excavation.
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Form of Proposal 7220-C-95(Q), Rev 0 3.7 Furnishing approximately 4,000-kip jacking system 3.8 Installing and removing approximately 4,000-kip jacking system 3.9 Operating approximately 4,000-kip jacking i
system l
3.10 Additional load test at 1.5 times the design load for 5 minutes (reference Section 6.3.2.d) c l
(price per each) 3.11 Additional load test at 1.5 times the design load (price per hour) 4.0 OTHER Payment for the work listed below which is specifically excluded from the lump sum price items or the lump sum unit adjustment items or added unit items shall be paid on a cost plus basis.
Cost shall be based on direct jobsite union labor plus labor burden, 5% of direct jobsite union labor for small (nonpowered) tools and consumables, and the invoice cost of materials, supplies, and equipment not owned by Subcontractor.
Subcontractor-owned equipment shall be based on current blue book rates.
An allowance of 25% of all direct costs shall cover all markup (job overhead, profit, general expense and administration fees, interect, home office expense, executive and management payroll, and travel).
4.1 Design, furnish, install, operate, maintain, and remove a dewatering system to remove local pockets of trapped water.
Note:
The cost of other lump sum or unit price operations such as caisson installation, mass excavation, support of excavation, and concreting are not included in the cost of the dewatering system, even though their efficiency and productivity may be affected by the presence of water or the dewatering system.
Subcontractor shall include whatever cost allowances deemed necessary for such g
inefficiencies or lack of productivity caused by water or the dewatering in the lump sum price, wherein the affected operation is compensated for, and that the prorated portion of the lump sua payment is accepted as the total compensccion for that work.,
1 Form of Proposal 7220-C-95(Q), Rev 0 Company Signature of Bidder Title Bidder's Reference Number l
Date of Bid i
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1 EXHIBIT "E" LIST OF DRANINGS
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7220-C-7[4
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.w EXHIDIT "E" LIST OF DRAWINGS Drawinc No.
Title Rev.
C-2010 Auxiliary Building Unit 1-a3=T
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Plant Area Dewatering c 20N h/. B auvG 44 Y Z MW M b *0"*.S REFERENCE DRAWINGS Yard Drawings CIVIL
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C-5 Detail Plan Area B 6
C-51 Circulating Water System - Plan & Sect.Lons 11 C-52 Circulating Water System - Misc. Details 8
M E
MECHANICAL M-166 Yard Piping Plan - Area B 3
J ELECTRICAL E-530-Sh.#1 Duct Bank Sections 12 E-530-Sh.42 Duct Bank Sections 3
E-531-Sh.#1 Duct Bank Layout - Plant Area 18 g
Turbine Building - Unit 1 & 2 n
CIVIL 4
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Concrete Foundatica Mat at El 614'-0" 11 C-501 C-504 Foundation Mat Reinforcing Plan 5
C-506 Foundation Mat Sections & Details - Sh.!1 8
C-500 Foundation Mat Sections & Details - Sh.f 3 7
C-701 Concrete Foundation Mat at El 614 '-0" 14 C-704 Foundation Mst Reinforcing Plan 6
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l C-710 Concrete Sections & Details - Sh. 12 5
i MECEANICAL M-14 Equipment Location at El 614'-0" 7
M-17 Equipment Location at El 614'-0" 11 1
M-89 Piping Drawing - Area 5 1
J M-97 Piping Drawing - Area 6
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M-105 Piping Drawing - Area 7 5
M-ll3 Piping Drawing - Area 8 3
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1 E-543 Embedded Conduit & Grounding 9 El 614'-0*
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E-547 Embedded Conduit & Grounding 3 El 614 '-0" 1Y j
7220-C-731R Exhibit "E"
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