RE-HABILITATION RESEARCH PROGNtAN

ai

,_TECHNICAL REPORT REMR-CS-7

DESIGN OF A PRECAST CONCRETEAD-A 185 0 8 1 STAY-IN-PLACE FORMING SYSTEM FOR

LOCK WALL REHABILITATIONcoft" by

ABAM Engineers, Inc.F"-it 33301 Ninth Avenue South

Federal Way, Washington 98003-6395

Mjur~i.EJuly 1987Mir .Final Report

-mml I•4" iP Approved For Puft Maless; Distibuto- UnliIrln I a;

ELECTESEP24MsE&

HORIZONTAL JOINT

Ppw.,w for DEARTMENT OF THE ARMYUS Armfy Cor. of EngineersW.+,,asn$00.1,, D 20314-100

Unlarf GobtMWrago. DACWP%-86-C-O014(Civil Vjrs Reaserch Work Unit 32273)

M00Wdd by $tru,:ture LAboratoryUS. Army EnGinsor Waterways Experiment StationPO Box 631, Vicksburg, Mississippi 391WO-0631

8r7

Tefoilo~wng two letters used se pean of the number Isslgntatng technical rotsof reerch pblis jneoheRplt,Evaluation, Maintenance, and Aehatli~tatlon (RENA) Re*serch Progrm Identify the problem ares under which ;;ie reportwas prepred:

Problem Area Probim Area

CS Concrete snd Stee Structures EM Electrical end MechanicalGT Giotechnical El Environmentso ImpactsHY Hydraulics OM Operations MaNagementCO C:'4sml

For example. Tichnlca Repor REMA-CG-7 is the seventh report published under the Concrvsg and Steel structuresproblern are.

Ekest" this report when no lunge neesiec. Do not returnit to the orlginator.

The findings In this report are not to be conetruced as nin officialDepartment of the Army position unless so designated

by other authorized documenfts

The contents of this report are not to be used foradvertising. publication, or promotional purposes.Citation of trade names does not constitute anoff Iato endorsement or approval of the use of such

commercial products.

COVER PHOTOS:TOP - Precast COncree Otay In--plaes formIng sy-stmrfmw lock wall rehWAllltaien.BOTTOM - Typ" oa orlzontsi joint betwen preoea

'inclassified

REPORT DOCUMENTATION PAGE14. WEORT SECURITY' CLASSIFICATtON 1b. RUTRICTIVI MARK~INGSUnclassified

H.SCURITY CAWSWAIMA1OAUTHOOMT A 01ITRMUtT040sAVAILASILITY Of IMPORT__________________________________ Available for public release; distributionJ~ OCLAS1PICTI0IU~*~g~U~ED~Eun limited.

Tech n ica 1.,Fpq~rt REMR-CS-7

$2. NANE1 OF PERPOMIN 111MAUIVNI 01013 YMBO ft. N~AME OF MO#4TMRNO 1RUAIEIATIOABAM ~ ~ ~ ( EnierIn.^.eAto& USAEWES

-,___Enginers, In c Structures LaboratoryBe. ADOPESS (CWS11111.& 3 a V~t 7 b. ADDRESS Oij ftfeW. anV WC0333301 Ninth Avenue South P0 Box 631Federal Way. WA 99003-6395 Vicksburg, MS 39180-0631

Ile. N4AME OF FUNOINGISPONSORING W&Sb OPPICE SYMBOL. 9. PROCUREMENT INSTRijMENT 13rNTIPICATION =1MEEORGANIZATIONEIUS Army Corps ofEngineers NUER

k-D~~sil.Sae andip cb* to. SOURCEHR

jEROLEMEN "I c TASK I WORK UNITWashington. DC 20314-1000 ELMET OJ. [WCESON NO..

11. TITLE ;= sir* baly OuaeMV.

Design of a Precast Concrete Stay-in-Place 'Forming System for Lock Wall Rehabilitation

12 PERSONAL AUTHI. I(S)

13a. TYPE OF REPORT 1t3b. TIME COVERED 14. DATE OP REPORT (Y'eaw, Uweth 0) 5PAGE COUNTFinal Report I ROM TO July 1987 0yr 105

16. SUPPLEMENTARY NOTATION Areport of the Concrete and Steel )tructures problem area ot theRepair, Evaluation. Maintenance, and Rehabilitation (REMR) Research Program, Availablefrom National Technical Tnform aion Service, 5285 Port Ro al Rcad, S rinofield, VA 22161

17. COSATI CODES 14. SUBJECT TERMS (Continue an reevere of neesr and eallntify by block number)FIELD GROUP sul-4ROUP Concrete design Precast concrete

Lock wall rehabilitation Stay-in-place forms

4!ASTRACT (Continue an rsve~ew Nf 'wceuussy and idsntilfr by block nunmbepjThe general approach to lock wall rehabilitation has been to remove 1 to 3 ft of concretefrom the face of the lock wall and replace it with new air-entrained concrete, One of themost persistent p:-oblems using this approach is cracking in the replacement concrete. Ithas been postulated that by using precast concrete as a stay-in-place form for the replace-Iment concrete, cracking problems can be eliminated. This report descr-bes the design ofsuch a forming system.

A range of design 'alternatives was evaluated through a process of value engineering andhorizontal precast ýar-.s constructed of conventional precast quality concrpte were se-lected for detailed quantitative investigation. The panels are tied to the lock monolithalong the top and bottom edges using form ties designed to stipoort the loads of the infillconcrete placement.

I,\ (Conti nued)

20 DISTRIBUTION /AVAILABILITY OP #jSTRACT 21. ABSTRACT SECURITY CLASSIFICATIONMUNCLASSIPIEOIUNLIMITED 03 5E AS NP?. DTic USERSt Unclassified FMESBO22a, NAME OP RESPON3 tILE NDIVIDUAI. 22b. TELEPHONE (Include AmreaC122.OFCESlO

00 FORM 1473,14 MAR El APR edition maey be used until exhausted. SECURITY CI.ASSIFICATION OF THIS PAGEAll other editions are obsolett.

Unclassified

Unclassifiedagumy 0e~i9WuUP 1" au

19. ABSTRACT (Coniiiiued).

The precast concretq stay-In-place forming system is a viable method for lock wall rehobil-itation. In addition'to providing a concrete surface of superior durability with minimalcracking, the estimated construction cost is about 15 percent less than conventional form-ing and concrete placement. Another advantage of the system is the potential reductionin the length of time that d lock must be closed to traffic during rehabilitation. Withproper detailing, sequencing, and scheduling of work activities, the rehabilitation workmay be accomplished with minimized impact on normal lock traffic.

Unclassified19CURITY CLAl8FICATIOM OP TMIS PAGI

PREFACE

The study reported herein was authorized by Headquarters, U.S. ArmyCorps of Engineers (HQUSACE), under Civil Works Research Work Unit 32273."Rehabilitation of Navigation Locks," for which Mr. James E. McDonald isPrincipal Investigator. This work unit is part of the Concrete andSteel Structures Problem Area of the Repair, Evaluation, Maintenance,and Rehabilitation (REMR) Research Program sponsored by HQUSACE. TheOverview Committee at HQUSACE for the REMR Research Program consists ofMessrs. James E. Crews and Bruce L. McCartney, and Dr. Tony C. Liu.Technical Monitor for this study was Dr. Liu.

The study was performed by ABAM Engineers Inc., under contract tothe U.S. Army Engineer Waterways Experiment Station (WES). The contractwas monitored by a Technical Review Board consisting of Dr. Liu;Mr. Thurman Gaddie, Ohio River Division; Messrs. Don Logsdon andDenny Lundberg, Rock Island District; Mr. Roy Campbell, Sr., WES; andMr. McDonald, Chairman. Principal investigators for ABAM Engineers Inc.were Messrs. Charles W. Dolan, Donald D. Mdgura, David C. Kuski, andElmer W. Ozolin.

The study was conducted under the general supervision of Mr. BryantMather, Chief, Structures Laboratory (SL), and Mr. John W. Scanlon,Chief, Concrete Technology Division (CTD), and under the direct super-vision of Mr. James E. McDonald, Research Civil Engineer (CTD), who wasthe Contracting Officer's Representative. Program Manager for" REMR isMr. William F. McCleese, CTD.

COL Dwayne G. Lee, CE, is Commander and Director of WES. Dr. Robert W.Whalin is Technical Director.

i I C J~i._ ll•0•, ••

V1 striOutIonl/

Avalo•i la de

1 Dist special

CONTENTS

PREFACE .. .......... ................ .............. ........... 1

CONVERSION FACTORS, NON-SI TO SI (Y.ETRIC)UNITS OFMEASUREMENT .. .. .............. ................ ....... 3

PART I:INTRODUCTION. .... .............. ................ ..... 4

Overview. .. ........ ................ .............. ..... 4Objectives .. .... .............. ................ ......... 6Approach. .. ........ ................ ....................7

PART II: CRITERIA.................................................................

Introduction .. .. ................ ................ ....... 8Durability .. .. ................ .............. ........... 8Functionality .. ........ ................ ................10Constructability. .. ........ ................ ............10Cost/Schedule .. .......... ................ ..............11

PART III: PREPARATION OF ALTERNATIVES. .. ........ ..............14

Introduction. .. ........ ................ ................14Material Options .. .. ................ ....................14Panel Systems and Configurations. .. .......... ............18Panel Types .. .......... ................ ................20Qualitative Comparisons and Findings .. .... ................21

PART IV: REFINEMENT OF ALTERNATIVES. .. .......... ..............23

Introduction. .. ........ ................ ................23Loading Criteria .. .. ................ ....................23Panel Design. .. ........ ................ ................24Form Tie Design .. .......... ................ ............25Details .. .......... ................ ....................26

PART V: RECOMMENDATIONS, FINDINGS, AND CONCLUSIONS .. ............28

System Description .. .. ................ ..................28Cost Analysis .. .......... ................ ..............31Schp-dole Analysis. .... ................ ..................34Conclusions .. .......... ................ ................34

REFERENCES .. .... .............. ................ ..............40

APPENDIX A: DESIGN CALCULATIONS, PHASE IIDEMONSTRATION PROJECT. .. .......... ................Al

APPENDIX B: CONSTRUCTION SPECIFICATIONS, PHASE IIDEMONSTRATION PROJECT. .. .......... ................B1

APPENDIX C: DESIGN DRAWINGS, PHASE II DEMONSTRATION PROJECT . C1

2

CONVERSION FACTORS,

NON-SI TO SI (METRIC) UNITS OF MEASUREMENT

Non-SI units of measurement used in this report can be converted to

SI (metric) units as follows:

Multiply By. To Obtain

cubic feet 0.02831605 cubic metres

cubic yards 0.7645549 cubic metres

Fahrenheit degrees 5/9 Celsius degrees or kelvlns*

feet 0.3048 metres

inches 25.4 millimetres

kips (force) 4.44822 kilonewtons

kip-inches 112.9848 newton-metres

kips (force) persquare inch 6.894757 megapascals

kips (force) persquare foot 47.88026 kilopascals

ounces (avoirdupois) 0.02834952 kilograms

pounds (force) persquare inch 0.006894757 megapascals

pounds (mass) 0.4535924 kilograms

pounds (mass) percubic foot 16.01846 kilograms per cubic metre

pounds (mass) percubic yard 432.49842 kilograms per cubic metre

square feet 0.09290304 square metres

* To obtain Celsius (C) temperature readings from iahrenheit (F)readings, use the following formula: C - (5/9)(F - 32). To obtainKelvin (K) readings, use K = (5/9)(F - 32) + 273.15.

3

DESIGN Of A PRECAST CONCRETE STAY-IN-PLACE

FORMING SYSTEM FOR LOCK WALL REHABILITATION

PART I: INTRODUCTION

Overview

..1. The stay-In-place forms project is a develoomntal design

effort which was initiated by the Corps of Engineers to evaluate the useof precast concrete as a means of controlling persistent cracking which

has been experienced on previous repairs of navigation locks usingcoiiventional cast-in-place concrete and to decrease the time the lock isout of service for repairs. Conventional repairs to gravity lock struc-

tures are typically made by removing between I to 3 ft of corcrete fromthe face of the lock wall and casting an overlay repair using air-entrained concrete and conventional wood or metal formwork (Figure 1).

Cracking of the replacement concrete due to thermal and shrinkage strainsin the new concrete overlay has consistently been a problem using thismethod of repair. It has been postulated that by using precast concreteas a stay-in-place form for the replacement, the thermal and shrinkagestrains can be controlled such that surface cracking of the repair canbe eliminated. The stay-in-place forming system may also improve theconstruction schedule and reduce lock closure times over conventionalrehabilitation methods.

2. The Corps of Engineers currently operates and maintains 133rnavigation locks which were built prior to 1940. More than 75% of these

older locks are located in the Corps' North Central and Ohio River

divisions, areas of relatively severe exposure to freezing and thawing.Due to the age and exposure of these structures, many exhibit significant

concrete dete-ioration since the concrete in these structures does notcontain intentionally entrained air and is therefore susceptible to

damage from freezing and thawing. The extent of deterioration rangesfrom surface scaling to several feet in depth and is generally confinedto that area of the wall above low-water pool elevation. In some

4

- CONCRETE REMOVAL& REPLACEMENTVARIES 12' TO 36"

.

TYPICAL APPROACH TO LOCK WALL REHABILITATION

FIGURE 1

5

instances, hcw4eer, repairs may be required 2 to 3 ft below low pool

elevation.

3. Concrete removal is usuaily accomplished by line drilling

and blasting, or by various nonexplosive methods. If required, concrato

removal continues beyond the removal line until all unsound or deterio-

rated concrete has been removed. When the concrete wall surface

preparation is completed, small-diameter holes are drilled into the face

of the wall into which dowels are grouted to anchor the replacement

concrete to the existing lock wall moAolith. Mats of reinforcing steel

are hung vertically on the dowels. In some cases, the reinforcing mat,

wall armor, and other lock wall appurtenances are installed on the form

prior to positioning the fcrm on the face of the lock wall. Once the

reinforcement and formwork are in position, repldcement concrete is

placed. Lift heights vary from 5 ft to the full wall height of approxi-

mately 40 ft. Forms are typically removed beginning one day after

placement, and a membrane curing compound is applied.

4. One of the most persistent problems in lock wall rehabilita-

tion using the conventional cast-in-place repairs is cracking in the

replacement concrete. To date, the replacement concrete in all of the

Corps' major rehabilitation projects has exhibited some degree of

cracking. Although several variations in concrete materials, mIA•ure

proportions, and construction procedures have been used in attempts to

control or eliminate the cracking, only limited success as been ichieved.

Objectives

5. The objectives of the stay-in-place precast concrete form

rehabilitation project are to develop a repair concept which provides

superior durability, minimizes the lock closure duration, accommodates

all of the normal lo,.k hardware and appurtenances, and can be imple-

mented at a wide variety of navigation lock sites throughout the United

States. To accomplish these goals, the system must satisfy a well-

defined set of durability, fun~ctional, constructability, and cost/

schedule criteria. Establishing the criteria and baselines for e,,alu-

ating the performance of the system is an integral part of the project

and was used in value engineering analyses of the individual elements of

the system.

6

Approach

6. The project was a two-phased effort. The first phase, which

is the subject. of this report, was the engineering development portion.The second phase was a demonstration project implemneted following

successful completion and evaluation of the Phase I work. Phase 1,Concept Development, was performed in four tasks. The four Phase Itasks were organized as a filter system to maximize the number of

possible options which were considered and used to test each optionagainst a definitive set of criteria. Value engineering analyses andcontractor input were used to select the final concept which optimizesthe return investment. In Task 1, the project objectives and criteriawere defined and quantified. In Task 2s the range of~ possible solutionswere generatedt and qualitatively evaluated against 'ne criteria. Thepurpose of Task 3 was to refine the preferred concipt by definitivetesting against the objectives, and in Task 4 the final plans, specifi-

cations, and estimates for the Phase II demonstration project wereprepared.

7

PART II: CRITERIA

I, troduction

7. A detailed set of criteria has been developed against which

to evaluate each of the possible stay-in-place form concept design

options. The basis of the criteria is a generic list of objectives

defined by the Corps in the initial solicitation. The generic objec-

tives for the stay-in-place precast forming system are listed below: --

a. Must be economically feasible in comparison with lockwall refacing by conventional mans

b. Must be of sufficient lurability to protect the under-lying concrete freom further deterioration under antici-pated service condition (freezing and thawing, wettingand drying, etc.)

c. Must be anchored and fully bonded to the existing lockwall concrete

d. Must be capable of accommodating the usual lock wallappurtenances, including wall armor, corner protection,exit ladders, line hooks, and floating mooring bitts

e. Panel sizes must be such that they can be transportedand erected using conventional equipment

f. Must not seriously affect appearance or operation uf thenavigation lock

.q For purposes of the design, a lock wall monolith widthof 30 ft and a height of 40 ft to be refaced was assumed

8. From this list, specific criteria were developed which are

grouped into four broad categories: durability, functionality, con-

structability, and cost/schedule. Each of these categories is described

below.

Durability

9. The durability objectives of the repair include eliminating

surface cracking, providing suitable resistance to cycles of freezing

and thawing for the replacement concrete and substrates, assessing creep

characteristics of prestressed options, and providing adequate cover or

physical protection for reinforcing. Each of these objectives was

evaluated in the design of the various precdst options.

8

".10. Differential strains between old and new concrete are arasult of thermal, shrinkage, creep and, to some extent, external actions.

The most significant source of strainin conventional repairs appears tobe the result of both pdastic and autogeno's shrinkage strains in the

fresh concrete repair. Thermal strains are important; however, they do- not appear to be the principal cause of the persistent cracking that has

been observed. The reasons for suspecting shrinkage as the primary

cause is based in part un reports from the Corps of cracking appearingon repairs within 24 hours of placing the cast-in-place overlay, and

even as the forms are being removed. Thermal tensile strains would not

be predominant at this early age since hydration of the repair concrete

would still be active. Also, cracking has appeared in structures con-

structed in hot weather reducing the influence of thermal "shock" during

form removal.

11. Several options exist for mitigating the influence of shrink-age and thermal strains. Such options include the use of low-heat

concrete mixture designs which utilize fly ash, chilled aggregates, and

mixture water, or by using other admixtures designed to limit the amountor rate of heat generation within the replacement concrete. Shrinkage

strains can be controlled through the use of suitable curing practices

or by limiting the free surface area of the concrete overlay. Unavoid-

able cracking can be made more palatable by using control joints or by

using reinforcing to distribute the cracks and limit crack widths.

12. Long-term durabilityof the repair requires that adequateresistance to cycles of freezing and thawing (the primary cause of the

deterioration of lock walls) be provided in the structure. Due to the

age of the structures, the concretes used in the original construction

were not intentionally air entrained and were not designed to be imperme-

able. Consequently, the structures are susceptible to deterioration

from freezing and thawing. Another aspect of this type of deterioration

that must be assessed is the possibility of moisture collecting behind

the repaired surface where it could freeze and fcrm ice lenses. Theseice lenses would result in debonding of the surface overlay and eventual

deterioration of the surface. If free moisture can be trapped beneath

the repair and if it is susceptible to freezing, then it must be allowed

to drain.

9

- - -.-- IL

13. The preferred choice for any repdir to the navigation locksis to use air-entrained concrete. Entrained air has been demonstratedto be instruimental in improving resistance of concrete structures tofreezing and thawing. In addition, impermeability of the mixture isimportant to prevent moisture penetration through the re~pair wtheve itmight cause continued deterioration of the substrates. Concrete protec-

tion for reinforcing also needs to be. considered. Adequate cover forreinforcing must be provided to prevent corrosion.

Functionality

14. Functionality criteria for the precast forming system requirethat it serve to adequately support the loads imposed by the inf illconcrete, that it accommodate all of the normal lock hardware and appur-tenances, that the panels accommodate tolerances on fabrication anderection, and that suitable deta ls are incorporated in the panel designto resist abrasion and impact from use of the lock. Normal structuraldesign of the forming system will account for the loads imposed on thepanels. Careful attention to detailing is necessary to satisfactorilyprovide for fabrication and erection tolerances. Precast concrete issomewhat unforgiving when misfitting or poorly aligned panels are to beincorporated into the work. Therefore, connections and inserts must bedetailed to allow for normal construction tolerances and practices.

15. For the precast system to serve as a viable alternative toconventional repairs, it must accommodate all of the lock hardware andappurtenances. In addition, panel joints must be armored where they aresusceptible to impact and abrasion. Standard hardware may need to bemodified, or special hardware developed to allow it to be integratedinto the precast -epair system.

Constructabil1ity

16. The overriding benefit to the use of precast concrete,stay-in-place forms for navigation lock repairs is in the construct-ability improvements that they offer. These benefits, stated ascriteria for the system design, require that the system provide formaximum scheduling flexibility, that it be suitable for use at a wide

10

÷,7

variety of construction sites and precasting facilities, that panel

sizes be favorable:to local transportation restrictions, that a maximum

of out-of-lock preasser..ly be accomplished, and that special techniques

and equipment usage be minimized.

17. Constructability benefits are best realized by careful

design and detailing of the panels. Embedding all armor and appurtenances

in the panels; designing and detailing the panels, connections, and,form

ties to allow for rapid erection; full-height concrete plocements;

interchanging of pieces; and limiting the size end weight of the panels

are all important to the success of tne system.

18. Industry standard practices should be employed in the panel

fabrication to permit the panels to be produced locally or at remote

sites. Concrete mixture designs should allow for local aggregates and

materials to be used. Prestressing may be employed when plant production

of the panels is possible. " '

Cost/Schedule

19. The criteria developed for evaluating the precast stay-in-

place forming system are based on a typical 30-ft-wide by 40-ft-high

concrete wall refacing. Cost and schedule data were developed from

repairs performed at the Brandon Road and Lockport locks on the Illinois

Waterway and from standard cost estimating and scheduling methods. The

schedule criteria are considered to be of paramount importance for the

design of the precast panel system, since a primary objective of the

stay-in-place form repair is to reduce the lock closure duration. Cost

data are used for comparison purposes only.

20. Figure 2 illustrates the baseline schedule criteria developed

for a conventional cast-in-place repair. The baseline indicates that a

conventional repair requires approximately 64 hours of effort to reface

the typical monolith wall. The schedule duration for a large repair

job, however, would be roughly one half or 32 hours per monolith due to

overlapping work on adjacent monoliths as indicated by Monoliths V

through W at the bottom of Figure 2. A contractor operating with experi-

enced crews and performing shift work could be expected 4o reface one

monolith every twc to three days.

11

0 1

11 A A I

ot 4 Ja

'aI I 0-

II ~I

Itn N 1 01 c0A*~ 2.C

1 0a 1 a#

It R I t A v

0H U a I 0l aiII1 If n I #a~

0n OX X 4

*u 14 +) It to

U. a1 Cn 06 'C 0Lc aa a o

It a in a a+b

ci 11 4U J6U

a, N 1, ItI- III 00 1.O

A 0

1n 1. a ka 1* -0

I~ "- a aL.tU1 M a a a-r-0 C

L. 0 0 c a84

at t-C U* IS #A IU 10~i

UU 4J 0 u. 0na- c L. 0 Ve 0 xC nC

) -ad 0 0 . 0 uC * ~ 1 0* . 411 0% OA CL

a I a L . - ua 4.b I5. IA#A S4 0. 'a E- a- 44Dnin4) L 0 - . 4.9 4 401 0n a- In' a a

o% .' 0 L 0 0 40 S 0:140.U+j 0' 4-i o U) III E& I'l C- 1 a a

C * u 0 * *x 0 1 - % f> - t () qj ~ ~ r_ a~ -4 -4 -4

- 4) "D 4b 11 411f12

21. The conventional rehabilitation projects generally involvemaintenance work to ancillary lock facilities such as gates, electricalsystems, or controls. With the conventional repair, this work may beaccomplished concurrent with wall resurfacing work. The schedule base-line assumes that wall refacing work is pacing the construction schedule,

however.

22. Table 1 11ustrates the baseline cost criteria developed fora cast-in-place repair and is used for comparing relative costs of the

stay-in-place form systems. The costs indicate that a conventionalj repair should.. cost ;on ?theo..r•r.der.of $137 per ..square foot of lock wall

surface.

13

PART III: PREPARATION OF ALTERNATIVES

Introduction

23. The range of possible options. for achieving the project

objectives was evaluattd through a process of valut; engineering. Theprocess involved listing' the available design alernatives and then

evaluating the attributes of the option against the criteria and objec-tives. The design' alternatives which were considered can be categorized

.as materials related, system configuration variables, and panel typesand sizes. An evaluation system was used to establish the relativepreferences of each of the options which were considered. The selectionof a most advantageous combination of panel design features was then

made.

Material-Options

24. The material options which were evaluated in the precaststay-in-place forming system design were concrete mixture variables,reinforcing options, and the possible use of surface treatments for the

panels. Rehabilitation of the lock walls will likely include a minimumof two separate concrete mixture designs. One mixture will be propor-

tioned specifically for the precast form elements with resistance (dura-bility) to freezing and thawing, low moisture absorption qualities,abrasion resistance, and strength as predominant criteria. A secondmixture for the inf ill concrete will be proportioned with low hydration

temperatures and high workability with rapid slump loss as primarycriteria. Reinforcing is provided as necessary to satisfy strength and

serviceability criteria. Conventional mild steel reinforcing) prestress-ing, or fiber reinforcing options are considered. Surface treatmentsare possible means of improving the durability of the precast concrete

panels. Such treatments might include surface hardeners or sealers toimprove the abrasion resistance and moisture absorption qualities of the

concrete.

14

Concretes

25. Conventional Concrete. The use of conventional concrete wasassumed to represent the oaseline case for evaluating material options

in panel performance. Conventional concrete as defined for this evalu-

ation consists of moderate- strength (f, 12 4000 psi), air-entrained

concrete. Such concrete is considered typical concrete that m'ght be

ustci for a conventional lock repair. A conventional concrete mixture,while used as the baselin2 for material performance, may be improved bythe addition of suitable admixtures and by design and quality control asdiscussed below. Functionally, a conventional concrete mixture. is

nearly as good as some of the enhanced mixtures which were evaluated;

however, its long-term durability and abrasion resistance may be somewhat

less. A conventional mixture may also prove difficult to place under

certain circumstances without admixtures t~o improve workability. How-

ever, the cost of conventional mixtures is the least of any of the

mixtures evaluated.

26. Precast Quality Mixtures. Precast quality ~cecrete is

assumed to be 6500-psi compressive strength concrete. The material and

batching controls necessary to achieve the higher strength will result

in enhancements in its long-term durability. In particular, the perme-

ability of the concrete will be reduced to the point that it will be

virtually unaffected by cycles of freezing and thawing. With a moderate

amount of entrained air, a precast quality concrete should exhibit

improved durability and abrasion resistance over conventional mixtures.

Admixtures may need to be introduced into the mixture to improve work-

ability. The cost premium for precast quality concrete is low.

27. Fly Ash Concrete. The use of fly ash in the mixture is con-

sidered beneficial in controlling thermal properties of the mixture, in

improving the workability of the fresh concrete, and in reducing the

cost of the mixture through cement replacement. The use of fly ash in

the mixture also reduces the permeability of the mixture and increases

the compressive strength of the concrete at later ages.28. Polymer Concretes. Several types of polymer concretes are

available. All offer greatly improved strength and durability over

typical concrete mixtures. Polymer concretes, however, have significant

constructability disadvantages in relation to the typical concrete

mixture types. The need to polymerize the mixtur. through the use of

15

heat or radiation provides a severe restriction in considering thesematerials for this application. The special equipment required for such

a process severely limits the number of facilities that could fabricate

panels. In addition, a system which relies upon highly specialized

expertise for a key element in the construction is subject to wide

schedule or price variation. The cost of polymer concrete is the primary

detriment of this material. Polymer concrete mixture: might prove to beeconom'ically viable fcr relatively sm,All repairs, however. Polymer

mixtures were therefore evaluated in conjunction with the very thin

panel types and for the bonded repair techniques.29. Silica Fume Concrete. Silica fume added to the concrete

mixture has recently been used as a cement substitute to increase thecompressive strength, greatly reduce the permeability, and improve the

abrasion resistance of the concrete. However, the impact resistance ofthe concrete may be reduced. Silica fume additives have historically

been rather expensive. With the commercial introduction of silica fumeadditives, the cost and availability of the material should improve.

Nevertheless, the use of silica fume is believed to have adverse cost

and schedule implications as compared to a conventional or precastquality mixture.

30. Fiber-Reinforced Concrete. Nonmetallic fiber additives in

the concrete mixtures could improve the durability of the concrete;however, the cost and constructability of the mixture would be adversely

affected. Glass fiber reinfo rcements (GFRs) are often used to increasethe tensile strength and ductility of the concrete. GFR concretes,however, are often difficult to place and are typically employed inspecialized products such as pipe where these enhanced properties areespecially beneficial. The long-term durability of GFR concretes has

not yet been demonstrated.

Reinforcing31. Conventional Mild Steel. Conventional mild steel reinforcing

for the precast panels was used as the baseline for comparison of thevarious reinforcing options. Mild steel designed and detailed to satisfythe provisions of applicable codes should be adequate for strength andserviceability performance. Loads due to panel handling may requirespecial consideration. Limiting crack widths to en-,ure durability of

16

%A.

the panels in the wet/dry environment is necessary for satisfactory

long-term performance.

32. Prestressina Strand. Prestressing was evaluated as a&means

to accommodate construction loads due to handling the precast panels, to

improve the serviceability stresses, and for crack control. The dis-

advantages of prestressing are the increased cost and the special

facilities required to prestress the panels. On-site prestressing ishighly improbable ut-less a mobile stressing bed were available. There-

fore, prestressing was only considered as an option if required for

stress and serviceability reauons.

33. Steel Fiber Reinforcing. Steel fiber reinforcing like GFRC

has been used to improve the tensile strengtn and ductility of concretes.

Like GFRC, steel fiber reinforcing is typically used in siecialized

applications and where the facilities are available to produce the

product. The primary disadvantage of steel fiber reinforcement is the

cost.

Special Treatments

34. Untreated Concrete. Untreated precast panels were considered

as the base case for evaluating the merits of the treatments which were

considered. Untreated panels should perform satisfactorily; however,

surface treatments may offer substantial improvements to performance at

a nominal cost. For this reason, surface treatments were evaluated.

35. Surface Hardeners. Several types of commercial surface

treatments are available which render a very hard, abrasion-resistant

finish to concrete surfaces. These treatments are typically used on

floors of warehouses where heavy loads, impact, and abrasion are present.

The typical treatment involves applying a powdered product to the fresh

concrete finish and troweling it into the surface. Spray applications

are also available. The product is either a metallic or nonmetallic

powder which, when worked into the surface of the fresh concrete, creates

a hard, dense, impermeable finish. Metallic hardeners tend to discolor

and rust the surface when used in moist environments. The products

could be applied to the inside surface of the precast panel form prior

to placing the concrete in the form, thereby creating a panel with a

hardened surface.

17

a "

36. Surface Sealants. Surface sealants are typically spray-

applied products designed to seal the surface of the concrete and prevent

moisture loss. The product improves the hydration of the concrete near

the surface and results in a more durable surface. Sealants also assist

in preventing moisture penetration into the surface and thereby improve

the resistance to freezing anI thawing deterioration. The use of surface

sealants to assist in curing the precast panels in the fabrication yard

is a possibility. The long-term performance of surface sealants in the

abrasive environment of a navigation lock is questinneble.

Panel Systems and Configurations

37. Two primary panel support systems were evaluated, a system

consisting of panels supported from the monolith with form ties and a

system which used external bracing systems to support the panels during

the infill concrete placing. A third type, consisting of bonded panels,

was evaluated but is not considered to be practical for large areas of

repair. With each of the support systems that was considered, the

panels can be oriented either vertically or horizofntally. There are

theo four combinations 0 panel support systems and configurations which

were evaluated.

Tied Panel System

38. The tied panel system uses form ties to maintain the align-

merit of the panels and to support the loads of the infill concreta

placement. The ties may also be used to replace the concrete anchors

normally used in Carps lock rehabilitation work. Advantages of the tied

panol systsam are that no major equipment is required in the lock during

panel installation and concrete plecing activities. The contractor also

has greater flexioilitv in scheduling and sequencing the work. The lock

may be returnod to use soon aftel" the infill concrete has been placed

and consolideted. This syttem would allow wotk to be performed on an

operational lock wth only minor disruptions in normal lock traffic

during concrete panel installation and concrete placement activities.

39. A disadvantage of the tied panel system is that it depends

heavily on the ability of the ties and panel connections to accommtodate

18

the maximum out-of-tolerance condition. If through tie holes are pm-vided in the panels, they will require patching. Also, the maximum size

of panel that may be used with this system may be governed by the capacity

of the form ties. Concrete placement rates may need to be restricted to

control loads on the panels or the ties.

Externally Braced System

40. The externally braced system uses a temporary support struc-

ture within the lock to support the precast panels while placing the

infill concrete. The brace needs to bo designed to support the full

pressure of the wet concrete and may become quite substantial, depending

on the height of placement. On the Brandon Road lock rapair, the cen-

tractor used a falsework truss to support monolith placements on each

side of the lock concurrently. The truss spanned the full width of thel oak.

41. Advantages of the external bracing system are that it does

not rely on the wall anchorage system, it can minimize tolerance inter-

faces, it can accommodate large panel sizes, and lock hardware and

appurtenances can be incorporated with minimal interference. Disadvan-

tages of the system are that major equipment is required in the lock

throughout the repair, the panels must be installed between the brace

and the lock wall, the normal concrete anchorage system is still required,

and the cost of bracing must be included in the cost of the repair.

Vertical Arrangement

42. The vertical panel arrangement requires that full-height of

panel infill concrete placements be used. Consequently, the form ties

or external braces must be designed for the full-height concrete loads.

Joints between panels must be match cast, armored, and of close tolerance

to prevent excessive abrasion from passing barge traffic. Horizontal

armor must consist of relatively short segments, making them more prone

to damage from misalignment at the joints. The full-height concrete

placements may result in a shorter overall construction schedule, assuming

that all work is performed on an out-of-service lock.

19

Hortzontal ArranaMnt43. This arrangement has two features which enhance the panel's

durability artj constructability over the vertical arrangement. First,the panel joints are orientel horizontally where they will be less proneto abrasion from passing barge traffic. Horizontal armor may run the

full width of the mono'ith and possibly be incorporated into the panelhorizontal Joints. Second, the ability to control infill concretepressures with staged lifts results in a reduction in the potential for

stress cracking of the panel. Staged concrete lifts may lengthen theoverall constructiun schedule. However, the lock may continue in opera-

tion, provided a tied support system is used.

Panel Types

Hollow Core Panels

44. Hollow core precast panels are often used in building con-

struction as floor, roof, or wall elements. They have the advantage of

being relatively lightweight, fire-r.sistant, and economical for that

application. They are produced in a sl1pform fashion by casting the

concrete around a mandrel which moves as the panel is cast. The primary

disadvantages with the use of hollow core elements for lock rehabilita-

tion work is that the panels are not particularly durable. The cores

would need to be filled, and the slipform casting procrss does not

readily accommodate lock hardware and appurtenances.

Flat Slab Panels

45. Flat slab panels are considered to be the most likely choice

for the stay-in-place forming elements. The principal advantages are

the ease of production and handling and the versatility of the panels

to a wide range of specific size and configuration requirements. Dis-

advantages include the possible need for stiffening or mechanical inter-

lock on the interior face of the panel to ardchor it to the substrate.

Double-T and Trn-Slab Panels

46. Double-T panels are considered to be a special case of the

flat panel system. Backside stiffeners in the form of ribs could be

added to the flat panels to assist in resisting the infIll concrete

20

pressures. Disadvantages to this configuration inclode the difficultyin forming the panels and integrating the lock hardware and appurtenancesinto the panel. Other problems include interferences between the panelribs and concrete anchors protruding from the monolith wall.

Thick or Thin Panels47. The possible use of exceptionally thick or thin panels was

evaluated to ascertain any potential advantage afforded by these options.Thin panel systems offer the advantage of light weight; however, theycannot accommodate lock hardware easily, and they will invariably require

supplemental exterior bracing to carry the inf ill concrete pressures.

Thin panels are viable for repair of small areas by directly bonding the

small thin panels to the substrate using epoxy bonding agent:; ho-Wever,

they are less euffective if there are large variations in the depth of

the wall to be repaired. Such panels could be produced from very durable

materials. Thick panels have the advantage of readily accommodating

lock hardware; however, they are difficult to handle and may be more

costly than the thinner panel systems.

Qualitative Comparisons and Findings

48. A value engineering analysis was performed on the variousmaterial, support, configuration, and panel type options that were

considered. The analysis used a qualitative comparison technique in

which the relative merits of the option were evaluated against an arbi-

trary baseline measure of performance. A value was assigned to the

option in each of the four primary criteria categories, depending on

whether that option was judged to perform better or worse than the

baseline in that category. The four primary criteria which were con-

sidered are durability, functionality, constructability, and cost/

schedule. The values and their assignment basis were as follows:

Value Definition

0 Baseline performance of option against criteria

-1 Option exhibits fewer criteria attributes thanthe baseline option

21

+1 Option exhibits greater crlteric attributes than

the baseline option-2 Option exhibits low degree of criteria attributes+2 Option exhibits high degree of criteria attributes ,

49. The results of the value engineering comparisons are shown

in Table 2. The value engineering analysis results provide an overall 4

rating of one option in relation to another. From these results, a

preferred choice of precast stay-in-place form design features can be

made. The preferred panel configuration consists of a tiedi flat panel $

constructed of precast quality concrete and oriented In a horizontal

arrangement.

50. The basis for selecting this configuration for further __

refinement mnay be summarized as fullows. Precast quality concrete meets

the primary objective of providing sufficient durability for lock exposure

and application. The tied horizontal panel arrangement provides the

greatest degree of flexibility in scheduling and sequencing of the work

and, potentially, may allow rehabilitation work to be performed on an

operational lock. Flat panels are the obvious option of choice; however,

stiffening may be required to carry inf ill loads.

22

PART IV: REFINEMENT OF ALTERNATIVES

Introduction

51. Using the preferred forming system identified in Part III,paragraphs 48 through 50, a detailed quantitative investigation was

conducted to determine actual sizes of form panels, tie details, hard-

ware details, etc. These details were then extrapolated to the scaled-

down demonstration installation which is to be carried out in Phase II

of the project.

Loading Criteria

52. The controlling loading for design of the forming system is

the lateral pressure exerted on the formwork by the fresh infill concrete.

Other secondary loadings included temporary construction and wind load-

ings on the erected formwork and strain loadings due to the shrinkage

and thermal effects of the inf ill concrete.53. The selection of the design lateral pressure affects not

only panel and tie design but also impacts construction methods and

cost. An iterative process was therefore used to select an allowable

lateral formwork pressure which results in a workable panel design basedon the criteria outlined in the next section yet does not adversely

impact conbtruction. A pressure of 1.25 ksf was selected, which corre-

sponds to potential placement rates between 5 and 9 ft per hour hased on

guidelines developed by the concrete industry. Use of a pressure due to

an unlimited placement rate was found to result in excessive panel

thickness for even the narrowest oanels. For the baseline 40-ft-high

monolith, the unlimited pressure would be approximately 6.0 ksf.

54. Due to the sensitivity of the overall forming concept to the

lateral formwork pressure, any reductions in pressures would result in

an overall cost reduction for this repair procedure. The concreteindustry guidelines used to select the design pressure are based on

historical data and cover a wide range of common formwork and concreteplacement practices. This project will involve very specific and con-

trolled practices which can be directed at reducing the pressures and

use of general guidelines may be overrestrictive. However, quantitative

23

data must be gathered in order to justify reduced design pressures andappropriate quality control measures must be instituted to assure that

the specified materials and practices are followed.

Panel Design

55. The formwork panels have been sized to provide strength and

serviceability consistent with their required function. As stated in

Part I of this report, the elimination of surface cracking is the main

thrust of this project. For this reason, serviceability criteria have

controlled much of the detailed design of the panels.56. The design procedure generally followed the requirements of

ACI 318, "Building Code Requirements for Reinforced Concrete." Due tothe importance of the serviceability criteria, flexural design was basedon the ACI 318 Alternate Design Method - Appendix B (Working Stress

Design). As a cross-check, the Strength Design Method was also usedwith a load factor of 1.9 applied to the lateral pressure as recommendedin Corps publication ETL 1110-2-265.

57. Based on the studies described in Part III, panel widthsranging between 5 and 10 ft were deemed optimum from a constructabilityviewpoint. These panel widths require horizontal tie spacings atapproximately one half of the width of the panel in order to maintainworkable tie loads. This combination of panel width to tie spacingproduces a vertical load path for distributing the lateral pressures.

Therefore, panels have been designed as one-way, simply supported ver'ticalbeams. The assumed load path was confirmed by finite element computeranalysis for a span length to tie spacing ratio of 1.5. Only minimaltwo-way load distribution was noted.

58. The principal serviceability criteria include cracking,deflection, and reinforcement cover. Design for crack-free panelswithout prestress results in either narrow or thick panels, each havingconstructability and cost impacts. The use of prestress in the verticaldirp'vtion to avoid cracking is impractical due to the lack of developmentlengt'hs for strands to transfer the prestress force into the panels.

59. Serviceability criteria was derived from ACI 224R, "Controlof Cracking in Concrete Structures," which contains guidelines foracceptable crack widths for various exposure conditions. The design

24

criteria selected to provide optimum serviceability for the leave-in-

place formwork includes the combination of maximum estimated crack

widths of 0.010 in. due to formwork pressures and minimum concrete cover

at the exposed surface of 2 in. A minimum concrete cover of 3/4 in.

will be used on the interior panel surfaces.

60. Panel bulging or deflections due to the lateral infill

concrete pressures were maintained within the erection tolerances. This

serviceability requirement did not control the design even though cracked

section properties were used in the deflection computaticns.

61. Erection and handling stresses were investigated assuming

several lifting arrangements in order to ascertain that adequate panel

strength was available in the longitudinal direction. The panels were

checked for a dead load of 160 pcf plus 25% impact factor. Lifting

inserts and embedments common to the tilt-up building construction

industry are likely to be used for panel handling.

Form Tie Design

62. Form tie loads were calculated using the design lateral

pressure in conjunction with tributary areas. The resultant tie force

which incorporates the worst cumulative effect of erection and precasting

tolerances can result in tie loads approximately 1.5 times the horizontal

reaction. Several form tie concepts were investigated with the optimum

choice being a weldable grade reinforcing bar grouted into the lock

.wall. The rebar tie is welded to a plate embedded in the precast panel.

For the test installation, a factor of safety of 3 on the resultant

working load was selected to ensure redundancy and improve reliability.

63. To simplify details, the ties were designed for tension

load5 only. Separate compression struts or kickers are provided to

resist inward construction, wind, or tie pretension loads. Since theties are grouted into lock walls of varying strengths, the capacity of

the ties must be verified by actual field pullOut testing to confirm the

anticipated pullout strengths.

64. The tie system replaces the No. 6 bar dowels on 2- and 4-ft

centers which have been previously used for the all-cast-in-place repair

procedure. The tie system provides a permanent connection to the form

panel. One other major difference between precast and cast-in-place

25

(CIP) repair procedures is the elimination of the reinforcing mat in theCIP inf Ill concrete.

Details

65. Details, have been, developed to enable incorporation of all

typical lock har .dware with the-stay-In-place form. lock repairý procedure,

either by casting the hardware directly into the form panel or locating

the hardware at panel joints. Additional details specific to this

repair, procedure have also been developed to assist with panel erectionor to ensure watertightness. Panels will be cast with the exterior face

down against the formwork in order to obtain a dense surface free of

rock pockets and air bubbles and to obtain a rough texture top surface

to bond with the inf ill concrete. This also enables careful positioning

of the embedments prior to placing concrete.

66. Horizontal armor, due to the limitations of the form panelthicknesses, has been made more compact. Depth of continuous plates

embedded into the panel have been limited to the depth of concrete cover

in order to minimize impact on panel strength. Headed concrete anchorswhich anchor the armor behind the reinforcing mat are provided. The

flexibility during handling of the revised armor may require fabrication

in shorter lengths and splicing with field welds immediately prior toplacing in the forms. Horizontal armor for the demonstration projecthas been sized full scale and will enable evaluation of the armorhandling flexibility.

67. The line hook has been incorporated into the precast formpanel but has been detailed so that the mooring loads are transferredinto the inf ill concrete through bearing and use of a drag strut.

Reinforcing bars have been doweled into the monolith in the immediatevicinity of the line hook and project into the postulated tension failure

wedge created by the drag strut. Additional vertical bars are installedfrom the top of the form panel after erection~. These bars also passthrough the failure wedge and serve to transfer the mooring load intothe monolith.

68. Check posts and horizontal corner arm~or are hardware itemsthat will be located within the CIP concrete cap section at the top ofthe lock. Existing hardware details may be used, except that some local

26

areas of additional lock: face may need to be removed to incorporate theposts. Existing vertlical armor units may also be used. These are

typically located:along the lock at points with major setbacks or geometrychanges where a CIP transition section may be required. The vertical

armor is not intended for use at vertical panel-to-panel joints.

69. Major lock appurtenances such as ladders and floating mooringbltts are Integrated into the design by using short precast panels Jadjacent to these items. Conventional supports and embedment detailsare to be used to anchor these appurtenances to the monolith.

70. Panel-to-panel joints have been detailed to aid in, the

erect-ion of panels and to maintain a waterproof seal. The key featurewhich will assist with the erection is a tapered lap joint and alignmentangle. Tolerances of the joint will limit relative horizontal displace-ment between form panels to approximately 1/8 in. Two different sealsystem- are provided. At the more frequent horizontal joint, a durable

50-durometer seal will be installed, and the weight of the form panelwill compress the seal. In addition, a thin nonshrink grout layer will

be provided to further seal the joint. At the less frequent vertical

seals, an asphalt-impregnated, open-cell foam will be used. This typeof seal is highly compressible and can tolerate more movement. The ease

with which these types of seals compress will simplify the form panel

erection.

71. All bottom form panels include vertical alignment screws.

These hardware items enable fine-tuning the location of the lowest

panel, which supports the remaining panels. Therefore, a tight toleranceat this location is important to maintaining the tolerance over the full

height of the overall panel installation. At other horizontal joints,elevations will be controlled by spacers or form ties supported off thelower panel. The alignment screws have been designed to support thecumulative weight of all panels for the full height of a monolith and aportion of the dead weight of the infill concrete. It has been assumedthat form ties provide no contribution to supporting vertical loads.

27

It

PART V: RECOMMENDATIONS, FINDINGS, AND CONCLUSIONS

System Description

72. The preferred stay-in-place forming system is Illustrated in

Figure 3. It consists of horizontal precast panels constructed of

conventional precast quality concrete. The panels are tied to the

monolith along the top and bottom edges using form ties designed to

support the loads of the tnfill concrete placement. Infill concrete Is

proportioned for optimum workability and to minimize shrinkage and

thermal strains.73. The panel design may be adapted to allow for work to proceed

in a "wet,' operational lock, but disruption of normal lock traffic

would be expected. This goal may be accomplished by using special

frames to support and align the bottom panel below water level while the

infill concrete for the bottom lift is tremied behind the panel. Once

the bottom lift has been placed, a clean work surface above low-pool

water level is available for subsequent panel installation and concrete

placements. A suggested detail illustrating this approach is shown in

Figure 4.

74. The panels are detailed with alignment keys along their

edges to facilitate installation. Placement of the bottom panel must be

accomplished within tight tolerances to prevent accumulation of mis-

alignment errors as the panels above are set. For this reason, alignment

screws are provided to adjust the elevation of the bottom panel. In

actual conditions, overbreakage along the bottom edge of the concrete

removal area may require special details to be developed for properly

aligning the bottom panel, which may have some impact on repair costs.

There are numerous methods that may be used to prevent or overcome

overbreakage. Figure 4 illustrates one method to accommodate over-

breakage so the panels can be aligned without a uniform bearing surface.

The overbreakage would be repaired as part of the infill concrete place-

ment. It is also possible to have the closure form only to a height

where a ledge can be cast that would accommodate panel installation. A

third possibility is to saw cut a horizontal joint that introduces a

failure plane minimizing or preventing overbreakage. This process will

provide a flat bearing surface to set the lowest panel.

28

U. Ix

&0 w

o 0

IL I

0 w 0U. IL

ww< -j

CLO

zI

w.c r

0

29

DRY WORK SURFACE

SACRIFICIAL

PRECAST PANEL'---= SUPPORT FRAME

LOW-POOL

WATER LEVEL

CLOSURE FORM -7 INFILL CONCRETE

O-IONAL COFFERDAM TO

AL W LOCAL DE-WATERIN"G"

_CONCRETE INSERTS

BELOW WATER CONSTRUCTION METHODS

FIGURE 4

30

75. Form ties may be any commercial or specially designed productcapable of carrying the loads of the inf ill concrete and of accommodating

the construction tol~erances that may be encountered. Standard manu-

factured form-tie pro~ducts were investigated, but the lack of simpleconnections to the existing lock wall and precast panels and limited

work space led to the selection of a welded rebar tie system. Welds to

plates embedded in concrete are routinely performed in the precastconcrete industry without thermally damaging the concrete. The tiesmust be installed snug with kickers and wedges or similar means prior toplacing infill concrete. A minimum factor of safety of 3. 0 on theultimate strength of the tie is recommended for design.

76. Panel joints should be tight fitting to prevent moisture

penetration between the panels where it could freeze. The detail whichhas been developed utilizes compressed neoprene seals and nonshrink

grout filler in the panel joint to ensure watertightness.

77. Lock hardware and appurtenances are integrated into thepanel design to the maximum extent possible, resulting in the need to

develop special armor hardware which will not compromise the integrityof the panels. Other standard lock hardware and appurtenances may bereadiily incorporated into the rehabilitation project which uses the

precast system. Several details which illustrate how the precast stay-

in-place panels interface with standard lock hardware and appurtenancesare shown in Figures 5 and 6.

Cost Analysis

78. The estimated construction cost for lock wall rehabilitation

using the precast stay-in-place forming system described above is approxi-mately $119 per square foot of lock wall face. This cost compares with

approximately $137 per square foot for conventional rehabilitation

methods.79. The costs are broken down as shown in Table 3. The cost

estimates are based on an average concrete removal depth of 16 in. for atypical rehabilitation project. Also, it is assumed that some special

allowance must be made to install the bottom panel below low-pool waterlevel. The case of full-height inf ill-concrete placements was used forcomparison purposes. It is also possible, however, to use staged

31

01

41

100

* ~10 cc

*1 iv14%-

32z

qU.j

t 0

co )I-Eta Co0 0

0 C160 CL 0

2z z_ _ _ _ _ _ _ _cLu

U)U 0 U

0 CC =1 0J

Lu-L00

0 o w-

LL<L Wo

I- zo o LLU0

Luz 0z roz

L L.

OwwU-CD

33W

placements. The cost estimate does not include costs attributable to

loss of revenue or any other consequential costs associated with loss ofuse of the facilit~y. It should be noted, however, that such costs arepotentially less for the precast system since much of the work may bedone with minimized impact on normal lock operations.

Schedule Analysis

80. A construction schedule assessment of the precast stay-in-place forming system is shown in Figure 7. The schedule indicates atotal work duration of 30 hours to reface a typical lock wall monolithbased on overlapping activities on adjacent monoliths. Work on the

adjacent monolith's segments is identified as Monoliths V through W inFigure 7. This schedule compares with 32 hours estimated for the con-

ventional repair system. However, the total time that the lock must be

out of service during the use of the precast system is estimated at only

16 hours per monolith which demonstrates the significant advantage of

the precast system over the conventional repair system. Restricted

operation of the lock, such as limiting available widths, may also be

required.

Conclusions

81. The precast concrete stay-in-place forming system is a

viable method for lock wall rehabilitation. The system results in arepair of superior durability without the persistent cracking which has

been experienced on conventional cast-in-place repairs. The system canaccommodate typical lock hardware and armor installation and does not

adversely affect the function of the repaired facility. Another

advantage of the system is the potential reductions that may be achieved

in the length of time that the lock must be closed to traffic. With

proper detailing, sequencing, and scheduling of wo~rk activities, the

rehabilitation work may be accomplished with minimized impact on normal

lock traffic.

34

IN I

'0 Uc AA

NN OA

U @i.*i I I en 0

U. IN~w 'A

I- on w

0 1a IL t U

10 ON44 0U uIA inU L A

u CLON U Ca

N1 .0 4-b Ito 4C4 0;%0* C

I35

Table 1 (Rev. 1 10/1/86) AA

Cost Estimate Baseline

cost EstimateItem Description Quantity -Unit Cost T*otl

*Concrete removal 72,250 cf $ 25.00 $1,806,250.00

"A*Concrete anchors 3,785 *a 48.00 181,680.00

"*Reinforcing bar 174,100 lb 1.31 228,071.00

**Fabric reinforcing 2,700 sf 0.63 1,701.00

*Concrete, Type C 2,820 cy 700.00 1,974,000.00

*Concrete, Type D 850 cy 210.00 178,500.00

*Armor, government-furnished 258,100 lb 4.00 1,032,400.00

*Armor, contractor-furnished 121,900 lb 4.00 487,600.00

"CLine hooks 30 ea 479.00 14,370.00

"CALadders, lock face 4 ea 6,702.00 26,808.00

Subtotal $5,931,380.00

Engineer's estimated cost per sq ft of lock wall face $137.05

Bases: o Based on Brandon Road Lock repair (December 1983)o Approximately 43,280 sq ft of wall surfaceo Costs do not include mobilization/demobilization, dewatering

A 1986 unit costs furnished by Rock Island District

* 1984 prices increased by 10% to 1986 prices

36

1- 4-)44J

50). 4J.15

>0

4J

o .C

4-.)

c 00

C 5-o c.

LL44J

4- )

0).CC

4.1 0)I. w ."4) 4 c 4

L.' Sý d

4- -)C d 4-) -C A aU J ) ) U r= #A4) 4)

L. 9-5 SC 41 C wt4.U10 r-0) ) j'a

5-' 50 CO =4) 4 ) vU. 5- U04 U I I

$A c A u 0 1 r- -C 4J 0 Uw o) g 0 E us-- U *4-) r- $- m kJ

4J -C 4-) > U .># w~n ~4- 4--C

CL - 4 0 c 4) 4 '4Jto -cuC S4 o - - -4-) -Pu L UL)0.LL0. )LC CLS 44 J5 54

0 i In WW O '4C5 CL 5

sn I S OOG S- S.4~5-370

* ~4-

94-

Eu

10

S-

4-)

Cr 3U

00

tO >

Cm m

LL4.

) ca C L

19- 0 6 0Jc

cm o I

-JC a)) C c

V) I-- ui .9to cS.r 0

ea 0 0 HO) M rLI- edC

0.t 3 ) l

CL- I)4 ';")0 V . tC 1 -LU4 U5- r - C- U - U.- - CS-

4- 5-00 -G 5--4-

CL wu. to-000 LU 0 f-

41 0 3W-U -r-- N. 0 30.-U a.

4U 0'- ý-U-0 L'-L4 4U 0 M ý9-LA

U LUJ z- J L~ LU

0 0.>a

38

Table 3 (Rev. 1 10/1/86)*

Precast System Cost Analysis

Item Description quantity Unit Cost Total

* Concrete Removal 1,600 cf $ 25.00 $ 40,000.00

Surface Preparation and Layout 1,200 sf 1.00 1,200.00

Precast Panels

FabricateReinforcing 8,360 lb 0.90 7,524.00

* Armor 4,700 lb 4.00 18,800.00Concrete 24 cy 1,850.00 44,400.00

Install* Form Ties 160 ea 50.00 8,000.00

Align and Set 8 ea 900.00 7,200.00

Cast-in-Place ConcreteFormwork 70 sf 30.00 2,100.00

* Armor 970 lb 4.00 3,880.00* Filler Concrete 34 cy 210.00 7,140.00* Structural Concrete 3 cy 700.00 2,100.00

Cure 100 sf 2.00 200.00

Subtotal $142,544.00

Estimated cost per sq ft of lock wall face $118.79

Bases: o Pased on a typical 30-ft wide x 40-ft high monolitho Assumes 16-in. average depth of concrete removedo Costs do not include mobilization/demobilization, dewateringo Costs do not include refurbishing ancillary facilities

* 1986 unit costs furnished by Rock Island District

39

REFERENCES

American Concret'ý Institute

ACI Committee 117, "Standard Tolerances for Concrete Construction and

Materials," ACI 117-81, 1981, American Concrete Institute, Detroit, MI.

ACI Committee 224, "Control of Cracking in Concrete, Structures," ACI

224R-80, 1980., American Concrete Institute, Detroit, MI.

ACI Committee 301, "Specification for Structural Concrete for Buildings,"

ACI 301-84, 1984, American Concrete Institute, Detroit, MI.

ACI Committee 318, "ACI Standard Building Code Requirements for Rein-

forced Concrete," ACI 318-83, 1983, American Concrete Institute,

Detroit, MI.

ACI Committee 347, "Precast Concrete Units Used as Forms for Cast-in-

Place Concrete," ACI 347.IR-69, 1969, American Concrete Institute,

Detroit, MI.

ACI Committee 347, "Concrete Formwork," ACI 347-78, 1978 (reaffirmed

1984), American Concrete Institute, Detroit, Mi.

American Concrete Institute, Designing for Effects of Creep, Shrinkage,

Temperature in Concrete Structures, Publication SP-27, American Concrete

Institute, Detroit, MI, 1971.

Hurd, M.K. , Formwork for Concrete, Publication SP-4, American Concrete

Institute, Detroit, MI, 1963.

Schrader, E., Dikeou, J., and Gill, D., "Deterioration and Repairs of

Navigation Lock Concrete," Performance of Concrete in Marine Environment,

Special Publication SP- 65, Ame;-ican Concrete Institute, Detroit, MI,

1980.

40

Corps of Engineers

"Dowels for Anchoring New Concrete Facing to Existing Lock Walls,"

ETL 1110-2-264, April 1981, U.S. Department of the Army, Corps of

Engineers, Washington, DC.

"Lock Wall Accessories,' ETI 1110-2-147, December 1979, U.S. Departmentof the Army, Corps of Engineers, Washington, DC.

"Marseilles Lock, Illinois Waterway, Refacing of Lock Walls," Projiect

Study Report, July 1974, U.S. Army Corps of Engineers, Chicago District,

Chicago, IL.

McDonaldý, J.E., "Rehabilitation of Lockport and Brandon Road Locks,Illinois Waterway," Memorandum for Record, WESSC, September 1984,

Vicksburg, MS.

"eNavigation Locks," EM 1110-2-2601, June 1959, U.S. Department of the

Army, %Corps of Engineers, Washington, DC.

"Planning and Design of Navigation Lock Walls and Appurtenances,"

EM 1110-2-2602, June 1960, U.S. Department of the Army, Corps of

Engineers, Washington, DC.

"Standard Practice for Concrete," EM 1110-2-2000, September 1982, U.S.Department of the Army, Corps of Engineers, Washington, DC.

"Strength Design Criteria for Reinforced Concrete Hydraulic Structures,"

ITL 112.0-2-265, September 1981, U.S. Department of the Army, Corps of

Engineers, Washington, DC.

41

APPENDIX A: DESIGN CALCULATIONSPHASE II DEMONSTRATION PROJECT

Al

AgShoot - __of _

Project C40C LODef ACE"IdLIt4?dA/dd Job No. 901

STA*W. IAI* PLAcf-Ap4~ -- Designer CIA

.oge E~seI N4 Subject 20Cljjcedr-g &s~A Date 9I f

CONSULTING ENGINEERSV

ýv4Lv*s 44i _h 4*'ec

CCiat CVJY,#A dAec Aj 4#

.0 wa selw w4"kedf

bU 3Zta;* 10 &ObZ 40or"'ilOwthR rk~trta tprh

RatediameAt p, m M 44y sm ftw,,1.. -,r.4 onr ACTtN JNN,?~v ifmde*401 .

Rjw,A ftpwhe Wou pa~itedm IP -""O 15' + 4 34 tlq

TABLE 5-2 MA IMUM LTERA PRESUR 107f U0. whFO DEIG OF WAL FORMSanat1 I

ta2 " r 3M iii 375 o 407iiiii b1 510 160 A. eeheteua fism a"

Ra 4o USiiiaist P. Maim 670e pisis pd fo 4.1z.4(m JaIM) R t aeeIateIi

90660 720 703 601 106041 .260 25 M6 3060 = il 3 * .tb'Ah moie tt of J p livswet rftotpnwgd hir ll tit thll,.2II 3 M106Vl 7 40 120 0 00 W 14 6*itdN otii~il. fl astlntttaw , Tin fliIstt aittta

3 310 676 1060 46 M46 M~i w Mtn ui~kA M bt ofa htu~la Sl t *,ia.n, ti fnn~tat

61 .7 0 0 M 110 1050 lam Ablu lith LI., EtI'or347, u l imla. lartis. Helen tow ,1 Tuning l'un,, i et h ll te.I I 93 IN 1126 146 IW promote stude s ( n,,nr lima 1haolla s. A@etl,,, ant@la i.Vt.at

to 94d 1043 117 1340 187 185OtUn~

A2

%&L 4. L ---

Shoet A3 o

Project wcw'O.' umA(6qirArigo4 Job No. Ao

- l~zrAY14 P"46 VOMS Designer F ,

lAge M3.4 NA Subject IM5 (.i4 1 QGE Date 116"56CONSULTING ENGINEERS

77

/Q: /7040 -

'Aie a TýlcAv ge Z oo c M..gfL o -h e Z#4ocu -.DP %

MIPA3' o~i.j

-f ALI

Sheet A4 of

Project L.0 REt44APiLItr'lIO Job No. *5 i

i.,rA'f- 1,J. LN& WbOAS -Designer f"

,oo EM,,90 Subgect ~ ~LJDate ZI"oo

CONSULTING ENGINEER~S

Tku~c 4. ~ 4ad~s. ar46-&lUrAL. ac4.

$.AA*~n C&w dU.4f%4-', 40 A .. c4.d Ter %rose"vm~d~o-LkwA AA~ooi AL~a&

,11.&. Ss ZSG44 44 k.L 3 ,, -

4ýAaýe eaý,

nc.'O.4Cv0' 41( ,1, Co 292.

Z4, oo k%;(6ra"rc:,t;t%

(" F V- 3 z 0) 1Ao49ac.34

3/E- 9_ 2.

A4

AS

project CaE Ck KF"A~~w4 JobNo.

TAIo4ft~-PA( FOIAMS Designer

ubet11M DESVF) Date LAUCONSULTING ENGINEERS

peoCAE Al. "

)e~~~ pan4 el 4.1 pfEr)? kci *jtdo'

WQ e ?.

4 W.01 It 46114Ac

St"__ oAozss-

ga~p skeW4 cA Ml' 04 Ler 4 red~cc c e~A

VJA- ~ ~ ~ ~ ku I*?4 VaiLp4 o. As-C'

Lcof eZ.ALc Akia'.A Sr:Yz (~4. 13 -3

<,4.t-k Acu%4 S 9,.,eey~

A5

Sheet A$ o

Project Job No.

, ~ ~ f4sk.aject Date AIPA -44CONSULTING ENGINSEFRS

r-ri 1.2) Z4 (9

(r ? I.Za%£/7 I r;

c A 'A.

,4 i /9.o e.

W-z 7O. 0' 97 1. S

Ados Ad a~ ý31sIn

~ /~3f

PJael 4h/Gfc

AAt

ATSheet-- of

Pro4,. ?-f A onx Re.44BjumneA7*SJjobNo. ._45666199eSTA'fAir-l PAt4CA A~bh*.S- Dosigno

o~th EBAN &AV Subtct 7Wtf PAVE,.. JCG4J Ab

CONSULTING INGINQERS JDA-JfiL #06Qý

49,e&S 490 K LL.(1

,4v

7 A

2r~ot &WU ir." 4oc *Jie -'JW

16.1r3 -1 1 £0. .f

/a7.

~~~~~.7'4 ifd 36L a~ 4411 r4 '4.u-p g ie-&4 a-- AM

AA5

Project do o a EIAsti, 0 x Job No. ~AS 21..)t ~ rvi".W DM-PAE~CS Cesigner .*

Adkh E046 ASubject M!&ý 0"6 DateCONSULTING INGINIEERS Mf li 1

4r O,.OtV./4 1w~7 &L'/

he*44,, ... OM.0' /*4 ALI'

hv% 4dk1~Jt,ýw o- 4acA 4,c. oewt

/Itst

,F. 07o * O.O3

Cl8 Ito.7Zo k t( 5

,W $44.

A8

Cv~ AA LOK.£tAAMLj rA!j!* Job t4

CONSULTING UNGINKINS

Asru.mpnoM5 t

i4o.'LT.c C.wu9Aewo Pf To. '4

Vu4-tLJ. r)vil HotGto~.w It/?."

7,Ruulft,, Tic. hoc

,ze

A9

Sheet A10ofproject CO .IA~~t4A Job No. IlkMOOT__

¶$YAj. iJ Designer Al

"laillt., E .--eýSubject Ti~c I4MkbwtAM V1ALS Date 11 AM Sco

CONSULTING ENGINEERS

Ac.WAL

ThSO~SfCAL.

III

VtoAL +,cro hL A.

AJ _Ll 4+

Shoot All o

ProjeCt CELCC tAS Job No. Ai=

~ It.* L&E VWD Desioner1002

,44hiiiM~oeý M Subject nIF 1$Ai.'ýWARL 1DFrAILS, Dot* I A~pi4 Gt.S

CONSULTING ENGINEERtS

FLgVA1TC.Jd- LOC.W WA."I. M

veiu.. t~oe dAlAx 7ro EAo4cAe 1.')c.4riaA!

w4* P~Oa W? CA44 'b.-dAAJ%~c&

All

SetA12

Project Lo ltfp A.,~,31?Arj? Job No, .A&(aozlI A4( 4- IOA Pbiebfi Designer 6'

~ 5%t~Subiect Of~~ '~ ate 17 AO4. g4CONSULTING ENGINEERS

wait lt c ,~ c#294. *i~i ,

4. lfjk la '4-wA. ioe.w-- i..-rW~- 6A. tnts-W case taMC.

-A 4-Adu t7

I4 9

4,& ic .I kozj jZ4 24' tjjj ~ s

/rt e /ee rw t 4 -4, 4 Sf-

74 5 r4S 8k

A12

A13Sheet -___ of____

Project CE~ Lzx--I 9..IAfItloA?1O Job No.Ab-V

S~h. i.9~4~. DvS4S O.ignhr 'A P

oNhk E oe Subject 1I ~DateCONSULTING ENGINEERS

~9a~uq $CS

C-Ara 5a 4ý As ir 0. *1K 0C A4 '5 ~ 4 5

cZ~m~c~4.s ?ier d 4IAt Z

i1 &~ ~a d~~4# Le*.P; 7

I5 4s = 6.314W4,-r

14pea~y row~ AL&. iwe" "

A#7~ hse -Ind- Co;A, 7 2 4

.9. ea don41 0-* n

4 l C C ~ r t AJ 30

0 -7

A14 ___

sheet __ __of

Project CODE 60ýId~Ai~?q, Job No. 446&_az_9

jf41. IJ.LOdLA 114POICM' Designer 9C

,00ý I%"ýN SubjeCt TIll Mb, fPLA f3C' J DateCONSULTIN13 ENGINEERS

4dla~ CAA) Cr4 *Tb 'TM5TAtOAOLtr LA b`,

E.I

544 4rf&a 4T 5~

.1 Ea4L W4 OA 2

6iaC' . 624,41 j ZW~ 6kA&. 64ic%

Fur -- 040G3C,' 144c ksii

0 W7S

QOac.. CAkLC~k_- Profot~i. ~~ds

;:- A t44Z is

A14

I :1

Sheet A 15 of ___

Project COE j-,cr- R6HA'SLILr.T~aroJ Job No. __________

ýLAJ. W-J PL*,CJ FbA Designer

1^6 9=tdnk Subject 111F LA V A-ovrZ e.NiP Date Vy 44- 5(CONSULTING ENGINEERS

IT IF. -T ~ ~ ,Y A c.

** vuA cb v ittvJo rc

TirT bI -14.5

BS W. a 4- /

T'- 96. Cgb'b4j.--Ao 9,t~. A. o 5-

A/e~ ~ ~ 02* lolý .0

van 0.1 I4al, I(,4 -7 ~ v~ 6L v&

A15

SheetA16 o

Project Cflng1 LA"J lZ b~4iIL1TA.T&4AJ Job No. 4J 72~JT1 I A PLA~ ~Designer

'~I~~4~t4Subject ti P bt Date12JL6CONSULTING ENGINEERS

Aii CIO', L'L CPA.4JL "6-~

A I v4LJ. C 4 k4 ' Cev.Spt2 4% .)- 4.i

V (.Sw A v4Cs AIL

(o-4 'v(4'6- s' . a4 4 Ct Iz o

T0 .04.~t KO W. 4040-0C S 9.S

ld v .O o40 qi 0.S 4 600. d ?o a

6,a s.e. * /V 4~ k A- 4'v14- 4lc4#....d *ee Ataoh- V' /4 4OAJG

A16

.- IL

Sheet A17 oProject Cap- LogJ( Rfi.44I#-lTAY'rAJ Job No. A4Spez9

d~ ~~I'L A Subject AW WAlkf M&31 &itL D~~A ate 4

CONSULTING ENGINEERS

ALle.QJlN6vJT AAlfIL( eL(.t

- DU~#J F~e 4C

:coon"co-e/ ýpparrw Ot/.-* pt71;e4

LJ i J Wca /Z04 ))7./0 ew

3l .75 . (4 Z7rS) B. .75Y,? C. 3

4.w Z773 A- s7r

Irv _

si /Z ~ gd ~ ~j ~

fr.eI., 40'e lef0 O CA/C-1 A1 a.4i*P4 5.9z

6 2 7.3 Pa.-ZZ -2

A17

AISSheet _____ of____

Project COE Ztl' RE14'44?CArPad Jot) No.04"6V

~7A~iJ* iAJ ~..lI DesignerA.M

~'. N4 SubectDate -q .9CONSULTING ENGINEERS

z it 9 72

LýAO4 IAGL' .9Era.04 A../ /e4 1

.sA-&d ujvil A, 4 U*-t4.p 77 1zeue*

&P Mae( 7/3, (4- / 72a

1. It9oc

70S

A19Sheet -___ of ___

Project 5-946 Lewc. at.I&4161?TjArw JobNo. 11075TAf -144- LAc$i pbg&C ý)esigner AZ

NA E~o-ýSubject Date ZJL GCONSULTING ENGINEERS

S. veLA 1y.' - Zeoa UpU0 ' 1/2

4s/us*4. (7o?*Ai WteIk Wet-d

7. 135

56A&W PLA& su Aa Lr BaeAieT.f

A,-~.,£~ .6 9.70L le/a4,1 4 4

ý'v v /3-c 3C

7e.7" It J t, A

A19

Shoot A20 of__

Project ~.LOCA R~A1IAIA Job No, A84igoi$TAVA!. IAJ-AACE, ftnPAS Designer J'A

odhIhai t Subject Date -5j.&1S iU dmyIL.CONSULTING ENGINEERS

dA.OA. .340*p, Shl ^ae /p4t.4e, Awe/

ht~~~~ Itt~ C4!a~i

Va.0

Ass&~~~.,.& Cr ~ ~ 6 ir foo 1.44Lod*/& ar'

C 2~,~

l~cll-03 4101& 61 4eke 6 plCAc

da.*4p &/zx &Ct. &Pay .e~,

~hp APe./ 0i ^7)~ e'a,$. P ?MJJC1AA Z "

pe~vd: all At) i0.1 a Al" u e ýCS~A~r A

A20

Sh~.t A21 -

Project C4C(Lk 6 Id741A Job No 862

4 , 1eN Sujc MJ61CW &M &.?AWyj.5AI&JL DateCONSULTING I#4GINEEflS

TABLE 5-2: MAXIMUM LATERAL PtSUagREFOR DESIGN OF WALL FORMS SoAfe S..

In" m AC 'amo sW pmwe bpa im AAT EA~

161 ft adr hr &dpmrpts In&.t

wa0o n 301 a0 l 31w aof /owFi

4 8 3M & 4 7140 370 ft haA.a

a on0 712 M1 to 06 too, /Aur kA'b.- 7' ta 4,ao as "1 1080 1230' 1N'

to M8 lo 1 I= 0 1410. Irt.OR5 973 1090 IM I I40 I-.-. a4~~44r~. ~i/~912 101*11130 I=S I=8 I" *6 f"A

PA2A

4 ZS- 17

Shot A22oPromlc Lc- Rt$AEd.Lir-rtoal job No. !d-J

sr'r IA4DL4~/~40eM S DeignqfA' g

d'k. DB 4hN,& Subject -11A OUIt -)yg Dat f9 Adt Sc0CONSULTING ENGINEERS 41 (e.m.toe&Jt SC41LS

PA.~~ee. WGa'

sA ees co k)4tA6 out'// 4 44,46" ~ poy to *~~tw,,ee

M2. 4i% - oc .j2vYj.'eSJak

e 75A~C b4e..- or- - IC.a

.Yfr.s s4/ tvw&ý. -a 14

&4k~je~ A4-J 91 wy, 10. o t 4

wiOLA a" wEil ,/*/ AS up"'A'ss ýýa -, .- ~

A22

Sh** A23 o

led ~LA.N 0.gneer d

dAý 4 oo MI4I% suhect L IMd ftQ, 102160A D.- I A Aft SkCONSULTING ENGINEERS

LAbJ "L.w. 21imi%

kAA.s' A -3( Vteck as &asp~b j

Lt^,- -Ie L

C' ~-3444

f - - 7.4

C

I~ ~'*t2 ,,' 4 o"

4-.s7 f

&WwkdGw odI .jfleA I~

A23

A24Sheet -___ of

Project LGK A5,L~~4t~'OAJ Job No.______

Sr4 l- iAl -P444 C44mDesigner E

CONSULTING ENGINEERS

C~c4 /.S.S/e~

Irv- 4.0 'l

7-=~ ~ ~ ~ 7&.S- !S-s ..

Lu ~O. 0'59 4ý4L

P'1 41kTk

p -

""x

0~ C.7 If 0 _V,& V

hel A25 of

Ploiect kt4A e~rv Job Nc A65

~r,4Y'. At 10-919& toj!C- Designer &A~~Aio Z* Suset sAAb Data 2s 'Apoei& d

CONSULTING ENGINEIRMS

.Pz.

r ly4 iN I

/.OAF

elf t4&) Aevk c e C /0~4d eA-; )A*&

'Lroc Zx"j ZZS3,8-7

A25

Shftet A28 oPr~iOjct Coie 40; fedl!N4'/rA4Toý Job No. 1&7'

,~ ~ ~ AIP21~ esigner 61Y

A~tS*, EM o^h. MA Subject &4l2"Mlev AAPh~fc Oat. 4iCi e

CONSULTING ENGINEERS

l( , a $ V, __ * .?3

PLA..J(

2, 2 5 Z$24 av.0 + -

1.~~ 7 ;0 5.4 ps'i24*o

t .0 pec~ao 9"

A26

Sheet A2 l-

Project CcW- Loc.x PR&JAii1LlTA7'I0-JJorNo. Azoo 9S r4J!- to 4 - PA Ge Fo C... & T Design~er

,--4h M'.4tA Subjecl bJ44640t CC.) Date_____CONSjLTLING ENGINEERS

~~~~~SA TrVW It~ d..4 ~9I1JSL

aA sskiŽr *-

A27

shtA2b of -

I'rolect ~tOLAf~JUInJJob No,

$;CA4MLji.. PL"&( rgfflg EDsign*r 94

~ j q A Subjec1 -A*A41%*44 WU,%,1 J DateW-CONSULTIN5G ENGINUEERS

vcetAt AL~i(.j&r .4 j 444g~j

PIVC~ P-T TO P- tA VAJ 4:&t7E53-t8.i4,43a 23.bt'

IOT& - Tlm etz4 n+ irtcL4A&. d. C,,,)~(&ebcw&4'taý

t, /L ~~

LLtaA. MA 4 ~ ~ 14(,

-~ _ 2it 41r

A28

Sheet A26 o

Project C20.LteLR4bTA-~ Job No Ate.3AI

ro rA%- LACE &IL4Pt Designer -t;,P

E3.00 t0 pl Subject 1-16I201N-Ie 2016 Date 13 Aýe 1- NOf.CON4SULTING ENGINEERS

pL4*Y 12-~ 23.-S 14ex

Ae ~23 7r ,A

Zo.l.

44MPL Pv-,h4AA4 (o k- .

1W, 5

TO P %1I A2XL 4

L "le 1

v 0.L 3

'./Z. 3z v

;37 7 I~`4

A29

APPENDIX B: CONSTRUCTION SPECIFICATIONSPHASE II DEMONSTRATION PROJECT

SECTION 1GENERAL PROVISIONS

1.1 GENERAL

1.1.1 Description of Work

a. This work consists of demonstrating the feasibility of repairingdeterioriated navigation lock wall surfaces through the use ofprecast, stay-in-place concrete form panels in conjunction withcast-in-place concrete bonding layers. This work will beperformed on dry land at the Corps of Engineers, waterwaysExperiment Station, using an existing one-half scale lock wallmock-up section.

b. The work includes providing all materials, labor, inspections,tests, and supervision required for a complete installation asshown on the drawings and described in these specifications.

1.1.2 Definitions

a. Corps: Shall mean the Corps of Engineers who is responsiblefor commissioning the work. The Corps shall have the finaldetermination regarding interpretation of contract drawings andspecifications.

b. Engineer: Shall mean ABAM Engineers Inc. who is responsiblefor design of the precast concrete stay-in-place forming systemand who shall perform reviews of Contractor's submittals,independent inspections, and surveillance of the work, andwhose personnel will be available to provide direction of thework and interpretation of the design requirements.

c. Contractor: Shall mean Premier Waterproofing, Inc. who isresponsible for performing all work as described in the speci-fications and on the drawings.

1.1.3 Prosecution of the Work

a. The stay-in-place precast form demonstration project will becarried out at the Corps' Waterways Experiment Station inVicksburg, MS. Contractor shall be required to abide by Corps'rules and regulations regarding use and access to Corps'facilities. Such regulations shall include requirements forenvironmental protection, health and safety, security and laborrelations.

B2

b. Corps' and Engineer' s personnel will be performing inspectionsand tests in conjunction with Contractor' s work. Full coopera-tion shall be given to Corps' and Engineer's personnel toinstall instrumentation, monitor and inspect the work.

C. Direction of the work w'ill be given by the Engineer. In caseof conflict, Contractor shall notify Engineer for resolution.

1.1.4 Quality Control

a. Contractor shall perform all work in accordance with referencedspecifications and standards.

b. Contractor shall maintain records of tests and inspections asrequired to demonstrate compliance with referenced standards.Such records shall be made available to the Engineer or to theCorps upon request.

1.1.5 Submittals

a. Contractor shall submit copies of all required drawings, testresults, inspections, and documentation ats required by thesespecifications to the Engineer. Contractor shall allow 7 daysfor review of submittals by Engineer.

b. Submittals will be reviewed by the Engineer for compliance withthe contract requirements and returned either reviewed withc'itcomment, disapproved, or reviewed with comment. For thosesubmittals disapproved or reviewed with comments, Contractorshall make the required changes and resubmit such submittalsfor rereview.

C. Contractor shall not proceed with work contingent upon Engineer'sreview until satisfactory review of necessary submittals hasbeen completed, unless written direction to proceed is receivedfrom the Engineer.

d. Contractor shall supply samples of materials used in the workto Corps' or Engineer's personnel as requested. Such sampleswill be considered incidental to the work and will be used bythe Corps or Engineer to verify material properties orperformance.

1.1.6 Housekeeping and Cleanup

a. Contractor shall maintain work area in a neat and orderlyfashion. Work area shall be cleaned daily at the close ofwork.

b. Refuse, shipping and packaging materials, wasted material andproducts, and discarded samples shall be disposed of as requiredby the Corps.

B3

IL - - - - _- - ._1 ______ I_

1.1.7 Project Photographs

The Contractor shall submit five copies of a photographic reportconsisting of approximately 30 photogr~aphs showing the differentstages of construction. Photographs shall be taken by a competentph~otographer and shall be black and white, standard commercialquality, 8 x 10 in. in size, and on single-weight glossy paper. Thenegatives of all photographs shall also be submitted.

The photographs shall be enclosed in standard three-ring binders inback-to-back double-faced plastic sleeves. Eac~h print shall have aninformation band alo'ng the front bottom edge with a description ofthe photcgraph's content, reference negative number, and date photo-graph was taken.

As a minimum., pictures of the following items or activities sho-l beincluded in the report:

o Formwork and formwork detaile

o Reinforcement installed in the forms

o Steel hardware with views of hardware positioned in the formns

o Precast panel casting operation

o Panel handling and transportation

o View of the existing monolith with surface prep completed

o Tie and dowel hole drilling

o Tie and dowel installation

o Tie and dowel testing

o Panel installation including completed tie connection, installationof seals and grout layer.

o Placement of the inf ill concrete

o Details of auxiliary formwork and reinforcement for the closurecap

o General view of the completed installation

B4

A

SECTION 2PRECAST CONCRETE

2.1 GENERAL

2.1.1 Work Included

The work inclut.4*. all materials and workmanship required for fabri-cation, delivery, handling, and erection of precast concrete leave-in-place form panels.

^.1.2 Related Work

Related work includes fabrication of lock hardware and appurtenancesand production and placing of cast-in-place concrete work.

2.1.3 References

a. ACI 301: Structural Concrete for Buildings

b. ACI 318: Building Code Requirements for Reinforced Concrete

C. PCI Design Handbook: Precast and Prestressed Concrete

d. PCI MNL-116; Manual for Quality Control for Plants and Produc-tion of Precast Prestressed Concrete Products

2.1.4 Submittals

a. Contractor shall submit shop and erection drawings for allprecast elements. Drawings shall indicate fabrication details,reinforcing, connection details, support items, dimensions, andtemporary attachments and work.

b. Contractor shall submit details showing proposed methods oflifting, handling, storing, and erecting precast elements.

C. Weights of precast elements shall be computed and listed onshop drawings.

d. Contractor shall subm~it results of tests on materials as speci-fied in Paragraphs 2.2.1 and 2.3.3.

e. Concrete mixture designs and qualifying data.

f. Catalog cuts of other miscellaneous products to be incorporatedinto the work such as nonshrink grout, joint seals, tie anddowel bonding agents, etc.

B5

2.1.5 Quality Control

a. All work shall be performed in accordance with PCI DesignHandbook - Precast and Prestressed Concrete, and ACI 301 Struc-tural Concrete for Buildings.

b. Precast concrete work shall be performed by experienced fabri-cators qualified in accordance with PCI MNL-116, Manual forQuality Control for Plaiits and Production of Precast PrestressedConcrete Products.

2.1.6 Delivery, Storage, and Handling

a. Delivery, storage, and handling of precast concrete elementsshall be performed in such a manner as not to adversely affecttheir appearance or use. Panels shall not be lifted from thLforms until panel strength has reach 0.7 f'.

C

b. Design of lifting embedments and handling devices shall be theresponsibility of the Contractor. Contractor shall providedetails of proposed lifting methods, attachments, and devicesfor engineer's review. Handling e;,.beds shall not be installedin the exposed exterior face of the panels.

c. Panels shall be lifted only from suitably designed liftinghardware embedded into the panel or with the use of slingsproperly placed and rigged to prevent damage to the panels.

d. Panels shall be adequately supportea at all times with suitablecribbing and bracing during shipping and storage to preventinadvertent damage from incidental loads or movemen%.s.

2.2 PRODUCTS

2.2.1 Materials

a. Concrete: Precast concrete materials shall conform to thefollowing requirements:

o Cement: Cement shall conform to the requirements of ASTMC 150.

o Aggregate: Aggregate shall confor'm to the requirements ofASTM C 33.

o Air-entraining admixture: Material shall conform to ASTMC 260.

o Water-reducing admixture: Material shall conform to ASTMC 494.

o Pozzolan: Pozzolan shall conform to ASTM C 618.

86

Precast concrete mixture shall be designed to satisfy thefollowing requirements. Prior to commencing operations, theContractor shall furnish the proportions of all ingredientsthat will be used in the manufacture of precast concrete panelelements.

Concrete mixture proportions shall be selected to satisfy thefollowing require-ments. The proportions may be based on pastfield experience or on trial mixtures in accordance with AC! 318,paragraphs 4.2 and 4.3. Contractor shall provide data demon-strating that the proposed mixture satisfies the followingrequirements:

o Minimum 28-day compressive strength: 6,500 psio Maximum coarse aggregate size: 3/4 in. nominalu Minimum entrained air: 5 to 7%o Maximum water cement ratio: 0.40o Minimum cement. content: 540 lb/cy (6-sack mixture)o High range water reducer (maximum). 5 oz/100 lb cement

b. Reinforcing: Mild steel reinforcing shall be new billet steelbar conforming to the requirements of ASTM A 615, Grade 60.

c. Ties: Weldable grade reinforcing steel conforming to therequirements of ASTM A 706, Grade 60, shall be used for formties.

d. Prestressing strand: Prestressing strand, if used, shallconform to the requirements of ASTM A 416, Grade 270.

e. Welded wire reinforcement: Welded smooth wire fabric shallconfnrm to the requirements of ASTM A 185.

f. Nonshrink grout: Grout for horizontal construction jointsshall be a prepackaged, cementitious based/natural aggregate,nonshrink grout. Mixing water shall be added in accordancewith the manufacturer's reccmmendations to obtain a plasticconsistency which will level off and redistribute under thepressure of the upper precast panel.

2.2.2 Accessories

a. Hardware and accessories shall be incorporated into the work asshown on the drawings. Hardware and accessories shall befabricated in accordance with Section 4.

b. Epoxy grout shall be Concressive 1463 as manufactured by AdhesiveEngineering Co., Carlstadt, NJ, or equal. Epoxy grout shall bemixed and applied in accordance with epoxy manufacturer'srecommendations.

c. Form ties shall be capable of withstanding the full anticipatedload of concrete infill placement with a safety factor of at

B7

least 3.0 on failure of the tie. Ties shall be anchored tomonolith concrete using epoxy grout or polyester resin cartridgeanchors.

d. Bearing pads and horizontal joint seals shall be preformedneoprene material of thi size, dimensions, and characteristicsshown on the drawings. Vertical joint seals shall be anasphalt-impregnated, open-cell foam.

2.2.3 Fabrication

a. Precast panels shall be fabricated to the dimensions shown onthe drawings. Dimi)nsional tolerances shall not exceed in thosespecified in Section 2.2.4.

b. All reinforcing, inserts, hardware, and appurtenances shall belocated as required and securely anchored to prevent movementduring concrete placement.

C. Contractor shall moist-cure precast panels until the concretereaches a minimum strength of 0.7 f'. Precast concrete panelsmay be steam cured. 'Control of con&ete temperature during thesteam cycle shall be maintained per the guidelines of PCIMNL-116. Membrane curing compound shall be applied to theoutside surface of the panel after completion of the moist-curing cycle.

d. Panels shall not be erected until concrete strength has reached6500 psi.

2.2.4 Tolerances

a. Dimensional Tolerances for Precast Panel Fabrication

o Length: ±1/2 in.

o Width: ±1/4 in.

o Thickness: ±1/2 in.

o Edge squareness: ±1/8 in.

o Planeness (measured with respect to a straight line drawnbetween any two opposite edges)

- Outside surface: t1/4 in.- Inside surface: 1/2 in.

o Location of embedments: ±1/4 in.

b. Location Tolerance for Precast Panel Erection

o Plumbness or vertical alignment: ±1/2 in.

B8

o Variation in horizontal alignment: ±1/2 in.

o Precast element joint to joint alignment

- Horizontal joints: ±1/8 in.- Vertical joints: ±1/8 in.

2.2.5 Finishes

Precast panels shall have a smooth dense finish on the outside,exposed surface such as is typical of steel form or high densityoverlaid plywood forms. The inside panel surface shall be clean,fi'ee of laitance, and shall be intentionally roughened to an approxi-mate amplitude of 1/4 in. The surface shall be cleaned by high-pressure water spray immediately prior to erection.

2.3 EXELUTION

2.3.1 Preparation

a. Contractor shall inspect and survey all existing work prior tofabricating and installing paiiels. Dimensional discrepanciesshall be immediLtely brought to the attention of the Engineer.

b. Contractor shall prepare a written erection procedure indicatinglifting, temoorary bracing, support and alignment methods.Sequence of operations and inspection hold points shall beidentified.

2.3.2 Erection

a. Precast panels shall be erected as shown on the drawings.Tolerances shall be as specified in Section 2.2.4.

b. Panel form ties shall be securely fastened. Temporary supportsand braces shall be used as necessary to maintain alignment.

C. Nonshrink grout joint sealant, bearing pads, and neoprene sealsshall be installed and applied as required on the drawings.Care shall be taken to prevent seals from being displacedduring panel installation.

d. Form tie holes shall be drilled into monolith using suitableconcrete drilling equipment. Ties shall be installed and setusing epoxy grout or polyester cartridge anchors. Form tiegrout shall be allowed to set for a minimum of 24 hours priorto erecting precast panels. Form ties shall be embedded andgrouted to develop a minimum ultimate tensile load of 33 kipswhen tested in accordance with Section 2.3.3.f.

B9

2.3.3 Inspections and Tests

a. Contractor, shall be responsible for inspection of panel fabri-cation and erection activities to ensure that the work conformsin all respects to the drawings and specifications. Record ofinspections and inspection results shall be maintained forEngineer's review.

b. Contractor shall inspect precast panel form prior to casting toensure dimensional configuration and location of all embeddeditems.

C. Contractor shall inspect panels after installation to ensureconformance to location tolerance and that panels are securelytied and braced for inf ill concrete placement loads.

d. Contractor shall sample and test concrete used in panel fabri-cation as follows:

o A minimum of two sets of three concrete specimens shall becast, cured, and tested for each batch of concrete to deter-mine the concrete compressive strength at 7 and 28 days.Contractor may make additional specimens to monitor strengthgain during cure.

o Determine slump of concrete mixture at time of placement.

o Determine air content at time and point of placement.

e. Contractor shall provide to the Corps or the Engineer, forindependent testing and analysis, such additional cast specimensof concrete as may be requested.

f. Contractor shall install a minimum of two additional form tiesand two additional dowels at a convenient location in themonolith as directed by the Engineer. Contractor shall conducttensile testing of the installed ties and dowels to determinethe minimum ultimate load of the installed ties and dowels.The minimum ultimate load of the tie or dowel shall be thatload at which it ruptures, slips excessively, or exhibitsgreater than 1/4 in. of total deflection between the face ofthe monolith and the connection to the form. The average ofthe two tension tests shall be used to establish the ultimateload of the ties and dowels.

2.3.4 Cleanup

a. Contractor shall immediately remove spills or runs of epoxy,grout, or other materials used in the construction from theoutside surface of precast panels.

BlO

b. Contractor shall maintain work areas clean and free of rubble,discarded product containers, packaging and shipping materialsaQ~ other refuse.

B11

SECTION 3CAST-IN-PLACE CONCRETE

3.1 GENERAL

3.1.1 Work Included

The work includes all materials and workmanship required for produc-tion, delivery, placing, and curing of cast-in-place concrete.

3.1.2 Related Work

Related work includes fabrication of embedded lock hardware andappurtenances, and fabrication and erection of precast concreteleave-in-place form elements.

3.1.3 References

a. ACI 301: Structural Concrete for Buildingsb. ACI 318: Building Code Requirements for Reinforced Concrete

3.1.4 Submittals

a. Contractor shall submit concrete mixture proportions and testresults as specified in Paragraph 3.2.1.a, below.

b. Contractor shall submit batch monitoring test results forinfill concrete placements as required by Paragraph 3.3.3.b,below.

3.1.5 Quality Control

a. All work shall be performed in accordance with ACI 301 and 318as applicable.

b. Contractor shall maintain records of tests and inspections asrequired herein and make copies of such records available toEngineer on request.

3.2 PRODUCTS

3.2.1 Materials

a. Concrete: Cast-in-place concrete materials shall conform tothe following requirements:

o Cement: Cement shall conform to the requirements of ASTMC 150.

B12

o Aggregate: Aggregate shali conform to the requirements ofASTM C 33.

o Ai'r-entraining admixture: Material shall conform to ASTM,C 260.

o Water-reducing admixture: Material shall conform to ASTMC 494, Type E.

o Pozzolan: Pozzolan shall conform to ASTM C 618.

Cast-in-place concrete mixture shall be designed to satisfy thefollowing requirements. Prior to commencing operations, theContractor shall furnish the proportions of all ingredientsthat will be used in the manufacture of cast-in-place concrete.The mixture proportions shall be accompanied by test resultsfrom an independent commercial testing laboratory, attestingthat the proportions selected will produce concrete of therequired quality.

o Minimum 28-day compressive strength: 3000 psi

o Maximum coarse aggregate size: 3/4 in. nominal

o Minimum entrained air: 3% to 5%

o Maximum water cement ratio: 0.5

o Minimum cement plus fly ash content: 450 Ib/cy (5-sackmixture)

o High range water reducer: Type F

b. Reinforcing: Mild steel reinforcing shall be new billet steelbar conforming to the requirements of ASTM A 615, Grade 60.

3.2.2 Accessories

a. Hardware and accessories shall be incorporated into the work asshown on the drawings. Hardware and accessories shall befabricated in accordance with Section 4.

b. Joint seals and joint filler materials shall be as shown on thedrawings.

3.3 EXECUTION

3.3.1 Preparation

a. Contractor shall prepare a written concrete placing procedure,identifying placing sequence, maximum allowable lift height andplacing rate, and including a checklist of inspections to be

B13

made. Contractor's proposed methods of concrete placement,consolidation, and curing shall be submitted to the Engineerfor review.

b. Contractor shall inspect all existing work prior to placingcast-in-place concrete to verify that such work is complete andready to receive concrete.

c. Contractor shall notify Engineer at least 24 hours in advanceof any concrete placement.

d. All embedded items and reinforcement shall be securely tied toprevent movement during concrete placement and consolidationactivities.

e. Formwork for cast-in-place concrete shall be in accordance withACI 301.

3.3.2 Concrete Mixing, Placing, and Curing

Production, conveying, placing, consolidation, and curing of concreteshall be performed in accordance with ACI 301, and of the followingrequirements:

a. Truck mixers may be used with written approval of the Engineer.When admixtures are dispensed into the truck at the site, truckcapacities and batch sizes shall be selected that enable thoroughand complete mixing of all constituent materials.

b. All exposed concrete surfaces shall be cured by application ofabsorptive mats or fabric kept continuously wet for a minimumof seven days after concrete placement. Membrane curing shallnot be used.

c. Contractor shall measure precast panel movements and deflectionsbefore and after placing concrete. The measurements shall betaken at all four panel corners and at the top, bottom, andmidheight along a vertical line passing through the middle ofthe panel. These measurements shall be made for Panels P-i,P-2, and P-7. The Contractor shall submit his proposed measur-ing procedures to the Engineer for review.

3.3.3 Inspections and Tests

a. The Contractor shall be responsible for inspection and testingof cast-in-place concrete activities to ensure that the workconforms in all respects to the arawings and specifications.Records of inspections and tests Ohall be maintained for Engi-neer's review.

b. The Conti-actor shall provide the following necessary qualitycontrol and testing services for each batch of concrete placed.

B14

o Two sets of three concrete specimens shall be cast, cured,and tested to determine the concrete compressive strongth at7 and 28 days.

o Determine slump of concrete mixture at time of placement.

o Determine air content of concrete mixture at time and pointof placement.

3.3.4 Cleanup

Contractor shall dispose of wasted concrete in accordance withCorps' requirements. Mixer trucks, pumps, tools, and placing equip-ment shall be cleaned in designated areas only, and wash water andspoil shall be contained as requii-ed.

815

SECTION 4HARDWARE AND APPURTENANCES

4.1 GENERAL

4.1.1 Work Included

a. The work shall consist of furnishing all labor, materials, andequipment for fabrication and furnishing of hardware and appur-tenances for the navigation lock repair mock-up demonstration,as shown on the drawings and as described in the specifications.

b. Hardware and appurtenances include

o Horizontal armoro Vertical armoro Line hooko Top curb armoro Panel joint assemblieso Panel alignment assemblieso Form ties

4.1.2 Reference Standards

a. AISC "Manual of Steel Construction", Eighth Edition

b. AWS D1.1-85, "Structural Welding Code"

C. SSPC-SP-6 Steel Structures Painting Council, "Commercial BlastCleaning"

4.1.3 Quality Control

a. Fabricator Qualifications: The fabricator shall be experiencedin the fabrication and working of metals, including cutting,bending, forming, welJing, and finish~nq. Fabrication of metalhardware and appurtenances shall be performed in accordancewith the AISC Code.

b. Welder Qualifications: Fabricators supplying welded componentsshall employ only welders, operators, and tackers qualified aso,.,' ned in AWS D1.1. Welding practices shall conform toAWz D1.1.

4.1.4 Submittals

a. Contractor shall submit complete shop drawings indicating allshop and erection details including materials of construction,

B16

finishes, methods of fastening, and location of cuts, copes,connections, holes, fasteners, and welds.

b. Contractor shall submit certificates of welder's qualificationsprior to start of work of this section.

c. Contractor shall submit mill certificates for structural steel,indicating specification compliance for chemical properties,tensile strength, yield point, and elongation.

d. Contractor shall submit catalog cuts and certificates of com-pliance for concrete anchors, fasteners, headed qtuds, andother commercial products incorporated into the work.

4.2 PRODUCTS

4.2.1 Steel

a. Structural steel shapes, plates, and bars shall conform to ASTMA 36, unless noted otherwise.

b. Steel pipe shall conform to ASTM A 53, Type E or S, Grade B,unless noted otherwise.

4.2.2 Bolting Materials and Fasteners

a. Bolting material shall be either ASTM A 307 or A 449 as shownon the drawings. Bolts shall be furnished with matching nutsand washers.

b. Headed studs shall conform to ASTM A 108.

C. Deformed bar anchors shall conform to ASTM A 496.

4.2.3 Other Materials

All other materals not specifically described but required for acomplete and proper installation shall be as selected by the con-tractor subject to approval by the Enigineer.

4.3 EXECUlION

4.3.1 Fabrication

a. All structural and miscellaneous steel for hardware and appur-tenances s,-,all be fabricated in accordance with the reviewedshop drawings and shall conform to the requirements of the AISC"Manual of Steel Construction."

b. Welding of steel hardware and appurtenances shall conform toAWS D1.1, "Structural Welding Code." Type, size, and spacing

317

of welds shall be as indicated on the reviewed shop drawings.Welding shall be accomplished in a manner which will minimizedistortion of the finished parts. Weld splatter and oxides onfinished surfaces shall be removed. Unless otherwise noted,headed studs and deformed bar anchors shall be welded usingautomatically timed stud welding equipment. The Contractorshall perform tests, as recommended by the welding equipmentmanufacturer, to verify proper operation and settings of thewelding equipment.

4.3.2 Surface Preparation and Protective Coatings

a. After fabrication, all steel surfaces shall be blast cleaned inaccordance with SSPC-SP-6, Commercial Blast Cleaning.

b. Iron and steel surfaces to be embedded in concrete in thecompleted work shall be uncoated.

C. All exposed surfaces of hardware and appurtenances shall begiven a shop coat of zinc-rich, rush-ir~hibitive primer. Thedry film thickness of the primer shall be 2 mils minimum. Thesteel surface shall be prepared, and the primer applied inaccordance with the coating manufacturer's recommendations.

d. Steel surfaces to be uncoated shall be free of loose rust, millscale, oil, and grease.

4.3.3 Inspection and Testing

a. Contractor shall be required to perform such inspections andtests to ensure that all work is performed in full compliancewith the contract documents.

b. Inspection and testing rPf welding shall be in accordance withAWS D1.1, Section 6.

C. Material and workmanship will be subject to inspection by theEngineer. Testing and inspection by the Engineer will in noway relieve the Contractor of its responsibility to furnishmaterials and construction in full compliance with the contractdocuments, and to provide its own quality control program.

B18

APPENDIX C: DESIGN DRAWINGSPHASE II DEMONSTRATION PROJECT

C1

tZISTINS LOCK W-C. I.P. OL."t". '11? M0110.17".

@e K LCCATINI@NAN

96-6 ______ J wafv"Im. Sri

I r"Ci? PICL ITWPI -c.,.P. cow"

Pii Fo Tics.K~10 1*.4f

mom Io,~ N c

WAILS KCIL

1\ELEVATION -LOCK SURFACE REHABILITAT ION MOCK-UP I-A\ SECTION -LOCK SURFACE REHABIL

LEGENOtraft lie. SEC

CTRAC4ORS'0.-c.WORK 9 STORAGE

* * * * * * * * gAREA

.. Ii~rr'1-iit- itINSTALL

'?t ~~ *** 00 0 60 0 0 -I

S ----4LOCK WALL TEST

3 0 06 00 **oe * 4ONOL TH-

---- 00 000 0600 0 060 00 00 t'. /

ISOUT.4 PLATTE STREET J!

i%-_SIEPPANNsel$ tgfs? 0`101 ltIs we W LS

4An 4, Dow. we 0101 9.

,~ELEVATION -FORM TIE, DOWCL C CONCRETE EXCAVATION LOCATIONS tooo~ . *

Preceding Page1S Blank

- - - ----- I.... ...

'IS? I6L11. FORl ALL0034 *88 .61.00 18.LO 388 0AC 8090P0A0LOCATION MO1401 00. L ST-8-PA P044.100MSK841.8310" ""1Sf548164 13, CL318840 Pftt301 CO~.1MPR080 PPOL ANN880&1IN11111HATI(NIAi. Ettl\ *qISCtILI*E01 Otil6L aea00U08s0 Fee I;Cz l 804 Iwo1 186~~W V1I 80. IMP~t 039MAr~&I N 0CIL8US88 lOCUOYI ASIAPN

"at -rot Its? NUN8114O8 LIMS P0p1@&060 106fM SO 80800

084008S IA 184 01P1.611 MM .8.d up00 low 00 We t me 0 P00410a0m0:061418. 0 IN ?ACCA8O "t 11 Cl 88.0 18600 1800.10

IC 01 811 00 0 1% -* 1 LO 001 At 0 INS 04 WA I I AY& mSSMO STATION 4 10 116 11) A

time 1880 AIO 1010110 S#. om0404 PON am1 000811U4L WFOPP.ITPACI8.10 19 SlhUgsO.

Lflq Pat0 CU?06C10 SMALL 00441 A P001.19484380 WOM 0106040.0-011 OltO to toA40Cloo Wow. emm008uk4? is 00480 we tal

INS IC880IRLa WILL *a 11404,11111110 TO98.011 1170 36031050 PASS IN0IINOPALL 041 10613040011 as1 TO 8T - 8I%" ON TG0110.

C.I.p. CONCRTE tMFILL 4. MIAMI U30840411I

* IOCme,1 LAMP A. SUVAFACO POIP, ORILL 886.00IN ALL6. ODALNOT190t. SOCT PANEL8 P-i 1. PLACI AP 884P1LL, CeMM~nS Fail lOF

MIST10 C0884C104E? k P04Lt P-1 .0 P-9"C. N7 =LLC 10-0 : P.O. PICI P 'WILLCUtI

L OC =.UL P.-0. PLACK CIP IIOPILL C401apt.C P01IP4 lC U 81.. opMamiP: ago.I Poftl.6 P PALMS alP INPFILL -a101

P05. 4

To P". PLACRI WILL CUOCONIP2 PILLCUIPIL-fl 8880 _117 CP-.n1AC

rO arti 3.6~ INS MR04 Of8.04 P040 800 F lORM P~C 1196 11646404 gOM OTIE DTAIL. ME 809330 OL 4 PMAX 185M Pflago 000*6 5 FINA

COCSN8*l P=6006 sop 1.35 Nor. PIAco)40 Mli IN 0188 IIP 8888ILLLIRI 084.. 5 8010LASO as A4 FEW IS RAC431, 1014"

GR. CCW&1s 108Me0RA.30

CIP CAM01CIIR4o .- 100PI* C 10-.0raw ToRCI IM A11.8 AMq A 11.l, 000 SO8868.00 WIRE FASAAIC. A""I A A8as081^440 WRL8. 01U001 AIM" IS

I~opa WA 06P00N Ok40 i""t A 496 Pr - IS allj011101MAI FOR HAIMMIIOIO A^01" A 36 380.030 018040810 4660-----lii 1740 481k 118C HAVNIAL.L0, A NO0049A ING I"**00N0

010111. roaNiclAlul, Aloe WioluA OF 010161 Cu4010U11804

be8.0884. 4080 08.8 -OS 0h0WCIft06 8868.388 CO". 8800

LOCK SURFACE REHABILITATION Fu0.6000060.910m401"1"104101s. ^CC, 001 l3t0VW18L4 CONCETFil P00 0*18.1840

MOC~K-UP A4 It's NUIL11,1I0 Co"t eoEulm0IO Pop

FM F1.805? 00 PRODUCIC8iON op "a

0jA.1 106 581.1,1140, C888F18810 CIA Cu"INSI Of CWHICARVII3 "$MPITTS*38881 14880 HSI WqW0I34041A104 18411ml ]Dow8F,@* AM AIR IN"840

004q0C81I04EACN4ATIM4 OP C0410111 FMRIN 188 .880001001 OW"Alt*%.MALMAGNET I C 11401P01804aMO0 MAI~00 8'040L81ING 1001.0 08806.8. 00 81110 00

NORTH CONIM410.4.44114800603MI S we04080.GOP 1041001.

9.ý 713,4118.9 TRIT140 OF SAMPLI! FOWl VA1* #*40 W 111400 1 aGL A Ovlb9017~I ING 881 880 PIC8IATION. 08388.8. a1 10404IC1E0 10o ISIVkISM 10

COTRCTR 008*00 a 08ist 04001 03998. 106 04"030840 "oPn" WALL.1 ad 4141PF8CIDITFCONTACTOR / irTI 058*08.0 A 94888883* FOIICR OP 33 MAPS. 846.00 FON PON 1ARS OM0

WORK & STORAGE 'fa 880.13 "0888 00 060809.11.080 WITH 0 10 1883101..80 080owl

AREA~~D~v AMI Iron0 "Let0 40. UP To I Aquelm MVA03 To1811 10 611 AO INIOR1AININD 0040806G MA8100800.

/ / 80. C34100C00 08388.8 P1990M04*-08*811A1A10011108413 OP 983IVINI L8C010.183 T*S. 1031 L 8404818 45 83803 106~ 880110"ac 1 MANTJUIflUIlO To 1lia

I48 Ho 80mom 10 04811 04801806 8*030 040 00.883 0408060 OP 83A4"

[1- ,4 /1.0110 P104-.18.8A381884. b*01A88.

Ad8.kV MW Vibm N.^w

4EST /o

H PLATTE STREET _SFORCONSTRUCTION_

SITE PLAN "CVA

50 C 5 ~ o 5 ~d ~ J l 4A R R A N G E M E N T C R S O N I E R

CCldlJTING CktEMIRa~ MNS~~~~~_A C3G . U 548 A A86029-1IMOW r______46___ALi ASNOTE ______________ smil11 i or

/ At

* ~ ~ SAE 1,C 1 2- IA-I 0R

1- 1- 3/4

-r 1 ,

Si In,

PAI

/7\ ELEVATION -PRECAST PANELS 'P-5' ,P3 .P * Al

/-\SECTION- TPRECASTP

L ~ ~ ~ ~ ~ CI GrTON - :4t

3.,.--.-

SCL k I I I t I , -0" C5/N

CK-IWCB ITYe I,

- B4*ICL

ti'?Cft.4p 2 CA BAY

GW ý3/ I -I/

AL I *"T Z-/2. 2 '0000ii___________~1/ o..SCp~I1/ 2

IK a.' (TV?

SCM..C:1.1- *p9 4

21

NA S E T O

-RC

S P N L

3 4 c

2 :/2* 2 1" 2 * CAT/CAIPS

C$"AtER ITYPI

IPL.ATE, ScCtjj

ItelrI CA WAY

ErACtI p (C4t WEALD TIErAA-W? 'CL" PLATE, SEE

CONTdINUJOUSAL I 014CH?DJE C ~ ( ETO RCS AE PI

* SECT ION -TY PRECAST PANEL '--

IVtRTICAL IO NICU*, Ml

PATE APPROML

X111( 4______ 1~jPRECASF FANEL CORPS OF ENGINEERS

C5/C6 -CL~~TL lC?2o

=". =149-

________ FOR_~IIL MIAMI.____

-• I .i '

ELEVATION - PRECA§T PANEL F'-8'

"TIt me 1*4" 1-U S3. 0. 2-0" -,.-3*. 3 -S V-0.

CSECT ION- PR

S-2 3/4' 3

/ ELEVATION - ?RECAST PANEL 'P.-7'

* I4~W1 1 I/4l4j-TC1AA4 '-6 2-::5 '-'O" ,S 3 2.

ELEVATION - PRECAST PANEL -P-6'SCALE1 /2%11-0 s C7/C8

' ' r3I I

$MAU 3,4'.k CA WAYCAST A"A IO

CO4T IM)W3~J

/ O~t~lOS CCf tTp___FOR DETAILS

SEE

I SECT ION PRECAST PANEL -P-7- /-' ECTION -PRECAST PANELVP-6';V SCAM 1 %-0* - 3CALEt '-1 '-0*

F~OR CONISTKUCT 1 ~l0.41104tACAPOC

A86029 - __________ __

WATERWAYS8

n . KoLK ICXItCW41 SYAT ION

D.--- PRCAST PAES CORPS OF ENGINEERS

C71C8 w__mWaa-____MAW A86029-3A_____________________________1_ A.@ m L CL.4 AS NOTMED' ýET

9111161:14 TEST

AT CON4TRACTOSS MWILL CONCRTE CS~GTSIWILL CONCRTE It PROIOE. TO, E

ALLO FOR

PRECAST PANEL rapt Ms PANELS

SE OE9 ION LEIOTC .SME I~T

BE[PLATE. SEE~

FO SECIO WELDED FOLM TIEA SETOIFROINA.AELBTONLTE SCLE Kt NOT SCAL

CIA ~ ~ ~ ~ ~ ~ ~ ~ HC CIECININCIA ... CINT

ril 11W)

RICE yop wp~aCONTRACTR. NOTWILL.

SETO WEDE FOR TIE SETO.FRrI A AELBTOOCHIO SCALE NOIN SCCALE

CONE AT ASTAC~' OPTIOISN.4L T'.-0. ARO I/2g OLf MOTmE IIIININIL-e - L 70 INOPRT CONCRETEEEMTES.____

romaT TI SlEET c. S. I/. C.:I.P I/4 FBR BA

SEE~C C..A PILCONCRETECSNI. RITI NOINT

LOCATION SCiJILPAI NG OF O

IN AS ~ FOI%4 TIES OO I SEEIL

ALHEEET 1 NL.SSEIETTrawj~ LEELLM. EIAG

PLTE I. P. INLOAD

NCONCRETE 30OIRIE

OUTL~~o~ I EOORR OM

SELON I/2I 17 A=DEAISolt P.C* PAIE TIE A SEYECESI

/-o' SECTION - HOR IZONTL RE CASP SECT ION V SERIAR AREO RECES SECT ION -VERT ICA;w OSCALEI PANEL- JOIN -,Z TIa * ' EMBCONNETIN .L NO SCALE C/1

MC L,,TIE WED ALNT OASR

1.:" ' , A to MAI L)

In,$ "KC. 1 LLOOMI. is MA11I

KC NOTE 11-Oft.

INSEL AT PANE BOTTOM

NOOt NOTEN 9:AATS

OULINEO IAWLT.10 IIITU~4 E ~ uIgO 1

U. ENISTINS TEST~ ~M EXTEN SEXCAVTION-SECAEXVTINTLNEHO

II ONOII SCLNE I-IM~ M'4 AELrc r xsi

EITINGI COTEMIST SETIN- PCILEXAVTONA LN HO

ASPK4ALT IMPREGiMTED. OPEN CELL FOAM.I"MIN KGEEA PUW COP TeT

A D WS I YE Old B O T H C O NT A C T S U V A C E S I N I L

INSECTION -VERTICAL EXPANSIONOPINLSRJTKAOPT INOOSCALE JOINTSI PRECAST PAWLISNOSCI. J INTCONCETIE IiKRT *P-I' TO PS

C.I.P. WNILL /-a\ SECTION -PLAIN END JOINT

SVCLLING.NOO I OEI 5 O-kL HU7 TO ASSIINE

INIFRid LOAD

__ * .rap0 AL I oNT

*~ .. . .... ASSEMBLY. SEE \

Wf I LL CONCA9 I AS NEEDED IGNINOIM11. IRV11GEL MORTAR. [TCI TO A62OBTAIN UNmirOM KARIN@ E. OZOL I u.a NwC4

0)MAUAAND CORPS OF ENGINEERS

KSECTION -VERTICAL ALIGNMENT DETAILS_________ A62-4

NOSE C9IC 10 SCREW R. MGMI II JULYT 01 %CAL1IS, AS NOTED I IIT 4 O 5

- r..-- - -~ , '.. - -- %A 4

I

i, I ft 3/

IT"

-- . V ,--' 1--WIG

trpi 11 WIG#+.tlo • 1

VERTICAL SECTION PARTIAL PLAN END SECTION "._

-A.--- 7__ -• _J- a. I, . i.

aAIM •I*0 ccHMO "I.l . WI3 L Dl w # I IIvTI L 0- 4I 0 P ARTIAL ELEVATION ,.t 114 SC•TIO

NDTI HORIZONTAL LOCK ARMOR tT DETAIL -CORNER ARMOR F

4 _

_____________________ I.'S

Kroft" LIo

AppmD Ka m. I *-a*

""BIut0 SO I41N AT 8" 0 .T

- PLAN A AELS-TI TL !ORD LSCN.Cs 3"-"%..•• I • P I S41ISI

A4tT•- PLAN- LA

PCAP P 0~1/4I i

IC A PLANS•,9 1-, ..

PIPE TABLE KLON

PL S4v 4T is0'-46' SECTION _ 4EOq•!m 21

1- G- 4-3C4* ff3/SWKI4~w~

1"0 HEAVY, _-- --' HEAV H .[N O ELEVATIlON SECT ION w * a ty

/\DETAIL -LAt.AIGNMENT ANGLETE"LEVATION

PL PL4 -

4 N 0*-4

I~~~i SPACIN LOt SVICACIIOl

MELEVATIONAT'm .- 4-" 'OLT LEVATIONSECTION" "" ui

LIISYII UiAS_______ ~~ O

/\ DETAIL -PANEL 'P-6E SHEAR KEY PLAA

/7\ DETAIL - VERTICAL ALIGNMENT E L No VASR

-Jll SCALCII- o"HARDWARE ASSEMBLY C11/C12

ELEVAT$ 101 SRIt .V~T~

VWW~n~ SO in

ISMI We*Ssl

to~ WALl"two4 IlS IUIA

IaS. V.0! t

114ZO A SECTION /

/ KAL P W4 ELE0-A1ION

/7\N FtTM -ROR L 4NE HOOK ASEML 4 4 EAL I EL LT

o me

I,~~~t 0Iat0SAAd~

ELEVATIO FOR COETATCTIO

SEE TABLETBELS

__8___0____ A86029-5

I I JLY SI STEELc HASDNO RE IEXMW STTON