Syphon TBM Specs2009

CITY OF NEW YORK
BOROUGH OF BROOKLYN AND STATEN ISLAND
THE REPLACEMENT OF THE

EXISTING WATER SIPHONS BETWEEN
BROOKLYN AND STATEN ISLAND
CAPITAL PROJECT GE-343
NEW YORK CITY

DEPARMENT OF
ENVIRONMENTAL
PROTECTION
NEW YORK CITY

ECONOMIC
DEVELOPMENT
CORPORATION
New York City
Economic Development
Corporation
December 2009
VOLUME 3 TUNNEL AND SHAFTS

TECHNICAL SPECIFICATIONS
NEW YORK CITY ECONOMIC DEVELOMENT CORPORATION

NEW YORK CITY DEPARTMENT OF ENVIRONMENTAL PROTECTION
CAPITAL PROJECT GE-343
THE REPLACEMENT OF THE EXISTING WATER SIPHONS
BETWEEN BROOKLYN AND STATEN ISLAND
VOLUME 3 TUNNEL AND SHAFTS TECHNICAL SPECIFICATIONS
PAGES
CONTENTS
DIVISION 1 - GENERAL REQUIREMENTS

01003
01025
01300
01400
Introduction Volume 3....................................................................... 01003-1 to 01003-4

Measurement and Payment Tunnel and Shafts ................................ 01025-1 to 01025-11
Submittals ............................................................................................. 01300-1 to 01300-8
Quality Control and Quality Assurance.............................................. 01400-1 to 01400-14
DIVISION 2 - SITE WORK

02145
02310
02315
02316
02330
02338
02340
02400
02416
02432
02495
02617
Control of Groundwater and Surface Water ......................................... 02145-1 to 02145-3

Shaft Support - Slurry Walls............................................................... 02310-1 to 02310-18
Earth Pressure Balance Tunnel Boring Machine ................................ 02315-1 to 02315-17
Slurry Tunnel Boring Machine ........................................................... 02316-1 to 02316-16
Tunneling by Tunnel Boring Machine................................................ 02330-1 to 02330-28
Shaft Support - Ground Freezing (Optional) ...................................... 02338-1 to 02338-11
Precast Concrete Tunnel Lining.......................................................... 02340-1 to 02340-19
Tunnel Cleaning.................................................................................... 02400-1 to 02400-4
Compressed Air Working ..................................................................... 02416-1 to 02416-4
Jet Grouting......................................................................................... 02432-1 to 02432-16
Instrumentation and Monitoring ......................................................... 02495-1 to 02496-16
Steel Water Main Piping and Valves in Tunnel and Shafts.................. 02617-1 to 02617-5
DIVISION 3- CONCRETE
03100
03200
03250
03301
03350
03360
03370
03380
03410
Concrete Formwork .............................................................................. 03100-1 to 03100-6

Concrete Reinforcement ....................................................................... 03200-1 to 03200-5
Concrete Accessories ............................................................................ 03250-1 to 03250-5
Backfill Concrete in Shafts and Tunnel ................................................ 03301-1 to 03301-8
Cast-In-Place Concrete ....................................................................... 03350-1 to 03350-27
Concrete for Precast Concrete Tunnel Lining..................................... 03360-1 to 03360-11
Reinforcement for Precast Concrete Tunnel Lining ............................. 03370-1 to 03370-4
Shotcrete (Optional)............................................................................ 03380-1 to 03380-11
Precast Concrete ................................................................................... 03410-1 to 03410-8
DIVISION 4 MASONRY (NOT USED)

1
DIVISION 5 METALS (NOT USED)

05000
05050
05500
Metals.................................................................................................... 05000-1 to 05000-8

Metal Fastenings ................................................................................... 05050-1 to 05050-2
Metal Fabrications ................................................................................ 05500-1 to 05500-3
DIVISION 6 - WOOD AND PLASTICS

06600
Plastic Fabrications ............................................................................... 06600-1 to 06600-6
DIVISION 7 - THERMAL AND MOISTURE PROTECTION (NOT USED)
DIVISION 8 - DOORS AND WINDOWS (NOT USED)
DIVISION 9 FINISHES (NOT USED)
DIVISION 10 - SPECIALTIES (NOT USED)
DIVISION 11 - EQUIPMENT (NOT USED)
DIVISION 12 FURNISHINGS (NOT USED)
DIVISION 13 - SPECIAL CONSTRUCTION

13000
13060
13120
13130
13140
13200
Tunnel and Shaft Safety........................................................................ 13000-1 to 13000-7

Shaft Construction ................................................................................ 13060-1 to 13060-8
Removal and Treatment of Tunnel Construction Water ....................... 13120-1 to 13120-5
Tunnel and Shafts Temporary Ventilation and Utilities .................... 13130-1 to 13130-8
Muck Disposal ...................................................................................... 13140-1 to 13140-3
Pre-construction and Post-construction Inspections ............................. 13200-1 to 13200-3
DIVISION 14 - HANDLING EQUIPMENT (NOT USED)
DIVISION 15 MECHANICAL (NOT USED)
DIVISION 16 ELECTRICAL (NOT USED)
SECTION 01003
INTRODUCTION VOLUME 3
PART 1 GENERAL
1.01
SCOPE OF WORK
A.
The Work indicated within the Contract Drawings, Specifications and attachments comprises one
(1) construction contract, which will include furnishing all labor, materials, equipment, facilities,
and services for the construction of the overall Work as described.
B.
The Contract specifications are divided into seven (7) volumes, as follows:
C.
1.
Volume 1 Front-end Contract Documents
2.
Volume 2 Common Technical Specifications
3.
Volume 3 Tunnel and Shafts Technical Specifications
4.
Volume 4 Siphon Chlorination Station Technical Specifications
5.
Volume 5 Land Piping Technical Specifications
6.
Volume 6 Geotechnical Reports
7.
Volume 7 Permits and Approvals
This introduction is pertinent to Volume 3 Tunnel and Shafts Technical Specifications. In

general, the Work covered within Volume 3 will include:
1.
Construction of two (2) tunnel shafts, including all necessary temporary and permanent
support, ground treatment, and groundwater and surface water control measures. The
launching shaft is located in a vacant plot of land adjacent to Murray Hulbert Avenue in
Staten Island. The Staten Island launching shaft is to be a minimum of 28 feet clear
internal diameter and approximately 85 feet deep to the top of the slab to provide access
to assemble, launch, and service the Tunnel Boring Machine (TBM). The launching shaft
will also be used to install the 72 internal diameter steel water main within the bored
tunnel. The receiving shaft is located in Shore Road Park opposite Fort Hamilton High
School in Brooklyn. The Brooklyn receiving shaft is to be a minimum of 24 feet internal
diameter and approximately 145 feet deep to the top of the slab to enable access to
receive, disassemble and remove the TBM.
2.
Construction of one (1) approximately 9,440 feet long 10-4 internal diameter tunnel
beneath the New York Harbor, to be mined using a pressurized face TBM and lined with a
reinforced, fully gasketed, precast concrete segmental tunnel lining.
3.
Construction of one (1) approximately 9,680 feet long single steel water main within the
tunnel and the shafts. The steel water main riser pipe within both shafts shall be 96 inch
internal diameter, totaling approximately 200 feet in length. The remainder of the steel
01003-1
water main in the shafts and the tunnel shall be 72 inch internal diameter, totaling
approximately 9,480 feet. At the top of each shaft the 72 inch internal diameter steel water
main shall be connected to the land piping and details of any special connections and
valves at the top of the tunnel shafts shall be covered by Volume 5 Land Piping
Technical Specifications.
4.
The treatment and drying of all shaft and tunnel muck and excavated soils on site and
control of drying operations. The handling, transport and disposal of all excavated soils
and tunnel muck to the identified disposal site.
5.
The installation and testing of all steel water main and appurtenances inside the tunnel and
the two shafts.
6.
Backfill concrete in the annular space between the 72 inch internal diameter steel water
main and the precast concrete segmental tunnel lining. Backfill concrete within the shafts
and formation of shaft access chambers at the top of each shaft, including the provisions
of removable precast concrete planks and maintenance access.
7.
All work within and above the shafts including: miscellaneous piping; manhole access
and ladders/steps; top slabs; sump gratings and pumps; and electric conduit, wire, and
lighting.
D.
All site work including field offices, construction fencing, staging, and temporary utilities
including the coordination and provision of temporary electric power for the operation of the
TBM is covered by Volume 2 Common Technical Specifications.
E.
Construction of the new Siphon Chlorination Station on Staten Island, adjacent to the launching
shaft is covered in Volume 4 Siphon Chlorination Station Technical Specifications.
F.
Land piping both on Staten Island and in Brooklyn, piping and appurtenances within the
launching and receiving shafts, and details of the shaft access chambers not covered by this
volume (Volume 3) are covered in Volume 5 Land Piping Technical Specifications.
G.
The Geotechnical Data Report and the Geotechnical Baseline Report are included in Volume 6
Geotechnical Reports.
H.
Permits and approvals are covered in Volume 7 Permits and Approvals.
I.
The Contractor is to furnish all labor, materials and equipment required for undertaking the Work
of the project for the bid price.
J.
The work is to be coordinated by the Contractor with a Project Manager located on the
construction site.
1.02
A.
SEQUENCE OF WORK
The construction of the tunnel shafts and the tunnel including the installation of the 72 inch
internal diameter steel water main must be sequenced in coordination with the construction of
the Land Piping and Siphon Chlorination Station, as these items require use of the same
construction worksites.
01003-2
B.
In general, the anticipated sequence of work to meet the time schedules is given below. This
sequence is presented for informational purposes only and the Contractor shall not rely upon it
for prosecution of the work to meet the schedule milestones in Part V.C of the Construction
Contract.
1.
Mobilize to site, initiate shop drawings submittals, establish work site.
2.
Coordinate with utility company for the provision of temporary electric power required
for all construction activities including the TBM.
3.
Construct Staten Island launching shaft including any necessary ground treatment
measures required for shaft construction and TBM launch.
4.
Manufacture and supply tunnel lining segments to site.
5.
Construct Brooklyn receiving shaft (must be completed prior to launch of TBM),

including any necessary ground treatment measures required for shaft construction and
TBM reception. See Contract Drawings for additional requirements of the Brooklyn
receiving shaft.
6.
Provide temporary shaft cover and security fence around the shaft and temporarily restore
park functionality until such time as the TBM is approaching the receiving shaft and the
site is required for disassembly and removal of the TBM.
7.
Assemble and launch TBM for tunnel drive beneath New York Harbor. Treat and dispose
of tunnel muck materials.
8.
Re-establish the Brooklyn shaft construction site in sufficient time prior to receiving the
TBM.
9.
Complete tunnel drive and remove the TBM from the Brooklyn receiving shaft.
10.
Install and test new 72 inch internal diameter steel water main within tunnel. The steel
water main for the tunnel shall be supplied from Staten Island shaft site only.
11.
Fill annular space between steel water main and precast concrete lining with backfill
concrete, ensuring that the pipe remains in position. Test steel water main on completion
of backfill as required.
12.
Install and test new vertical 96 inch internal diameter steel water main within the Staten
Island and Brooklyn shafts and backfill shafts with concrete. Test steel water main on
completion of backfill as required.
13.
Installation of riser pipe top assembly and any other necessary connections and valves is
covered by Volume 5 Land Piping Technical Specifications. The installation of these
elements shall be coordinated with the completion of the shaft access chamber/shaft top at
each shaft location.
14.
Construct shaft access chamber and install removable precast concrete roof planks at each
shaft.
01003-3
15.
1.03
A.
Landscaping, site cleanup and demobilization is covered in other specification volumes.
PERFORMANCE REQUIREMENTS
For any alternatives proposed by the Contractor for shaft or tunnel excavation, support or other
Work related issues including tunnel enlargements, the Contractor shall submit a full design
stamped and sealed by a Professional Engineer registered in the state of New York for the REs
approval. The design shall include calculations, shop drawings, and detailed descriptions of any
modifications and restoration to the permanent works that are required for the proposed
alternative design. The Contractor shall not perform any alternative or additional work before
approval in writing by the RE. It is the Contractors sole responsibility for the design and
construction proposed of that alternative and the design of any additional works needed to
accommodate the final product as well as any temporary support, if needed. Any approvals or
comments given by the Corporation or RE to any procedure, operation, or construction methods
do not relieve the Contractor from full responsibility for the adequacy and safety of the proposed
excavation method or the Contractors proposed tunnel design and construction. Additional
requirements are given in the respective Specification Sections.
PART 2 PRODUCTS (NOT USED)

PART 3 EXECUTION (NOT USED)
END OF SECTION
01003-4
SECTION 01025
MEASUREMENT AND PAYMENT TUNNEL AND SHAFTS
PART 1 GENERAL
1.01
SCOPE OF WORK
A.
Payment for all work included for the Harbor Siphon Tunnel and Shafts at Staten Island and
Brooklyn will be a single lump sum cost. The lump sum cost shall include all compensation to
be received by the Contractor for furnishing all tools, equipment, supplies, and manufactured
articles, and for all labor, superintendence, materials, operations, and incidentals appurtenant to
the items of work being described, as necessary to complete the various items of the Work. The
Contractors Lump Sum Cost shall be in accordance with the requirements of the Contract
Documents, including all appurtenances thereto, and including all costs of permits and cost of
compliance with the regulations of public agencies having jurisdiction, including Safety and
Health Requirements of the State of New York and the Occupational Safety and Health
Administration of the U.S. Department of Labor (OSHA).
B.
After bids are received and the Contract awarded, the Contractor shall provide as a minimum, a
Schedule of Values (SOV) for specific units of work. The schedule of values shall include the
Contractors price breakdown for specific tasks included in the work. The inclusion of all work
included in the overall scope of the Contract shall be reflected in the specific schedule of values.
Should any work included in the overall project, whether specified or implied, be overlooked in
the schedule of values by the Contractor, no additional compensation other that the original
lump sum price should be anticipated by the Contractor.
1.02
A.
1.03
RELATED SECTIONS
Schedule of Values is included in Section 01370.
SUBMITTALS
A.
The Contractor shall submit to the RE for approval, in a form as specified in Related Sections or
as directed otherwise by the RE, a complete schedule of values of the various portions of the
Work, including quantities and unit prices, aggregating the Contract Price. An unbalanced
breakdown providing overpayment to the Contractor on items of Work that would be performed
first will not be approved.
B.
Submit application for payment on a form approved by the RE showing allowances, lump sum
schedule of value items, and unit price items in accordance with the Contract.
1.04
A.
LUMP SUM ITEM

Payment of the Lump Sum item established in the Contractors Bid shall be full compensation
for all labor, materials, and equipment required to furnish, install, construct, test, and warrant
the Work covered under the Lump Sum bid item.
01025-1
B.
Payment of the Lump Sum item established in the Contractors Bid shall also fully compensate
the Contractor for any work which is not specified or shown, but which is necessary to complete
the Work.
C.
The Lump Sum item shall be specifically subdivided by Activity, broken-out in the Schedule of
Values.
D.
Payment for the Lump Sum items specifically broken-out in the Schedule of Values will be
based upon physical progress for each activity in accordance with the breakdown of Lump Sum
prices agreed to in the Schedule of Values.
1.05
A.
1.06
A.
DEFECT ASSESSMENT
Replace defective Work, or portions of defective Work, not conforming to specified
requirements.
NON-PAYMENT FOR REJECTED PRODUCTS
Payment will not be made for any of the following:
1.
Products wasted or disposed of in a manner that is not acceptable.
2.
Products determined as unacceptable before or after placement.
3.
Products not completely unloaded from the transporting vehicle.
4.
Products placed beyond the lines and levels of the required Work.
5.
Products remaining on hand after completion of the Work.
6.
Loading, hauling and disposing of rejected Products.

PART 3 EXECUTION
3.01
MINIMUM SCHEDULE OF VALUES FOR TUNNEL AND SHAFTS
A.
The Contractor shall provide a Schedule of Values for the following aspects of the Project. The
Contractor can offer additional breakdowns for consideration and approval by the RE. Each
Schedule of Value item shall be further itemized as needed to assist in the evaluation of work
completed and the processing of payment requests.
B.
For Schedule of Value Nos. TS-4.1 and TS-4.2, the Contractor shall determine the preferred
method of either Slurry Wall construction or Ground Freeze construction for the Staten Island
Shaft and provide a Schedule of Value for the elected method.
C.
For Schedule of Value Nos. TS-6.1 and TS-6.2, the Contractor shall determine the preferred
method of either Slurry Wall construction or Ground Freeze construction for the Brooklyn Shaft
and provide a Schedule of Value for the elected method.
01025-2
3.02
A.
SCHEDULE OF VALUE NO. G-1 - MOBILIZATION AND DEMOBILIZATION AND

BONDS
Payment
1.
Lump Sum Breakdown for work included under this schedule of values shall include
at a minimum the Contractors price for Mobilization and Demobilization and Bonds.
Also include, shall be full compensation to the Contractor for: site security; fencing;
lighting; move in of equipment, tools, supplies, material, and personnel to the job site,
including the cost of insurance, tools, equipment and personnel necessary for the
transportation and set up of any Subcontractors for the Work as described in the
Contract Documents; furnishing and erecting project signs; Contractor's plant;
installing temporary power, water, sanitary, and other utility services; monthly utility
bills; developing required safety plans; provision of temporary field office facilities,
including power, telephone, computers and connection service, water and sanitary
facilities; monthly utility bills; obtaining all required bonds, insurance, and permits;
daily clean up of job site; on-site environmental protection, and move out and final
cleanup of job site after the project is completed and accepted by the Corporation.
2.
Value for Mobilization and Demobilization shall be limited to ten (10%) percent of
the original Contract value.
3.
Work under this schedule of value will be paid for in prorated payments as follows:
4.
3.03
A.
a.
When the Progress Payment request is greater than or equal to five percent (5%)
of the original total Contract Price (excluding mobilization and demobilization),
fifty percent (50%) of schedule of value no. 1 or one and one-quarter percent
(1.25%) of the total Contract Price, whichever is less, will be paid.
b.
When the Progress Payment request is greater than or equal to ten percent
(10%) of the original total Contract Price (excluding mobilization and
demobilization), seventy percent (70%) of schedule of value no. 1 or one and
three-quarters (1.75%) of the total Contract Price, whichever is less, will be
paid.
c.
When the Progress Payment request is greater than or equal to fifty percent
(50%) of the original total Contract Price (excluding mobilization and
demobilization), ninety percent (90%) of schedule of value no. 1 or two and
one-quarter (2.25%) of the total Contract Price, whichever is less, will be paid.
d.
After Final Acceptance of the work by Corporation, the remainder of total

contract amount bid for mobilization and demobilization will be paid. Nothing
herein shall be construed to limit or preclude partial payment otherwise
provided by the Contract.
The Corporation will not pay additional mobilization compensation for work under a
Contract Change Order. Payment for mobilization and demobilization shall be subject
to retainage.
SCHEDULE OF VALUE NO. TS-1 SITE WORK AT STATEN ISLAND SHAFT

Payment
1.
Lump Sum Breakdown for work included under this schedule of values shall include
at a minimum the proper installation of all site work at the Staten Island Shaft,
01025-3
including protection of existing utilities; temporary and or permanent relocation of

above and below ground utilities as required; the furnishing and installation of
temporary fencing; erosion and sedimentation control; and grading the site as
necessary.
2.
3.04
A.
3.05
A.
3.06
The lump sum price breakdown shall also include site restoration to a condition equal
to or better than its original condition including the removal of temporary fencing and
gates; removal of any access drives and temporary gravel from the Contractors
staging area; grading of site; providing and spreading of top soil and seeding of site;
replacement of any damaged sidewalks, asphaltic paving, guard rails and concrete
paving and curbs, all in accordance with Drawings and Specifications.
SCHEDULE OF VALUE NO. TS-2 SITE WORK AT BROOKLYN SHAFT

Payment
1.
Lump sum breakdown for work included under this schedule of values shall include at
a minimum the proper installation of all site work at the Brooklyn Shaft shall be for
the proper installation of all site work including protection of existing utilities;
temporary and or permanent relocation of above and below ground utilities as
required; traffic maintenance; the furnishing and installation of temporary fencing and
shaft covers; erosion and sedimentation control; and grading the site as necessary.
2.
The lump sum price breakdown for this item shall also include both temporary and
permanent site restoration to a condition equal to or better than its original condition
including the removal of temporary fencing and gates; removal of any access drives
and temporary gravel from the Contractors staging area; grading of site; providing
and spreading of top soil and seeding of site; reinstallation of any permanent fencing,
damaged sidewalks, asphaltic paving, guard rails and concrete paving and curbs, all in
accordance with Drawings and Specifications.
3.
The lump sum price breakdown for this item shall also include any additional
requirements, whether temporary or permanent, and in any stage of the construction
period by the Corporation and/or the New York City Department of Parks and
Recreation.
SCHEDULE OF VALUES NO. TS-3 INSTRUMENTATION AND MONITORING

Payment
1.
The lump sum breakdown for work included under the schedule of values for
Instrumentation and Monitoring shall be for the establishment of benchmarks,
installation, monitoring, protection, maintenance and repair of geotechnical
instrumentation devices for monitoring ground and structure movements and
monitoring noise and vibration, as shown on the Drawings, specified in the
Specifications and as directed by the RE.
2.
Payment shall also include Work necessary to properly achieve the disposition of
instruments as required in Section 02495 of the Specifications upon Project
Completion.
SCHEDULE OF VALUES NO. TS-4.1 STATEN ISLAND SHAFT OPTION 1 SLURRY

WALL CONSTRUCTION
01025-4
A.
3.07
A.
Payment
1.
The lump sum breakdown for work included under the schedule of values for the
Staten Island Shaft Slurry Wall Construction shall be for the proper excavation of
Staten Island Shaft and shaft walls down to the elevations shown on the Drawings.
This item shall also include: all costs to furnish and install the slurry walls in
accordance with the Drawings and Specification Section 02310 Shaft Support
Slurry Walls, and Section 13060 Shaft Construction; the furnishing and installation
of guide walls; the installation of a cast in place reinforced concrete ring beam; and
removable pre-cast concrete planks; as shown in the Drawings.
2.
Included in the schedule of values shall be all required excavation for the shaft; shaft
support and preparation; the furnishing and installation of formwork, steel
reinforcement and concrete; protection of utilities; the furnishing of all drawings,
samples and appliances necessary to complete the work as specified, shown on the
Drawings, and required for the proper completion of the installation.
3.
Also included in the schedule of values shall be all costs associated with ground
treatment such as the Contractor deems as necessary to allow shaft excavation and to
satisfy the mitigation of groundwater and soil ingress near the base of the slurry walls,
as required in the Contract Documents.
4.
The schedule of value for this item shall include all excavation, storage, handling,
transport and disposal of all spoil.
SCHEDULE OF VALUES NO. TS-4.2 STATEN ISLAND SHAFT OPTION 2 GROUND

FREEZING CONSTRUCTION
Payment
1.
Staten Island Shaft Ground Freezing Construction shall be for the proper excavation
of Staten Island Shaft and shaft walls down to the elevations shown on the Drawings.
This item shall also include: all costs to furnish and install the ground freeze and
shotcrete liner as permanent works in accordance with the Drawings and Specification
Section 02338 Shaft Support Ground Freezing, and Section 13060 Shaft
Construction; the installation of a cast in place reinforced concrete ring beam; and
removable precast concrete planks as shown in the Drawings.
2.
support and preparation; ground freezing instrumentation; the furnishing and
installation of formwork, steel reinforcement and concrete; shotcrete finishing of shaft
interior, protection of utilities; the furnishing of all drawings, samples and appliances
necessary to complete the work as specified, shown on the Drawings, and required for
the proper completion of the installation.
3.
Also included in the schedule of values shall be all costs associated with ground
treatment, such as the Contractor deems as necessary to allow shaft excavation and to
satisfy the mitigation of groundwater and soil ingress into the shaft, as required in the
Contract Documents.
4.
The schedule of value for this item shall include all excavation, storage, handling,
transport and disposal of all spoil.
01025-5
3.08
A.
3.09
A.
SCHEDULE OF VALUES NO. TS-5 CONTROL OF WATER AT STATEN ISLAND

SHAFT
Payment
1.
Control of Water at Staten Island Shaft shall include but not be limited to design,
installation, operation, maintenance, control and removal of water from the Staten
Island Shaft; providing redundant power, discharge conveyance pipelines, maintaining
the shaft free of water on a continuous basis, permits, submittals, and disposal of water
consistent with the requirements as set forth in the Contract Documents.
2.
Partial payments under this schedule of value item will be made based upon the
approved Schedule of Values for work as completed each month.
3.
The schedule of value shall include installation, operation, maintenance and removal
of pumping facilities to deal with ground water by means of pumping of water that
originated from the underground works.
4.
The schedule of value shall include full compensation for the operating and running of
pumping equipment, moving pumping equipment to suit the advancing face and the
various measuring devices including the use and maintenance of these.
SCHEDULE OF VALUES NO. TS-6.1 BROOKLYN SHAFT OPTION 1 SLURRY WALL

CONSTRUCTION
Payment
1.
The lump sum breakdown for work included under the schedule of values for
Brooklyn Shaft Slurry Wall Construction shall be for the proper excavation of
Brooklyn Shaft and shaft walls down to the elevations shown on the Drawings. This
schedule shall also include all costs to furnish and install guide walls and the slurry
walls as in accordance with the Drawings and Specification Section 02310 Shaft
Support Slurry Walls, and Section 13060 Shaft Construction; the installation of a
cast in place reinforced concrete base slab; and removable precast concrete planks, as
shown in the Drawings.
2.
Included in the schedule of value shall be all costs associated with wall tie-in and toe
grouting at wall as necessary to satisfy groundwater ingress limits as required in the
Contract Documents; furnishing all labor, material and equipment necessary to
excavate the ground at the bottom of the Brooklyn Shaft as necessary to complete the
works shown on the Drawings; and a cast in place reinforced concrete base slab
including jet grouting pre-treatment as shown in the Drawings.
3.
Also included in the schedule of value shall be all required excavation for the shaft;
shaft support and preparation; the furnishing and installation of formwork, steel
samples and appliances necessary to complete the Work as specified, shown on the
4.
Finally, included in the schedule of value shall be all costs associated with ground
treatment including jet grouting and seals or gaskets at shaft eye for receiving of the
TBM, such as the Contractor deems as necessary to satisfy the mitigation of
groundwater and soil ingress into the shaft upon TBM retrieval, as required in the
Contract Documents.
01025-6
5.
3.10
A.
3.11
A.
The schedule of value shall include all excavation, storage, handling, transport and
disposal of all spoil.
SCHEDULE OF VALUES NO. TS-6.2 BROOKLYN SHAFT OPTION 2 GROUND

FREEZING CONSTRUCTION
Payment
1.
Staten Island Shaft Ground Freezing Construction shall be for the proper excavation
of Staten Island Shaft and shaft walls down to the elevations shown on the Drawings.
This item shall also include: all costs to furnish and install the ground freeze and
shotcrete liner as permanent works in accordance with the Drawings and Specification
Section 02338 Shaft Support Ground Freezing, and Section 13060 Shaft
Construction; the installation of a cast in place reinforced concrete base slab; and
removable precast concrete planks as shown in the Drawings.
2.
support and preparation; ground freezing instrumentation; the furnishing and
installation of formwork, steel reinforcement and concrete; shotcrete finishing of shaft
interior, protection of utilities; the furnishing of all drawings, samples and appliances
necessary to complete the work as specified, shown on the Drawings, and required for
the proper completion of the installation.
3.
Also included in the schedule of value shall be all required excavation for the shaft;
shaft support and preparation; the furnishing and installation of slab formwork, steel
samples and appliances necessary to complete the Work as specified, shown on the
4.
Finally, included in the schedule of value shall be all costs associated with ground
treatment and seals or gaskets at shaft eye for receiving of the TBM, such as the
Contractor deems as necessary to allow shaft excavation and to satisfy the mitigation
of groundwater and soil ingress into the shaft upon TBM retrieval, as required in the
Contract Documents.
5.
The schedule of value shall include all excavation, storage, handling, transport and
disposal of all spoil.
SCHEDULE OF VALUE NO. TS-7 CONTROL OF WATER AT BROOKLYN SHAFT

Payment
1.
Control of Water at Brooklyn Shaft shall include but not be limited to design,
installation, operation, maintenance, control and removal of water from the Brooklyn
Shaft; providing redundant power, discharge conveyance pipelines, maintaining the
shaft free of water on a continuous basis, permits, submittals, and disposal of water
consistent with the requirements as set forth in the Contract Documents.
2.
01025-7
3.12
A.
B.
3.
of pumping facilities to deal with ground water by means of pumping of water that
4.
SCHEDULE OF VALUE NO. TS-8 - TUNNEL BORING MACHINE MOBILIZATION

Included Items
1.
The intent of this Schedule of values item is to permit the Contractor to identify the
capital cost of furnishing the Earth Pressure Balance or Slurry Tunnel Boring
Machines (TBMs) and associated equipment, specially designed and fabricated for the
ground conditions to be encountered under the New York Harbor.
2.
The Contractor shall not be entitled to any additional compensation for ownership of
this equipment throughout the life of the project.
3.
Equipment paid for under this bid item shall remain the property of the Contractor.
4.
This schedule of value shall compensate the Contractor for the initial costs of
providing the following items for the tunnel drive:
a.
TBM
b.
Trailing gear
c.
Associated equipment, regardless of supplier:
d.
Muck handling, ventilation, soil conditioning, segment handling and erection,

annulus grouting, dust control, fire suppression, water handling, alarm, and
emergency backup systems that are mounted directly onto the TBM or trailing
gear.
e.
TBM instrumentation and guidance systems that are mounted directly onto the
TBM or trailing gear.
f.
Erection costs.
g.
Slurry separation plant and slurry booster pumps when combined with a Slurry
TBM. Pump lines are not included in this schedule of value item.
h.
Consumables, including replacement cutters, rippers and picks; soil

conditioners; spare parts; power; hydraulic oil; tailskin grease; are not included
in this schedule of value item.
Payment
1.
For compensation under this schedule of value the Contractor shall documentation
based on the sum total of all contracts and/or purchase orders with the TBM supplier
and any other suppliers of equipment payable under this schedule.
2.
Payment of allowable costs under this schedule shall be made on the basis of paid
invoices, submitted on completion of each item of the following progress schedule for
the TBM:
3.
Item 1
Upon completion of the REs review of the TBM design and shop drawings.
01025-8
a.
4.
Item 2 Upon shop floor assembly of the completed TBM or refurbishment of the
TBM prior to delivery to the jobsite and written certification that the TBM equipment
spread is the property of the Contractor:
a.
5.
Item 3
a.
6.
3.13
A.
Upon delivery of the TBM and associated equipment to the jobsite:

10% of the TBM schedule of value amount.
Item 5 Upon the satisfactory completion of 100 lineal feet of tunnel excavation
using the TBM in accordance with specified requirements and installation of the
trailing gear and all equipment in the tunnel, and with the on-site participation of the
TBM manufacturers representative:
a.
8.
Item 4 Upon set up of the TBM in the Staten Island Shaft, and testing of the TBM
and associated equipment demonstrating that the TBM and associated equipment is
ready to perform the work for which it was designed. The demonstration shall include
the complete erection of a precast concrete segment ring (excluding backfill grouting)
using the methods to be employed in all subsequent precast concrete segment erection:
a.
7.
Requests for payment must include:

a.
A certified accounting of the Contractors actual expenditure.
b.
A copy of the purchase agreement(s) or other form of contract(s).
c.
Supporting documentation, including receipted bills, and certified copies of

freight bills.
d.
A certificate from the Contractor:

1)
Showing that it has acquired the TBM, trailing gear, and associated
equipment free from all encumbrances.
2)
Agreeing that the TBM, trailing gear and associated equipment will not
be removed from the site without the written permission of the RE.
3)
The allowable costs will not be subject to mark-up of any kind.
4)
Any unpaid balance of this bid item remaining after payment for TBM
mobilization that has been made in accordance with the provisions herein
shall be included in the final payment to the Contractor.
SCHEDULE OF VALUE NO. TS-9 TUNNEL EXCAVATION AND LINING

Payment
1.
Under this schedule of value, the Contractor shall provide a breakdown of work
associated with all tunnel excavation by TBM including; design, furnishing, handling,
storing and installing bolted and gasketed pre-cast concrete segmental lining; annulus
grouting; controlling alignment and grade, required survey control, maintaining the
tunnel free of, and removing water from the tunnel; furnishing, installing and
maintaining temporary utilities and ventilation as the tunnel work progresses;
consumables; soil conditioning, removing and conveying all excavated material to the
temporary storage area on the surface; treatment, storage, loading, hauling, and
01025-9
disposal of excavated material and used soil conditioner to the designated facility;
ground treatment necessary for tunnel excavation; maintenance of the TBM; TBM
break in and break out at the shafts, any temporary tunnel excavation deemed
necessary by the Contractor to facilitate TBM assembly or tunnel operations such as
but not limited to TBM erection chambers and tail tunnels for train movements,
including any and all ground support and treatment required to support and maintain
the tunnel excavation for the duration needed; backfilling of such temporary tunnel
excavations with backfill concrete; TBM removal, disassembly, storage and
transportation of the TBM and associated equipment from the tunnel, receiving shaft,
and worksite; cleaning the invert and all other incidental work required to excavate,
support, and maintain the tunnel excavation watertight. Payment will be based upon
the percent complete of each particular breakdown item.
3.14
A.
3.15
A.
SCHEDULE OF VALUES NO. TS-10 CONTROL OF TUNNEL GROUNDWATER

Payment
1.
Control of Water for tunnel shall include but not be limited to design, installation,
operation, maintenance, control and removal of water from the tunnel through Staten
Island Shaft; providing redundant power, discharge conveyance pipelines, permits,
submittals, and disposal of water consistent with the requirements as set forth in the
Contract Documents.
2.
3.
of pumping facilities to deal with groundwater by means of pumping of water that
4.
SCHEDULE OF VALUE NO. TS-11 STEEL WATER MAIN: CARRIER PIPE

INSTALLED IN TUNNEL AND SHAFTS AND CONCRETE BACKFILL
Payment
1.
Under this schedule of value item the Contractor shall provide a breakdown of costs
for the installation of 72-inch and 96-inch internal diameter water main, 6-inch
bypass, valves, seals, and appurtenances within the tunnel and shafts in accordance
with the Drawings, Specifications and as directed by the RE. Measurement under
schedule of value no. 15 shall commence and terminate at the inside face of the shafts
as shown on the Drawings. The schedule shall identify costs for the pipes, pipe initial
and permanent support; pipe installation; completing joints; pipe bracing and tiedowns; formwork; bulkheads; backfilling of pipelines in place within the tunnel and
shafts with backfill concrete; shaft access chambers construction including but not
limited to steel reinforcement, cast in place concrete, coring of openings, internal and
external waterproofing, sump, floor slope and steps; concrete finish work; and pipe
testing, complete, as specified in the Contract specifications and shown on the
Drawings.
01025-10
3.16
A.
SCHEDULE OF VALUE NO. TS-12 UTILITY CHARGES FOR TBM POWER SUPPLY
AND INSTALLATION OF TEMPORARY FACILITIES
Payment
1.
Under this schedule of value item the Contractor shall provide a breakdown of costs
associated with fees and charges incurred by the Contractor for establishing the
primary power supply for the TBM. The Contractor shall arrange for power to be
supplied from the Corporations Homeport Substation in coordination with the
Corporations on-call electrical contractor, Linco Electric, and be on a minimum order
of 10-15 kV with 200-300 Amps. This item also includes all labor and materials for
conduit, wiring, cabling and substation work performed by the Contractor as necessary
for proper service for the Work. This item shall also include monthly power usage
charges which shall be identified in a schedule of values breakdown.
END OF SECTION
01025-11
SECTION 01300
SUBMITTALS
PART 1 GENERAL
1.01
SCOPE OF WORK
A.
Submittals shall be in accordance with the requirements of this Section and the requirements set
forth in Volume 1 of the Specifications. In the event of conflicts, the requirements of Volume 1
will take precedence relative to submittal requirements and procedures.
B.
This Section specifies the general methods and requirements of submissions applicable to the
following work related submittals: Shop Drawings, Product Data, Samples, Mock Ups,
Construction Photographs, Construction or Submittal Schedules.
Detailed submittal
requirements will be specified in the technical sections.
C.
This Section shall override the requirements of Section 01300 of Volume 2 Common
Technical Specifications.
1.02
A.
RELATED SECTIONS
Quality Control and Quality Assurance is included in Section 01400.
1.03
REFERENCE STANDARDS (NOT USED)
1.04
DEFINITIONS (NOT USED)
1.05
SUBMITTALS
A.
Within 20 days of the Notice to Proceed, submit a Submittals Schedule.
1.06
DELIVERABLES (NOT USED)
1.07
PERFORMANCE REQUIREMENTS (NOT USED)

PART 3 EXECUTION
3.01
A.
GENERAL
Coordination of Submittal Times: Prepare and transmit each submittal sufficiently in advance
of performing the related work or other applicable activities, or within the time specified in the
individual work of other related Sections, so that the installation will not be delayed by
processing times including disapproval and resubmittal (if required), coordination with other
submittals, testing, purchasing, fabrication, delivery and similar sequenced activities. No
01300 - 1
extension of time will be authorized because of the Contractor's failure to transmit submittals
sufficiently in advance of the Work.
B.
Submittals that do not conform to the requirements of this Section, the requirements set forth in
Volume 1 of the Specifications, and the technical specification sections will be returned to the
Contractor without review.
C.
All submittals by subcontractors shall be sent directly to the Contractor for checking. The
Contractor shall be responsible for their submission at the proper time to prevent delays in
delivery of materials.
D.
Submittals shall be scheduled, managed, and tracked using the Submittal Management System
required by Section 01400.
3.02
A.
B.
SHOP DRAWINGS, PRODUCT DATA, AND SAMPLES

Shop Drawings:
1.
Shop drawings include, but are not necessarily limited to, custom prepared data such
as fabrication and erection/installation (working) drawings, calculations, method
statements, scheduled information, setting diagrams, actual shopwork manufacturing
instructions, custom templates, special wiring diagrams, coordination drawings,
individual system or equipment inspection and test reports including performance
curves and certifications, or other information required to be provided by the
Contractor, subcontractor, manufacturer, supplier, or distributor.
2.
Contractor shall check all subcontractor's shop drawings regarding measurements, size
of members, materials and details to make sure that they conform to the intent of the
Drawings and related Sections. Shop drawings found to be inaccurate or otherwise in
error shall be returned to the subcontractors for correction before submission thereof.
3.
All details on shop drawings submitted for approval shall show clearly the relation of
the various parts to the main members and lines of the structure and where correct
fabrication of the work depends upon field measurements, such measurements shall be
made and noted on the drawings before being submitted for approval.
Product Data:
1.
C.
Product data as specified in individual Sections, include, but are not necessarily
limited to, standard prepared data for manufactured products (sometimes referred to as
catalog data), such as the manufacturer's product specification and installation
instructions, availability of colors and patterns, manufacturer's printed statements of
compliances and applicability, roughing in diagrams and templates, catalog cuts,
product photographs, standard wiring diagrams, printed performance curves and
operational range diagrams, production or quality control inspection and test reports
and certifications, mill reports, product operating and maintenance instructions and
recommended spare parts listing and printed product warranties, as applicable to the
work.
Samples:
01300 - 2
1.
D.
Samples specified in individual Sections, include, but are not necessarily limited to,
physical examples of the work such as sections of manufactured or fabricated work,
small cuts or containers of materials, complete units of repetitively used products,
color/texture/pattern swatches and range sets, specimens for coordination of visual
effect, graphic symbols and units of work to be used by the RE or Corporation for
independent inspection and testing, as applicable to the work.
Review shop drawings, product data and samples, including those by subcontractors, prior to
submission to determine and verify the following:
1.
Field measurements.
2.
Field construction criteria.
3.
Catalog numbers and similar data.
4.
Completeness and conformance with related Sections and Contract Drawings,

including reference to those Sections and Contract Drawings.
5.
Coordination of the work shown with the work of subcontractors and suppliers.
E.
Each shop drawing, sample and product data submitted by the Contractor shall have affixed to it
the following Certification Statement including the Contractor's Company name and signed by
the Contractor: Certification Statement: by this submittal, I hereby represent that I have
determined and verified all field measurements, field construction criteria, materials,
dimensions, catalog numbers and similar data and I have checked and coordinated each item
with other applicable approved shop drawings and all Contract requirements. Shop drawings
and product data sheets 11-inches by 17-inches and smaller shall be bound together in an
orderly fashion and bear the above Certification Statement on the cover sheet. The cover sheet
shall fully describe the packaged data and include a listing of all items within the package.
F.
No portion of the work requiring a shop drawing, sample, or product data shall be started nor
shall any materials be fabricated or installed prior to the approval or qualified approval of such
item. Fabrication performed, materials purchased or on site construction accomplished which
does not conform to approved shop drawings and data shall be at the Contractor's risk. The
Corporation will not be liable for any expense or delay due to corrections or remedies required
to accomplish conformity.
G.
Project work, materials, fabrication, and installation shall conform with approved shop
drawings, applicable samples, and product data.
3.03
SUBMISSION REQUIREMENTS
A.
Make submittals promptly in accordance with approved schedule and in such sequence as to
cause no delay in the work or in the work of any other contractor.
B.
Submittals shall be transmitted individually with a separate transmittal for each required
submittal. Submittals that are combined and provided under a single transmittal will be returned
to the Contractor without review.
01300 - 3
C.
All submittals and the transmittal shall be dated and shall be clearly identified by reference to
Specification Section Number, Paragraph, Drawing Number or Detail as applicable and the
dates of any previous submissions. All components of submittals shall be clear and legible and
of sufficient size for clear presentation of data.
D.
The Contractor shall utilize a submittal identification numbering system as provided by the RE.
E.
Give express and unambiguous written notice of each deviation from the requirements of the
Contract Documents in the transmittal and identify deviations in the submittal.
F.
Number of submittals required:

1.
Shop Drawings as defined in Paragraph 3.02A: Twelve copies.
2.
Product Data as defined in Paragraph 3.02B: Twelve copies.
3.
Samples: Submit the number stated in the respective Sections.
G.
Submittals shall also be provided electronically.
H.
Submittals shall contain:
I.
1.
Submittal date and dates of previous revisions.
2.
The Project title and number.
3.
Contractor identification.
4.
The names of:

a.
Contractor
b.
Supplier
c.
Manufacturer
5.
Identification of the product, with the section number, page and paragraph(s).
6.
Field dimensions, clearly identified as such.
7.
Relation to adjacent or critical features of the work or materials.
8.
Applicable standards, such as ASTM or Federal Standards numbers.
9.
Identification of revisions on resubmittals.
10.
A blank space suitably sized for Contractor and RE stamps.
Where calculations are required to be submitted by the Contractor, the calculations shall have
been checked by a qualified individual other than the preparer. The submitted calculations shall
clearly show the names of the preparer and the checker.
01300 - 4
3.04
SUBMITTAL REVIEW
A.
Following receipt of a full and complete submittal package from the Contractor, the RE will
record the Submittal and forward it to the appropriate parties for review. Within 25 working
days of receipt by the RE, the RE will return one copy to the Contractor stamped with a review
code as identified below, with comments and required revisions noted thereon.
B.
Review and approval by the RE of Submittals, including drawings and proposed methods, will
be for general conformance with the design concept and Contract Documents and shall not be
construed to:
1.
Relieve the Contractor of responsibility to comply with all Contract requirements, for
the adequacy of their design, construction, and use, nor for the safety of persons and
property by reason thereof, nor for the safety and successful execution and completion
of the Work.
2.
Permit any departure from the Contract requirements.
3.
Relieve the Contractor of responsibility for any errors, including details, dimensions,
and materials.
4.
Approve departures from details furnished by the RE, except as otherwise provided
herein.
C.
The Contractor remains responsible for details and accuracy, for coordinating the work with all
other associated work and trades, for selecting fabrication processes, for techniques of
assembly, and for performing work in a safe manner.
D.
If the shop drawings, data or samples as submitted describe variations and show a departure
from the Contract requirements which RE finds to be in the interest of the Corporation and to be
so minor as not to involve a change in Contract Price or time for performance, the RE may
return the reviewed drawings without noting an exception.
E.
Submittals will be returned to the Contractor under one of the following codes.
Code 1
APPROVED is assigned when there are no notations or comments on the

submittal. When returned under this code the Contractor may release the equipment
and/or material for manufacture.
Code 2
APPROVED AS NOTED. This code is assigned when a confirmation of the

notations and comments IS NOT required by the Contractor. The Contractor may
release the equipment or material for manufacture; however, all notations and
comments must be incorporated into the final product.
Code 3
APPROVED AS NOTED/CONFIRM. This combination of codes is assigned

when a confirmation of the notations and comments IS required by the Contractor.
The Contractor may, at his own risk, release the equipment or material for
manufacture; however, all notations and comments must be incorporated into the
final product. This confirmation shall specifically address each omission and
nonconforming item that was noted. Confirmation is to be received by the RE within
15 calendar days of the date of the RE's transmittal requiring the confirmation.
01300 - 5
Code 4
APPROVED AS NOTED/RESUBMIT. This combination of codes is assigned

when notations and comments are extensive enough to require a resubmittal of the
package. This resubmittal is to address all comments, omissions and non conforming
items that were noted. Resubmittal is to be received by the RE within 15 calendar
days of the date of the RE's transmittal requiring the resubmittal.
Code 5
NOT APPROVED is assigned when the submittal does not meet the intent of the
Contract Documents. The Contractor must resubmit the entire package revised to
bring the submittal into conformance. It may be necessary to resubmit using a
different manufacturer/vendor to meet the requirements of the Contract Documents.
Code 6
COMMENTS ATTACHED is assigned where there are comments attached to the

returned submittal which provide additional data to aid the Contractor.
Code 7
REVIEW NOT REQUIRED.
Codes 1 through 5 designate the status of the reviewed submittal with Code 6 showing there has
been an attachment of additional data. Code 7 shall be used for Deliverables.
F.
Resubmittals will be handled in the same manner as first submittals. On resubmittals the
Contractor shall direct specific attention in writing on the letter of transmittal to revisions made
from the previous submission. Text documents shall use revision marks to indicate text added or
deleted and drawings shall include a cloud and revision triangles or other similar methods to
clearly show the changes made from the previous submission. Any such revisions which are
not clearly identified shall be made at the risk of the Contractor. The Contractor shall make
corrections to any work done because of this type revision that is not in accordance to the
Contract Documents as may be required by the RE.
G.
Partial submittals may not be reviewed. The RE will be the only judge as to the completeness
of a submittal. Submittals not complete will be returned to the Contractor and will be
considered NOT APPROVED until resubmitted. The RE may at his/her option provide a list
or mark the submittal directing the Contractor to the areas that are incomplete.
H.
Repetitive Review:
1.
Shop drawings and other submittals will be reviewed no more than twice at
Corporations expense. All subsequent reviews will be performed at times convenient
to the Corporation and at the Contractors expense based on the Corporations then
prevailing rates. The Contractor shall reimburse the Corporation for all such fees.
Submittals are required until approved.
2.
Any need for more than one resubmission, or any other delay in obtaining REs
review of submittals, will not entitle Contractor to extension of the Contract time.
I.
If the Contractor considers any correction indicated on the shop drawings to constitute a change
to the Contract Documents, the Contractor shall give written notice thereof to the RE at least 7
working days prior to release for manufacture.
J.
When the submittal has been completed to the satisfaction of the RE, the Contractor shall carry
out the construction in accordance therewith and shall make no further changes therein except
upon written instructions from the RE.
01300 - 6
3.05
A.
3.06
A.
DISTRIBUTION
Distribute reproductions of approved shop drawings and copies of approved product data and
samples, where required, to the job site file and elsewhere as directed by the RE. Number of
copies shall be as directed by the RE but shall not exceed twelve.
PROFESSIONAL ENGINEER (P.E.) CERTIFICATION FORM
If specifically required in other related Sections, the Contractor shall submit a P.E. Certification
for each item required, in the form attached to this Section, completely filled in and stamped.
01300 - 7
P.E. CERTIFICATION FORM

The undersigned hereby certifies that he/she is a Professional Engineer registered in the State
of New York and that he/she has been employed by
______________________________________________________________________ to design
(Name of Contractor)
_____________________________________________________________________________
(Insert P.E. Responsibilities)
in accordance with Section __________________________________________________ for the

____________________________________________________________________________.
(Name of Project)
The undersigned further certifies that he/she has performed the design of the_________________
____________________________________________________, that said design is in
(Name of Project)
conformance with all applicable local, state and federal codes, rules, and regulations, and that his/her signature and P.E. stamp have been affixed to all calculations and drawings used in, and resulting from, the
design.
The undersigned hereby agrees to make all original design drawings and calculations available to the New
York City Economic Development Authority, or Corporation's representative with seven days following
written request therefor by the Corporation.
___________________________________ ___________________________________
P.E. Name
Contractor's Name
___________________________________ ___________________________________
Signature
Signature
___________________________________ ___________________________________
Address
Title
___________________________________
Address
END OF SECTION
01300 - 8
SECTION 01400
QUALITY CONTROL AND QUALITY ASSURANCE
PART 1 GENERAL
1.01
SCOPE OF WORK
A.
Management of quality in the construction of the Work to achieve an end product conforming to
the level of quality required by the Contract Documents.
B.
Requirements to establish, implement, and maintain a Contractor Quality Control (QC) program
to assure that the Work complies with the requirements of the Contract Documents.
1.02
A.
RELATED SECTIONS
Submittals are included in Section 01300.
1.03
1.04
DEFINITIONS
A.
Quality Control: All those planned and specified actions or operations necessary to produce a
product or service that will meet requirements for quality as specified. Quality Control is the
responsibility of the Contractor.
B.
Quality Assurance: Those planned and systematic operations conducted to ensure that the
operations and products incorporated into the project meet the Specifications. Quality
Assurance (QA) encompasses: oversight of the Contractors Quality Control; verifying the
results of Contractor testing; review of sampler, tester and laboratory qualifications;
independent QA sampling and testing; and inspection for conformance with the plans and
specifications. QA is the responsibility of the RE.
1.05
SUBMITTALS
A.
Within 30 days after the Notice to Proceed the Contractor shall submit a Project specific Quality
Control (QC) Plan. The QC Plan shall contain a comprehensive account of the Contractors QC
procedures as applicable to this Project and in conformance with the requirements of this
Section.
B.
Submit details of subcontractor or supplier Quality Management System, if required, at least 30days prior to engaging them on this Project.
C.
Submit qualifications of third-party testing laboratories 30-days prior to engaging them on this
Project.
1.06
A.
DELIVERABLES
Provide copies of all quality records within 7-days from the time they are prepared, or upon
request by the RE.
01400 - 1
B.
1.07
A.
1.08
A.
B.
Provide Monthly Quality Certification Report by the 10th working day of the next month.
The Contractor shall establish and execute a Quality Control (QC) program for the services that
are being procured from the Contractor. The QC program shall provide the Contractor with
adequate measures for verification and conformance with the requirements of the Contract
Documents by the Contractor, subcontractors, manufacturers, and suppliers. This program shall
be described in a QC Plan responsive to this Section.
QUALITY CONTROL PLAN REQUIREMENTS
General: The Contractors QC Plan shall:
1.
Ensure the achievement of adequate quality throughout all areas of the Contract.
2.
Describe the QC program and include procedures, work instructions, and records.
3.
Include specific instructions defining procedures for observing and recording all Work
in progress to demonstrate compliance with the Contract requirements (organized by
specification section).
4.
Include specific procedures for resolution of differences between the RE, Contractors
QC representative, and production QC representative.
Organization, Staffing, and Responsibilities:

1.
Describe Contractors Project organization including major subcontractors,

manufacturers, and suppliers, and include an organization chart showing names, titles,
contact information, lines of authority, and the inter-relationship of those involved in
managing and directing the Project.
2.
QC Representative(s): The Contractor shall provide personnel with assigned QC

functions reporting to a Field QC representative. The Field QC representative shall
report to a senior manager of the Contractor and shall have no supervisory or
managerial responsibility over the work force. Persons performing QC functions shall
have sufficient qualifications, authority, and organizational freedom to identify quality
problems and to initiate and recommend solutions. Contractor QC representative(s)
shall be on-site as often as necessary (but not less than the daily hours specified in the
Contract Documents) to demonstrate that Work is being performed properly and to
make multiple observations of all Work in progress. The Contractors QC Plan shall
include a statement by the Contractors senior manager designating the QC
representative(s) and specifying authorities delegated to the QC representative(s) to
direct cessation or removal and replacement of defective Work.
C.
Submittal Management System: The QC Plan shall detail a submittal management system that
schedules, manages, and tracks all submittals required by the Contract Documents including
those of Subcontractors and suppliers. The submittal management system shall be established
and maintained for the duration of the Contract.
D.
Document Control System:
01400 - 2
E.
F.
G.
1.
The QC Plan shall detail a document control system for control of Project documents,
data, and records, either generated by Contractor or generated by others, such as
Contract Drawings, Shop Drawings, Specifications, calculations, calibration records,
inspection procedures, test procedures, inspection and test results, method statements,
special work instructions, and operational procedures.
2.
Describe how documents are distributed and provide assurance that the latest
approved Contract Drawings and Specifications and related documents are made
available to all required users and are at each Work location prior to the start of the
Work. Obsolete documents shall be promptly removed from each Work location. Any
superseded documents retained as a record document shall be clearly identified as
such.
Subcontractors and Suppliers: The QC Plan shall assure that items and services procured from
subcontractors and suppliers meet all requirements of the Contract Documents.
1.
Contractor shall ensure inclusion of all applicable quality requirements in agreements

with subcontractors and suppliers.
2.
Subcontractors and suppliers shall comply with the Contractors QC Plan and shall
provide written notification signed by a principal of the firm indicating their intent to
comply with the Contractors QC Plan. If a subcontractor or supplier is to work under
their own Quality Management System, it shall be reviewed to ensure it meets the
quality requirements of this Contract and shall be submitted to the RE for review and
approval.
Identification and Control of Material and Equipment:

1.
The QC Plan shall contain provisions for verification that material and equipment
meet specified quality and Contractual requirements and that they are properly
received, stored, handled, used, installed, and maintained to ensure that the quality is
not degraded.
2.
The procedures shall provide for proper identification and preventive maintenance in
accordance with the manufacturers written requirements, and prevent the use of
incorrect or defective materials. All materials and equipment shall be positively
identifiable and traceable to a specified origin point.
3.
Purchased items entering the Site shall be inspected including their supporting
documentation for verification that subcontractors and suppliers have met the
appropriate quality requirements of the Contract Documents. Certificates of
compliance and/or conformance shall be submitted for materials as required in the
Specifications. Materials for which required certifications have not been received shall
be identified, segregated, and prevented from being incorporated into the Work.
Inspection and Testing Plan:

1.
The QC Plan shall include a detailed Inspection and Testing Plan (ITP) including the
following information for each identified inspection and test:
a.
List of inspections and tests to be performed.
01400 - 3
b.
Identify the specification paragraph containing the inspection or test

requirements.
c.
Identify if Contractor, subcontractor, or supplier is responsible for each type of

test.
d.
Schedule of inspections and tests.
e.
Identification of independent test laboratories to be used.
f.
List specialized equipment and/or personnel training or qualifications required.
g.
Identify the characteristics to be inspected, examined, and tested at each activity

point.
h.
Specify inspection and test procedures and acceptance criteria to be used.
i.
Identify inspection checklists and test reports.
j.
Identify hold points as described herein below.
2.
The applicable portion of the Contractors ITP shall be included in each method
statement and shall be reviewed before any activity inspection or test takes place and
shall include test requirements, acceptance criteria, and test conditions. Update the
plan to reflect any changes in the ITP.
3.
Written guidelines shall be established to assure that suitable education, experience,

and technical qualifications are maintained for personnel performing inspections and
tests. Copies of these qualifications shall be maintained by the Contractor and made
available to the RE upon request.
4.
A listing of hold points shall be established as part of the ITP. The hold points may
also be used by the RE to perform verifications of Contractors Work and/or that
required inspection and testing has been performed and quality records completed.
5.
Contractors ITP shall identify the procedure for properly notifying the RE of planned
inspection, testing and/or sampling.
6.
Include a sample of the Contractors Daily Field Report showing how inspection and
testing will be recorded.
H.
Control of Measuring and Testing Equipment: The QC Plan shall describe the methods for
ensuring that equipment used for measuring and testing is calibrated as applicable to provide
accurate test and inspection results.
I.
Non-conformance And Corrective Action:

1.
Non-conformances are defined as documentation, drawings, material, equipment, or

Work not conforming to the specified requirements.
2.
The QC Plan shall include procedures for:

a.
Identifying,
conditions.
documenting,
controlling
01400 - 4
and
correcting
non-conforming
3.
J.
b.
Re-inspecting and re-testing repaired or reworked items to the original specified

requirements.
c.
Precluding the covering of deficient or rejected Work.
d.
Halting or rejecting Work.
e.
Implementing corrective and preventive actions.
f.
Determining and documenting the cause of conditions adverse to quality and

developing measures to be implemented to prevent recurrence.
Include sample Non-conformance Report.
Special Processes and Personnel Qualifications: The QC Plan shall include detailed procedures
for the performance and control of special processes (e.g. tunneling, welding, cleaning,
nondestructive testing, etc.).
1.
Personnel performing special process tasks shall have the experience, training and
certifications commensurate with the scope, complexity, or nature of the activity. They
shall be approved by the RE before the start of Work on the Project.
K.
Audits: Contractors QC Plan shall provide for documented audits and include an audit schedule
to verify that QC procedures are being fully implemented by the Contractor as well as its
subcontractors and suppliers.
L.
Acceptance of QC Plan: The REs review and approval of the Contractors QC Plan shall not
relieve the Contractor from any of its obligations for the performance of the Work. The
Contractors QC staffing is subject to the REs review and continued approval. The
Corporation, at its sole option, without cause, may direct the Contractor to remove and replace
the QC Representative. No Work covered by the QC Plan shall start until the REs approval of
the Contractors QC plan has been obtained.
1.
The RE will perform independent QA audits to verify that actions specified in the
Contractors QC Plan have been implemented. No RE audit finding or report shall in
any way relieve the Contractor from any requirements of this Contract.

PART 3 EXECUTION
3.01
PREPARATION
A.
The Contractor shall check and verify all dimensions and conditions in the field continuously
during construction. The Contractor shall be solely responsible for any inaccuracies built into
the Work due to the Contractors (including subcontractors) failure to comply with this
requirement.
B.
The Contractor shall inspect related and appurtenant Work and report in writing to the RE any
conditions that will prevent proper completion of the Work. Failure to report such conditions
shall constitute acceptance of all Site conditions, and any required removal, repair, or
01400 - 5
replacement caused by unsuitable conditions shall be performed by the Contractor solely and
entirely at the Contractors expense.
3.02
GENERAL
A.
All work performed by the Contractor and subcontractors shall be inspected by the Contractor
and nonconforming Work and any safety hazards in the Work area shall be noted and promptly
corrected. The Contractor is responsible for the Work to be performed safely and in
conformance to the Contract Documents.
B.
The Work shall be conducted under the general observation of the RE and is subject to
inspection by representatives of the Corporation to ensure strict compliance with the
requirements of the Contract Documents. Such inspection may include mill, plant, shop, or field
inspection, as required. The RE, representative of the Corporation, or any inspector(s) shall be
permitted access to all parts of the Work, including facilities where materials or equipment are
generated, fabricated or manufactured.
C.
The presence of the RE, representative of the Corporation, or any inspector(s), however, shall
not relieve the Contractor of the responsibility for the proper execution of the Work in
accordance with all requirements of the Contract Documents. Compliance is the responsibility
of the Contractor. No act or omission on the part of the RE, representative of the Corporation, or
any inspector(s) shall be construed as relieving Contractor of this responsibility. Inspection of
Work later determined to be non-conforming shall not be cause or excuse for acceptance of the
non-conforming Work. The Corporation may accept non-conforming Work when adequate
compensation is offered and it is in the Corporations best interest as determined by the
Corporation.
D.
All materials and articles furnished by the Contractor or subcontractors shall be subject to
documented inspection, by qualified personnel, and no materials or articles shall be used in the
Work until they have been inspected and accepted by Contractors QC Representative and RE
or other designated representative. No Work shall be backfilled, buried, cast in concrete,
covered, or otherwise hidden until it has been inspected. Any Work covered in the absence of
inspection shall be subject to uncovering. Where un-inspected Work cannot be easily
uncovered, such as in concrete cast over reinforcing steel, all such Work shall be subject to
demolition, removal, and reconstruction under proper inspection.
E.
All materials and articles furnished to the Contractor by the Corporation shall be subject to
inspection by the Contractors QC Representative before being used or placed by the
Contractor. The Contractor shall inform the RE, in writing, of the results of said inspections
within one (1) working day after completion of inspection. In the event the Contractor believes
any material or articles provided by the Corporation to be of insufficient quality for use in the
Work, the Contractor shall immediately notify the RE.
3.03
A.
IMPLEMENTATION OF QUALITY CONTROL PLAN

The Contractor shall follow all procedures described in the approved QC Plan at all times
during performance of the Work and shall assure that the Work is performed in accordance with
the applicable codes, standards, specifications, or other special Contractual requirements using
qualified personnel and/or equipment.
01400 - 6
B.
Subcontractor and Supplier Control: Source inspection shall be performed at the

subcontractors/suppliers plants. The source inspection activities shall be coordinated with the
RE.
C.
Distinguish between inspected and accepted items and non-accepted items by using suitable
control devices from delivery through installation to operation of the constructed Work.
D.
Control of Measuring and Testing Equipment:
E.
1.
Measuring and/or testing instruments shall be adequately maintained, calibrated and

adjusted to maintain accuracy within prescribed limits. Calibration shall be performed
at specified periods against valid standards traceable to nationally recognized
standards and documented.
2.
Establish methods to ensure proper handling, storage, and care of measuring and test
equipment to maintain the required accuracy of such equipment. Material and test
equipment that is considered out-of-calibration or subjected to possible damage shall
be identified as non-conforming and shall be removed from service, replaced, or
repaired according to the manufacturers instructions. All inspections or tests
accepted by the use of the non-conforming measuring and test equipment since its last
valid calibration date shall be reviewed to ensure acceptability.
3.
Ensure that all measuring and testing equipment selected for measurements, tests, or
calibration is of the proper range and type, and is controlled, adjusted, and maintained
at specified intervals identified in the QC Plan or before use to assure conformance to
the established requirements or predetermined accuracy.
4.
The equipment shall have a tag affixed attesting to the current calibration status and
shall indicate the name of the individual responsible for the last calibration and the
date (or other basis) that inspection or recalibration is next required.
5.
Contractors measuring and testing equipment shall be made available for use by the
RE, if requested.
Non-Conforming Conditions:
1.
Non-conforming conditions shall be documented and corrected before continuing.
2.
Perform planned maintenance of equipment used in construction to ensure continuing

process capability.
3.
When equipment, materials or workmanship does not conform to contract

requirements, and it is discovered by the RE, the RE will direct the Contractor to
document and resolve the non-conformance in accordance with the QC Plan. If the
Contractor does not address the discrepancy in accordance with the QC Plan within
three days, the RE will document the discrepancy using a Deficiency Report (DR) and
provide the Contractor with this written notification of the deficiency. The Contractor
shall after receipt of the DR have another three days to respond in writing with the
corrective action, time frame as to when the work will be performed, and the action
that the Contractor plans to take to prevent recurrence of the deficiency.
01400 - 7
F.
G.
3.04
A.
B.
Audits:
1.
Perform audits including subcontractor and supplier audits in accordance with the
audit schedule to assess compliance with the requirements of the QC Plan and
Contract Documents.
2.
The RE shall be notified in writing 15-days (30-days if the audit is to be conducted

more than 50-miles from the Site) in advance, of the date, time, and location of each
audit.
3.
The audit results shall be documented and shall be used to correct deficiencies and
prevent their recurrence.
Training:
1.
The Contractor shall provide training in the requirements of the QC Plan to

Contractors management team. Such training shall begin within 90-days after Notice
to Proceed and continue throughout the duration of the Contract as the need arises.
2.
Notify the RE at least 7-days in advance of the date, time, and location of the training.
The RE or its designees will have the option of attending the training.
3.
Records shall be kept of the training documenting the date, time, duration, location,
attendees, trainers name and qualifications, and the items discussed. Copies of these
records shall be provided.
INSPECTION AND TESTING

Provide verification and control of inspection and testing, including:
1.
Verifying and noting on Daily Field Reports all required testing performed and
documenting results if available.
2.
Providing location maps for all tests performed or location of Work covered by the
tests.
3.
Ensuring testing lab(s) are functioning independently and in accordance with the
Specifications.
4.
Ensuring tests and re-tests are properly taken and documented.
Timing of Inspections and Tests:

1.
Samples and test specimens required under these Specifications shall be furnished and
prepared for testing in ample time for the completion of the necessary tests and
analyses before said articles or materials are to be used. The Contractor shall furnish
and prepare all required test specimens at the Contractors own expense. As provided
in the Contract Documents, performance of the all tests will be by the Contractor. QA
testing will be borne by the Corporation at no cost to the Contractor except that the
costs of any test, which shows unsatisfactory results, shall be backcharged to the
Contractor.
01400 - 8
2.
C.
D.
Prior to inspection, testing, or sampling, the Contractor shall properly notify the RE a
minimum of 24-hours in advance that the specific area has been prepared and is ready
for inspection, testing and/or sampling. Re-testing is the responsibility of the
Contractor. Failure of the Contractor to notify the RE at least 24-hours in advance of
any such inspections shall be reasonable cause for the RE to order a sufficient delay in
the Contractors schedule to allow time for such inspection. The costs of any remedial,
or corrective work required, and all costs of such delays, including its impact on other
portions of the Work, shall be borne by the Contractor.
Sampling and Testing:

1.
When not otherwise specified, all sampling and testing shall be in accordance with the
methods prescribed in the current standards of the ASTM, as applicable to the class
and nature of the article or materials considered. However, the RE reserves the right to
use any generally accepted system of inspection, which in the opinion of the RE will
ensure that the quality of the workmanship is in full accord with the Contract
Documents.
2.
The Corporation reserves the right to waive tests or QA measures, but waiver of any
specific testing or other QA measure, whether or not such waiver is accompanied by a
guarantee of substantial performance as a relief from the specified testing or other QA
requirements as originally specified, and whether or not such guarantee is
accompanied by a performance bond to assure execution of any necessary corrective
or remedial work, shall not be construed as a waiver of any technical or qualitative
requirements of the Contract Documents.
3.
Notwithstanding the existence of such waiver, the Corporation shall reserve the right
to make independent investigations and tests as specified in the following paragraph
and failure of any portion of the Work to meet any of the qualitative requirements of
the Contract Documents shall be reasonable cause for the Corporation to require the
removal or correction and reconstruction of any such Work.
4.
In addition to any other inspection or QA provisions that may be specified, the

Corporation shall have the right to independently select, test, and analyze, at the
expense of the Corporation, additional test specimens of any or all of the materials to
be used. Results of such tests and analyses shall be considered along with the tests or
analyses made by Contractor to determine compliance with the applicable
specifications for the materials so tested or analyzed provided that wherever any
portion of the Work is discovered, as a result of such independent testing or
investigation by the RE, which fails to meet the requirements of the Contract
Documents, all costs of such independent inspection and investigation and all costs of
removal, correction, reconstruction, or repair of any such Work shall be borne by the
Contractor.
5.
The distribution and number of tests conducted for the materials to be supplied and/or
placed shall be located uniformly within and along work areas and within the facility
components to be constructed in order to provide a reasonable sampling of work
quality in accordance with current engineering practices and standards for similar
materials and components.
Testing Services:
01400 - 9
3.05
1.
All tests which require the services of a laboratory to determine compliance with the
Contract Documents shall be performed by an independent commercial testing firm
acceptable to the RE. The testing firms laboratory shall be staffed with experienced
technicians, properly equipped and fully qualified to perform the tests in accordance
with the specified standards.
2.
The RE shall have the right to inspect work performed by the independent testing
laboratory both at the project and at the laboratory. This shall include inspection of the
independent testing laboratorys internal QA records (quality assurance manual,
equipment calibrations, proficiency sample performance, etc.).
3.
Upon the REs request, the Contractors materials testing laboratory shall provide a
list of all equipment and documented evidence of current calibration records.
Equipment not requiring calibration will require service certificates. The laboratorys
Quality Procedures Manual should contain this data and shall be made available for
review by the RE.
4.
The Contractor shall obtain the REs acceptance of the testing firm before having
services performed, and shall pay all costs for these testing services.
5.
Unless otherwise specified, and in addition to other specified testing requirements,

Contractor shall provide all testing services required by the Specifications including
tests and engineering data required for REs review of materials and equipment
proposed to be used in the Work.
6.
QA testing services provided by the Corporation, if any, are for the sole benefit of
Corporation, however, test results will be available to the Contractor. Testing
necessary to satisfy Contractors internal QC procedures shall be the sole
7.
Transmittal of all Field and Laboratory Test Reports: Written reports of all field and
laboratory QC tests and engineering data furnished by the Contractor for QA review
of materials used in the Work shall be submitted to the RE within twenty-four (24)
hours after completion of the tests. Each report for each type of test shall be
consecutively numbered.
DOCUMENT CONTROL/QUALITY RECORDS
A.
The QC Plan shall identify the types of quality records to be maintained, their retrievability and
retention periods, and shall include a sample of all quality records and checklists to be used on
this Project.
B.
The Contractor shall maintain evidence that all activities by the Contractor and subcontractors
affecting quality comply with the requirements of the QC Plan. Records shall include:
1.
Records of inspections and tests including results.
2.
Non-conformance Reports and Deficiency Reports.
3.
Audit reports.
01400 - 10
4.
Material analyses.
5.
Personnel qualification and certification records.
6.
Document review records.
C.
Quality records shall be maintained for both conforming and non-conforming Work in a manner
that provides for timely retrieval, and traceability. Quality records shall be protected from
deterioration, damage, or destruction.
D.
Source and Field Testing/Sampling Log: The Contractors QC staff shall create and
continuously maintain this log. It shall contain a detailed log, in tabular format, indicating the
characteristic or quality to be tested or sampled, the test method followed, the frequency, the
sample or test location, and the designation of responsibility.
E.
As-Built Record Drawings Update: The Contractors QC staff shall maintain a dedicated set of
as-built record drawings that indicate the location and test number of the specific field test
performed during the progress of the work. Entries shall be both in the plan view and
profile/elevation view at the approximate location indicated on the submitted report. Entries
shall include the date and test number and a P for passing results and/or F for failed results.
Retests shall be included, however, a retest sometimes cannot be taken in the same location, so
retests shall be entered similarly except circled with a connecting line to the corresponding
failed test. This set of plans shall not be removed from the Contractors field office and must be
updated daily for the Corporations QA review to determine compliance
F.
Unless otherwise required by the RE or by law, retain all quality records for a period of at least
three years after Final Completion and make them available to the RE or Corporation upon
request.
G.
Provide a Monthly Certification Report, which clearly identifies Work completed for the month
and the status of this Work. The report shall identify inspection and testing completed for the
month, and shall also identify any Work that has been found to be in non-conformance. The
Monthly Certification Report shall be provided within 10 days from the end of the month.
H.
RE will furnish one copy of each field and laboratory QA test to Contractor.
3.06
READINESS REVIEWS
A.
The RE will conduct readiness reviews prior to all key Work activities. A method statement
shall be developed for each of the activities noted below and in accordance with the
Specifications. The Contractor and each involved subcontractor and applicable support staff
shall participate in readiness reviews.
B.
The readiness review subjects will be determined by the RE. At a minimum, readiness reviews
will be held for the following activities:
1.
Design.
2.
Survey layout and control.
3.
Utility relocations and protection of existing facilities, structures, and utilities.
01400 - 11
4.
Exploratory drilling, geotechnical borings, and test pit excavations.
5.
Shaft support of excavation systems, either slurry wall or ground freeze, including
assessment of ground movement and potential damage caused by the Work.
6.
Shaft excavation including shotcreting, if applicable, and installation of base slab,

including assessment of ground movement and potential damage caused by the Work.
7.
Temporary restoration of the Brooklyn Receiving Shaft site.
8.
Precast concrete segment fabrication.
9.
Precast concrete segment delivery, handling, storage and on-site transport.
10.
Ground treatment.
11.
Geotechnical instrumentation installation and maintenance.
12.
TBM launch frame installation.
13.
Delivery and assembly of TBM and backup equipment/systems.
14.
Rigging for TBM lifts for assembly and disassembly.
15.
Tunnel safety, including emergency and evacuation procedures.
16.
TBM launch (break-out from Staten Island Launching Shaft) including tunneling
through slurry wall and treated ground.
17.
Tunneling, including: tunnel contingency plans; face pressure control plans; settlement
action plans; TBM guidance systems, alignment control, and surveying; precast
concrete segment erection; precast concrete segment annular and secondary grouting;
and tunnel muck handling, transport, treatment, and disposal.
18.
Probing ahead of TBM.
19.
Entry to TBM cutterhead chamber, including ground treatment and compressed air
work.
20.
Re-establishment of Brooklyn Receiving Shaft site to receive TBM.
21.
TBM reception (break-in to Brooklyn Receiving Shaft) including tunneling through

treated ground and slurry wall.
22.
Disassembly and removal of TBM and backup equipment/systems.
23.
Cleaning of tunnel, installation of carrier pipe, testing of welds, and backfilling of

annular void with concrete.
24.
Installation of riser pipe in shafts and backfilling annular void with concrete.
01400 - 12
25.
C.
Construction of shaft access chambers including cast-in-place and precast concrete

structures (including reinforcement, waterproofing, embedments, etc.), valves and
appurtenances, and connection with land piping.
Readiness reviews will evaluate the preparedness for accomplishing designated construction
operations or activities and will include the following items:
1.
Safety issues and procedures.
2.
Quality requirements and procedures:

a.
Inspections.
b.
Tests.
c.
Expected quality records.
3.
Review of the method statement, including work scope, schedule, submittal status,
status of materials to be used, and key personnel.
4.
Permits and required third-party approvals.
5.
Environmental issues and requirements.
6.
Traffic and pedestrian access and maintenance.
7.
Qualifications and training of personnel.
8.
Special construction security issues.
9.
Contingency plans, if required.
10.
Any other relevant issues, including review of any open items because of this meeting.
D.
As part of the review session, outline the sequence of Work, planned hold points, and
contingency plans in place.
E.
The Work being reviewed shall not proceed until the RE has indicated acceptance of the method
statement and satisfactory conclusion of the readiness review, either by issuance of meeting
minutes or subsequent correspondence. The method statement will be attached to the readiness
review meeting minutes.
3.07
A.
RIGHT OF REJECTION
RE or designated representative, acting for the Corporation, shall have the right at all times and
places to reject any articles or materials to be furnished which, in any respect, fail to meet the
requirements of the Contract Documents, regardless of whether the defects in such articles or
materials are detected at the point of manufacture or after completion of the Work at the Site. If
RE or designated representative, through an oversight or otherwise, has accepted materials or
Work which are defective or in any way contrary to the Contract Documents, such materials, no
matter in what stage or condition of manufacture, delivery, or erection, may be rejected.
01400 - 13
B.
The Contractor shall promptly remove or replace rejected articles or materials from the Site
after notification of rejection.
C.
All costs of removal and replacement of rejected articles or materials, as specified therein, shall
be borne by Contractor.
D.
Failure to promptly remove and replace rejected Work shall be considered a breach of this
Contract and the Corporation may, after 7-days notice, terminate the Contractors right to
proceed with the affected Work and remove and replace the Work and issue a back-charge to
cover the cost of the Work.
END OF SECTION
01400 - 14
SECTION 02145
CONTROL OF GROUNDWATER AND SURFACE WATER
PART 1 GENERAL
1.01
A.
SCOPE OF WORK
The Work specified in this Section includes, but is not limited to the following:
1.
Protecting shafts and tunnel against surface-runoff water accounting for maximum flood
elevations given in the Contract Documents; and
2.
Disposing of surface-runoff water in a manner approved by all applicable regulations and

laws and as specified herein.
B.
Dewatering, depressurization, or other methods to control groundwater are not proposed as part
of the shaft or tunnel excavations.
C.
Control and removal of infiltration water into the shaft and tunnel excavations is covered in
Section 13120.
1.02
RELATED SECTIONS
A.
Environmental Protection is included in Section 02270.
B.
Shaft Support Slurry Walls is included in Section 02310.
C.
Tunneling by Tunnel Boring Machine is included in Section 02330.
D.
Tunnel and Shaft Safety is included in Section 13000.
E.
Shaft Construction is included in Section 13060.
F.
Removal and Treatment of Tunnel Construction Water is included in Section 13120.
1.03
REFERENCE STANDARDS
A.
Federal Regulations, 29 CFR Part 1926, Standards-Excavation, Occupational Safety and Health
Administration (OSHA).
B.
State Pollutant Discharge Elimination System (SPDES) permit, Chapter X Division of Water
Resources.
1.04
A.
1.05
DEFINITIONS
Control of surface drainage: the diversion of surface water away from excavations by ditches or
other means.
SUBMITTALS
02145 - 1
A.
Submit drawings indicating all surface water control measures including means, methods, and
locations of disposal of water.
B.
Submit pump models, capacities and any technical details required by the RE.
1.06
1.07
A.
The Contractor shall prevent water from entering the shafts and any other excavations.
PART 2 PRODUCTS
2.01
EQUIPMENT AND MATERIALS
A.
The Contractor shall select the equipment and materials to meet the requirements of controlling
the surface water. Drainage systems may include any pumping equipment deemed necessary by
the Contractor.
B.
Maintain equipment in good repair and operating order.
C.
Arrange for standby equipment and materials such that the drainage systems are available at all
times.
PART 3 EXECUTION
3.01
GENERAL
A.
Install, operate, and maintain the surface water control measures in a manner compatible with
construction methods and site conditions. Notify the RE in writing of any changes made to
accommodate field conditions and changes to the Work.
B.
Provide flood protection for the shafts and tunnels against the maximum flood plain elevations
given on the Contract Drawings, plus an additional 3-feet.
C.
Provide additional drainage installations, or change the methods, if the installations do not
achieve satisfactory results.
D.
Remove system components on completion of the works.
3.02
SURFACE WATER CONTROL
A.
Intercept surface water and divert it away from excavations. This includes temporary works
required to protect adjoining properties from surface drainage caused by construction
operations.
B.
Divert surface water into sumps. Obtain REs approval for pumping and discharging the water
into drainage channels, settling basins, or storm drains. Observe and record elevation of water
level daily or as determined by the RE.
02145 - 2
3.03
DISPOSAL
A.
Corporation may allow disposal of non-contaminated water into the nearest sanitary sewer,
given proper notice and Contractor compliance with Contract Documents and all applicable
codes and regulations. Discharge to a sanitary sewer is subject to prior written approval of the
RE.
B.
No contaminated water shall be discharged into storm sewers, open waterways, or onto the
ground surface unless treated in accordance with applicable standards and regulations and a
permit has been obtained by the Contractor and approved by the RE.
END OF SECTION
02145 - 3
SECTION 02310
SHAFT SUPPORT SLURRY WALLS
PART 1 GENERAL
1.01
SCOPE OF WORK
A.
The Work specified in this Section includes the installation of reinforced concrete diaphragm
walls constructed by the slurry trench method (slurry walls), as intended to provide ground
support during shaft and tunnel construction.
B.
Excavation from within the completed slurry wall shaft is covered in Section 13060 Shaft
Construction.
1.02
RELATED SECTIONS
A.
Control of Groundwater and Surface Water is included in Section 02145.
B.
Jet Grouting is included in Section 02432.
C.
Instrumentation and Monitoring is included in Section 02495.
D.
Concrete Formwork is included in Section 03100.
E.
Concrete Reinforcement is included in Section 03200.
F.
Concrete Accessories is included in Section 03250.
G.
Cast-in-Place Concrete is included in Section 03350.
H.
I.
J.
K.
Tunnel and Shafts - Temporary Ventilation and Utilities is included in Section 13130.
L.
Muck Disposal is included in Section 13140.
M.
Pre-construction and Post-construction Inspections is included in Section 13200.
1.03
REFERENCE STANDARDS
A.
ACI 318
Building Code Requirements for Structural Concrete and Commentary
B.
ACI 440
Guide for the Design and Construction of Structural Concrete Reinforced

with FRP Bars
02310 - 1
C.
API SPEC 13A
Specification for Drilling-Fluid Materials
D.
API RP 13B-1
Recommended Practice for Field Testing Water-based Drilling Fluids
E.
ASTM A36
Specification for Carbon Structural Steel
F.
ASTM A497
Specification for Steel Welded Wire Reinforcement, Deformed, for Concrete
G.
ASTM A501
Specification for Hot-formed Welded and Seamless Carbon Steel Structural

Tubing
H.
ASTM A615
Specification for Deformed and Plain Carbon-Steel Bars for Concrete

Reinforcement
I.
ASTM D4380
Test Method for Density of Bentonitic Slurries
J.
ASTM D4381
Standard Test Method for Sand Content by Volume of Bentonitic Slurries
K.
ASTM D6910
Standard Test Method for Marsh Funnel Viscosity of Clay Construction

Slurries
1.04
DEFINITIONS
A.
Guide Wall: A pair of walls constructed to establish the location of the slurry wall and to
prevent the top of the trench from caving in.
B.
Lean Mix Concrete: Low strength Portland cement concrete. Also referred to as Controlled Low
Strength Material (CLSM), Controlled Density Fill (CDF), Unshrinkable Fill (U-Fill) or
Flowable Fill.
C.
Primary Panel: Slurry wall panel excavated through soil using one or more passes of the slurry
wall machine with no adjacent panels.
D.
Secondary Panel: Slurry wall panel excavated using one or more passes of the slurry wall
machine between two primary panels.
E.
Slurry: Water-based drilling fluid used to provide temporary earth support during trench
excavation for slurry walls.
F.
Slurry Wall: Reinforced concrete diaphragm wall panel constructed below ground using the
slurry method of trench stabilization. Slurry walls are structural walls.
G.
Theoretical Excavation Line: Theoretical line of excavation inside of which no earth or

surrounding ground shall protrude.
H.
Tremie Concrete: Concrete placed by means of tremie pipe equipment, for depositing concrete
under water or slurry, the discharge end of the pipe being kept submerged in the freshly
deposited concrete so that the concrete-water or concrete-slurry interface is not disturbed.
02310 - 2
1.05
A.
SUBMITTALS
At least 30 days prior to commencement of shaft construction, submit the following for review
by the RE:
1.
Qualifications of slurry walls supervisory and operating personnel.
2.
A site plan showing the arrangement of stationary plant and equipment associated with
slurry wall construction, ground treatment and shaft excavation, and on-site traffic
routes.
B.
Submit pre-construction inspections as required by Section 13200 Pre-construction and Postconstruction Inspections.
C.
Provide a comprehensive Method Statement and shop drawings detailing the overall
construction methodology and sequence for both project shafts and associated ground treatment
or other measures required for launching and receiving of the TBM. The following
documentation shall be submitted in detail to the RE for approval at least 30 days prior to the
commencement of any operations on site:
1.
Shaft dimensions, design criteria, and details for shaft initial support system using the
slurry wall method including special requirements for shaft penetrations, the tunnel
break-in or break-out and any ground improvement techniques to be used outside the
shaft excavation limits. Allowable surcharge loads and any restrictions on surcharge
capacity, including live loads, shall be clearly shown on the shaft construction
drawings. Thrust blocks or other reactions required for TBM launch shall be shown, as
applicable.
2.
Complete specifications for all equipment proposed to be used for the shaft
construction using the slurry wall method including maximum depth capability and
verticality control.
3.
Design of concrete in accordance with Section 03350 Cast-in-Place Concrete.
4.
Location of and methods for bentonite slurry preparation, site distribution, reclamation
and disposal, including back-up provisions.
5.
Slurry mix composition, plus monitoring and testing to be used to assure compliance
with approved quality control requirements.
6.
Procedures for monitoring and maintaining slurry level in excavations left open
overnight, or for an extended period of time.
7.
Procedures for maintaining stability of excavations in case of sudden loss of bentonite

suspension.
8.
Procedures for real-time monitoring of deviation from vertical of wall panels during
excavation of the shaft walls, plus details of proposed corrective measures to be
implemented if necessary.
02310 - 3
9.
Methods to be used for checking the bottom of the excavation for cleanliness and
soundness of foundation material prior to concreting.
10.
Procedures for constructing joints between adjacent wall panels including checking
plumb and deviation, excavation of secondary panels with overcut into primary panels
including shear key, and details of corrective measures to be implemented if
construction tolerances are exceeded.
11.
Methods and procedures for installing instruments in the slurry walls including an
instrument installation schedule, all in accordance with Section 02495
Instrumentation and Monitoring.
12.
Procedures for installing, splicing and securing reinforcing cages in the excavation
including details to prevent GFRP reinforcement from floating or otherwise moving
designed location during cage installation and concreting.
13.
Procedures for tremie placing of concrete.
14.
Procedures for pumping and treating displaced slurry.
15.
Procedures for excavating of slurry-filled trench panels through any expected ground
as described in the Geotechnical Baseline Report (GBR), and hauling, pumping, and
disposing of the excavated materials and bentonite slurry to an approved disposal site.
16.
Procedures for monitoring and confirming complete closure of slurry walls around
perimeter of shaft to prevent groundwater and/or soil flow into shaft during
excavation.
17.
Procedures for the sealing of any joint where, on exposure of the wall, water leaks are
found in excess of the maximum permissible water inflow criteria.
18.
Methods, procedures and grout mix designs planned by the contractor for reducing
water inflows into the shaft in order to meet the water inflow criteria.
19.
Procedures and mix designs for grouting of the toe of the panels to seal the slurry
wall/ground interface, where applicable.
20.
Provide shop drawings of the guide walls showing:
21.
a.
Layout information, including survey control points used.
b.
Details and dimensions including reinforcing steel.
c.
Construction tolerances.
Provide shop drawings of the slurry wall panels showing:

a.
Details and dimensions of the panels, including required tolerances.
b.
Reinforcing steel including provisions for stiffening, lifting, splicing and

control of orientation, including required tolerances.
c.
Details of reinforcement in and around the tunnel eye for break-ins and breakouts.
02310 - 4
D.
d.
Guides and spacers to be used in placing the reinforcing steel cages.
e.
Details of panel blockouts, including locations, materials and means of securing

them to prevent movement during cage installation and during concreting
operations.
f.
Details of embedded instruments.
g.
Shaft temporary covers.
h.
Manufacturers technical information and test data for threaded inserts, couplers
and other embedded items.
i.
Complete sequence of construction.
During slurry wall construction, submit to the RE:

1.
Excavation Report: Submit within 24 hours after each panel excavation has been
completed. Excavation report shall include complete and detailed printed output from
slurry wall excavation equipment data recording device.
2.
Verticality Verification Report: Submit within 24 hours after each excavation pass for
each panel completed.
3.
Bentonite Slurry Report: Submit daily.
4.
Reinforcement Placement: Submit within 24 hours after each panel is completed.
5.
Concrete Placement Report: Submit within 24 hours after each concrete placement.
E.
Provide results of quality control tests performed on the bentonite slurry the same day that test
results are completed. Submit copies of job test records to the RE each week.
F.
Provide a contingency plan setting forth the steps that shall be taken should the shaft
deformations exceed specified values.
G.
Provide details of each utility service that shall require protection or temporary/permanent
diversion, the type and duration of interruption to the service and provision for non-interruptible
services.
H.
Records of noise and vibration monitoring shall be in accordance with Section 02495
Instrumentation and Monitoring.
1.06
A.
DELIVERABLES
Maintain and submit to the RE as-built records of slurry walls including:
1.
Panel identification.
2.
Plan dimensions of the excavation and elevation of guide walls, and top and bottom of
slurry wall panels.
02310 - 5
1.07
A.
3.
Dates and times of panel excavation, reinforcing steel placement, and tremie concrete
placement. Indicate volume of excavation, and theoretical and actual volume of
concrete placed.
4.
Description of soils encountered, obstructions, and excavation problems, if any.
5.
Reference to reinforcing steel shop drawings and cutouts.
6.
Details of instrumentation installed in the panels, if any, plus instrumentation required

adjacent to the panels, if any.
7.
Details and records of toe grouting where performed.
8.
Plumbness and deviation from plan location, as measured during installation of each
panel.
9.
Sketches showing locations of repaired areas in concrete panels.
Qualifications:
1.
Slurry Wall Specialist: Detailed qualifications of the Contractor or the proposed

specialist Contractor who undertakes the construction of the slurry walls. Such
Contractor must have at least five years of experience on projects of a similar nature
particularly in the excavation and construction of large diameter slurry wall shafts
using similar approaches to that proposed by the Contractor for this work.
2.
Slurry Wall Designer: All design calculations and drawings for the Work of this
Section shall be sealed by a Professional Engineer registered in the State of New
York, who possesses a minimum of five years of experience in the design of slurry
walls.
3.
Slurry Wall Superintendent: Slurry wall construction shall be supervised by a

Superintendent that has a minimum of ten years experience excavating and installing
slurry concrete walls and slurry wall shafts. Provide documentation of successful
completion of three similar projects, including contact details of references.
B.
Control testing of Bentonite Slurry: Use suitable apparatus to control testing of bentonite slurry
to determine the density and Marsh Cone viscosity that conform to the requirements of API RP13A, of freshly mixed slurry as a check on the quality of slurry produced.
C.
Calibration: Calibrate density measuring devices monthly, or more frequently if directed by the
RE, to an accuracy of 0.05 pounds per cubic foot.
D.
Test Equipment and Methods: Provide test equipment and perform tests in conformance with
the requirements of API RP-13B-1.
E.
Bentonite Slurry Inside Trench:

1.
During Excavation: Perform tests as specified below to verify that properties of slurry
inside trench excavations are within the specified limits. Take samples from the top
02310 - 6
and bottom of the trench, and perform tests every four hours of work on each panel,
unless otherwise specified.
2.
Prior to Placing Concrete: Immediately prior to placing concrete in any wall panel,
take a sample of the slurry 12 inches from the bottom of the trench, and test it for
density and sand content. Modify or replace the slurry in the trench if the density of
the sample is found to exceed limit specified. Do not place any concrete in the trench
until the density is correct and the sand content has been found to be five percent or
lower. Perform additional tests, such as measurement of fluid loss, if requested by the
RE.
3.
Tests:
a.
Density, by mud density balance.
b.
Viscosity, by Marsh Cone method.
c.
Fluid loss, by filter press.
d.
pH.
e.
Specific gravity.
f.
Sand content.
F.
Monitoring: Monitor placement and chart actual volume of concrete placed versus theoretical
volume required.
G.
Concrete Testing: Testing and inspection of concrete used in slurry walls shall conform to the
requirements stated in Section 03300 - Cast-In-Place Concrete and in this Specification.
1.08
A.
TOLERANCES
Guide walls:
1.
The guide walls shall be installed at locations as indicated on reviewed guide wall
submittals. The installed locations shall not deviate more than 1-inch from the planned
locations.
2.
The finished face of the guide wall on the side of the trench shall be vertical and shall
represent the theoretical inside line of the slurry wall. The inside faces of the guide
wall shall not have any ridges or abrupt changes. The clear distance between the inside
faces of the guide walls shall be the required design width of the slurry wall plus a
maximum of 1-inch. The top of the guide walls shall be horizontal and have the same
elevation on both sides of the trench. The top elevation of the guide wall shall be
within plus or minus 1-inch from the designed elevation.
3.
Groundwater and surface runoff shall be controlled by the contractor to maintain the
trench in a stable condition during construction of the guide walls.
4.
At the time of concreting the guide wall the prepared trench shall be in a firm and dry
condition.
02310 - 7
5.
B.
Slurry walls:
1.
Slurry wall panels shall be constructed to a vertical tolerance of 0.33 % of the depth.
During excavation the verticality of the wall panels shall be checked every 15 feet of
depth in each panel as a minimum.
2.
Local variations of the inside face of the wall at any point shall be limited to a total
horizontal dimension of 6 inches from the face of the reinforcing steel assembly. Any
bulges, protrusions, or cavities where there is insufficient cover to reinforcement in the
wall that exceed this tolerance or compromise wall integrity or interfere with means
and methods shall be repaired in a manner acceptable to the RE.
3.
Formed Recesses: Position formed recesses and other devices necessary for the
temporary construction or other appurtenant structures indicated within plus or minus
1 inch of the indicated location.
4.
Secondary panel overcut into primary panel: Dimension shown on Contract Drawings
with a tolerance of plus 6 inches; minus 0 inches.
5.
Notwithstanding the required tolerances for position and verticality, the step between
adjacent panels at any location shall not exceed 4 inches.
6.
Grade differences between the bottom of adjacent panels shall not exceed 2-feet unless
accepted by the RE to accommodate field conditions or as shown on the Contract
Drawings.
7.
Reinforcement cages shall be fabricated and placed to the following tolerances:
8.
1.09
A.
The contractor shall furnish and operate all appropriate devices as necessary for
removing water from the trench during construction of the guide walls.
a.
Normal to wall: Plus or minus 1 inch. Maintain minimum concrete cover to

reinforcement as shown on the Contract Drawings.
b.
Horizontal (along longitudinal axis of wall): plus or minus 2 inches.
c.
Vertical: plus or minus 1 inch. Maintain minimum concrete cover to

reinforcement as shown on the Contract Drawings.
d.
Minimum clear cover: 3 inches or as indicated otherwise on the Contract

Drawings.
e.
Dowels: 3 inches from indicated position.
f.
Width of reinforcement cage: plus or minus 1 inch.
Excavation support walls shall not deflect more than 0.1 feet, either during the
excavation process or throughout service duration.
WATER INFLOW CRITERIA

The shaft shall be considered watertight when the following criteria are met:
02310 - 8
1.
2.
B.
1.10
On completion of the slurry walls the maximum permissible water inflow into the
shaft including the tunnel break-out/break-in, tremie base slab, and the interface
between the tremie base slab and the shaft lining, shall be as defined below.
a.
Overall inflow into shaft:
0.07 gpm
b.
From any single source:
0.0125 gpm
No running water from the wall or formation of droplets on the wall is permitted. The
formation of damp patches allowing water to evaporate from the surface is permitted.
Remediation of any wall sections or break-out/break-in locations not meeting these criteria shall
be performed immediately upon detection of excessive leakage or draw down of the
groundwater elevation. The contractor shall determine the method of remediation work and
submit the methodology to the RE for review and approval.
DESIGN CRITERIA
A.
Design Criteria are included in Section 13060 Shaft Construction for the convenience of the
Contractor in the event that the Contractor proposes an alternative slurry wall design to that
shown on the Contract Drawings. These criteria are intended to be the minimum acceptable
design criteria. Earth support shall be designed to withstand all temporary loading conditions
throughout the entire construction duration. All designs shall be in accordance with the
standards referenced in these specifications.
B.
Panel walls shall be designed and constructed so as to be free of running or seeping water. The
Contractor shall be responsible for the sealing of any joint or other wall area where, on exposure
of the wall, water leakage exceeds the criteria.
C.
The Contractor shall be responsible for developing appropriate procedures in order to meet the
minimum design criteria. The design shall include, but is not limited to, the following:
D.
1.
The design and construction of guide walls to enable construction of the slurry wall
panels to the indicated tolerances.
2.
The detailing and construction of the slurry wall panels.
3.
The detailing and construction of joints between adjacent wall panels.
4.
The detailing and construction of the reinforcing for the slurry walls panels.
5.
The selection and operation of equipment appropriate for the Work.
6.
The detailing and operation of the real-time monitoring of the excavation.
7.
The detailing and execution of methodology for TBM or other break-ins/break-outs

from the shafts as it relates to the design of the shaft walls.
The inside face of the slurry wall shall be designed and constructed to be straight, free from
flaws and other imperfections, and within the tolerances defined in this specification section.
Any concrete that encroaches into the final structure as shown on the Contract Drawings shall
be removed. The panel excavation shall be carried out in a continuous manner to the lines and
02310 - 9
grades established on the guide walls. The slurry shall be pumped in a continuous manner so
that the trenches are filled to within three feet of the top of the guide walls or higher if necessary
to prevent inflow of soil beneath the guide walls.
PART 2 PRODUCTS
2.01
A.
B.
C.
MATERIALS
Cast-in-place Concrete
1.
Cast-in-place concrete shall conform to Section 03350 Cast-in-Place Concrete,

except as modified herein.
2.
Proportion mixes to achieve the following properties:

a.
Guide walls: per Contractors requirements
b.
Structural slurry wall panels:

1)
Minimum compressive strength: 4000 psi.
2)
Minimum cement content: Minimum cement requirement of Section

03300 may be waived if the Contractor proposes an alternative that is
submitted to, and approved by, the RE.
3)
Initial slump: 8 inches minimum.
4)
Slump after 12 hours: 5 inches minimum.
5)
Coarse aggregate: Natural rounded stone; maximum size 3/4 inch.
6)
All other mix parameters, including maximum water/cement ratio,

maximum coarse aggregate size, air content, and admixtures, are to be
specified by the Contractor and submitted to the RE for approval.
Reinforcement
1.
Steel Reinforcement: As specified in Section 03200 Concrete Reinforcement.
2.
Spacers: industry-standard precast concrete or plastic spacers.
3.
Lap splice couplers: Drop forged U-bolt and saddle type wire rope clips, or approved
equal.
4.
Fiberglass reinforcement shall be Aslan 100 GFRP bars manufactured by Hughes

Brothers, or similar approved equivalent.
Slurry: Sodium bentonite (sodium montmorillonite) and water solution to API RP 13A, Section
4, meeting the following requirements:
1.
Unless directed otherwise by the RE, mix design including required preparation
procedures and hydration time, shall be provided by a Slurry Wall Designer for
approval. Minimum hydration time shall be 8 hours.
2.
Slurry additives: as approved by the RE.
02310 - 10
3.
Water: Potable.
4.
Design criteria:
a.
Gel strength: as specified by the Slurry Wall Designer and sufficient to seal all
ground types described in the GBR.
b.
Initial slurry properties:
c.
2.02
A.
B.
1)
Between 5.5 and 7 percent bentonite per unit weight of water.
2)
Minimum unit weight: 64 pcf.
3)
Minimum apparent viscosity: 12.5 centipoise (36 Marsh seconds) at 68

degrees F, as measured by the direct-indicating viscometer.
4)
Maximum filtrate loss: 20 cm3 in 30 minutes at 100 psi, as measured by

filter press (per API RP-13B).
In-trench slurry properties:

1)
Unit weight: between 65 and 80 pcf.
2)
Minimum apparent viscosity: 15 centipoise (40 Marsh seconds) at 68

degrees F, as measured by the direct-indicating viscometer.
3)
Maximum filtrate loss: 20 cm3 in 30 minutes at 100 psi, as measured by

filter press (per API RP-13B).
4)
pH: between 7.0 and 11.0.
5)
Maximum sand content: 5 percent measured 1 foot from panel bottom

per API RP-13B.
EQUIPMENT
Slurry wall excavation equipment:
1.
General: The equipment used shall be capable of excavating through the range of the
expected ground conditions as described in the Geotechnical Baseline Report (GBR).
2.
Accuracy: equipment must have demonstrable capability of excavating trench walls to

a horizontal accuracy of 0.33 percent of depth at a depth of 180 ft.
3.
Equipment shall be capable of continuously cutting the adjacent previously-placed

slurry wall concrete, including a shear key as shown on the drawings, so as to obtain a
clean construction joint between primary and secondary panels.
4.
The equipment used must have suitable chisels or other capacity to excavate through
boulders as described in the GBR.
5.
Data recording equipment shall be installed on the slurry wall excavation equipment to
record the horizontal and vertical position of excavation equipment and operating
parameters. The data recording equipment shall be maintained in a fully operational
state at all times during slurry wall excavation.
Slurry plant:
02310 - 11
1.
General: all slurry plant and piping to be designed and located to prevent leakage and
spillage, and to facilitate handling of wet and dry materials. Facilities shall include
provisions to enable inspection and sampling of the slurry by the Contractor and the
RE.
2.
Slurry mixing: Use equipment that produces a stable suspension of bentonite and
water along with necessary mechanical agitation. Transport slurry via temporary
pipeline.
3.
Slurry separation: use equipment that separates bentonite from excavated material
sufficiently to maintain the in-trench slurry properties at all times.
4.
Slurry storage: Provide storage volume sufficient to enable excavation and concreting
to proceed on a continuous basis.
PART 3 EXECUTION
3.01
GENERAL
A.
Perform preparatory work to locate, maintain or relocate, and restore utility service facilities.
B.
Special framing, bracing or shoring required around tunnel eyes or other penetrations shall be
in-place according to shaft construction drawings before the liner or any bracing or shoring at
the penetration is cut or removed.
C.
Drill a borehole on the centerline of each slurry wall panel for both shafts:
1.
The boreholes shall be drilled to the planned toe elevation of the slurry wall panels,
and sampled for a depth of at least 15 feet below this elevation
2.
The end of the borehole shall be within 6 inches horizontally of the collar location.
3.
Drilling through rock:
4.
a.
Where rock is encountered at or below the planned toe elevation of the slurry
wall panel, the rock shall be cored continuously for a depth of at least 15 feet.
All rock core samples shall be retained and stored on site in core boxes labeled
with rock core location, elevation, and depth. Rock logs and core photographs
shall be developed for all rock cores and submitted to the RE within two days of
completing the borehole.
b.
The rock core shall be assessed and evaluated by the Contractor to determine
the final toe elevation of each slurry wall panel, and then agreed with the RE.
For a depth of at least 5 feet below the final toe elevation of the slurry wall
panel the rock shall be moderately weathered to fresh rock. The borehole and
final toe elevation of the slurry wall panel shall be extended if necessary to a
depth sufficient to satisfy this requirement.
c.
Cores shall be taken using HQ triple tube thin walled core barrels.
Drilling through decomposed rock or soil:
02310 - 12
a.
Where soil is encountered at or below the planned toe elevation of the slurry
wall panel, the soil shall be sampled continuously using a driven Standard
Penetration Test (SPT) split spoon sampler for a depth of at least 15 feet. All
samples shall be retained and stored on site labeled with sample location,
elevation, and depth. Borehole logs shall be developed for all borehole locations
and submitted to the RE within two days of completing the borehole.
b.
The SPT N-value shall be assessed and evaluated by the Contractor to

determine the final toe elevation of each slurry wall panel, and then agreed with
the RE. For a depth of at least 5 feet below the final toe elevation of the slurry
wall the decomposed rock or soil shall have an SPT N-value of at least 50
blows per foot. The borehole and final toe elevation of the slurry wall shall be
extended if necessary to a depth sufficient to satisfy this requirement.
D.
Employ construction methods and procedures that prevent spillage of excavated materials,
slurry or concrete onto utilities, streets, sidewalks or other facilities.
E.
Prior to the start of construction, ensure all environmental protection measures are in place and
functioning to ensure compliance with all regulatory and specification requirements, especially
measures related to the capture and containment of excess slurry as well as measures relating to
the disposal of slurry.
3.02
GUIDE WALLS
A.
Construct guide walls in accordance with the approved Shop Drawings, with due provision for
tolerances and clearances
B.
Construct at an elevation that shall allow the lowest slurry level in the trench to be maintained at
least 1 foot above the bottom of the guide wall and no more than 3 feet below the top of the
guide wall, without leakage or contamination.
3.03
SLURRY WALLS
A.
Slurry Preparation: ensure sufficient quantity of slurry is prepared and ready for use to complete
the excavation operation as specified below.
B.
Excavation:
1.
Do not begin excavation of slurry walls until the boreholes specified in Article 3.01
have been completed and the results evaluated by the Contractor and the RE.
2.
Do not begin excavation of the slurry walls until all geotechnical instrumentation for
monitoring ground movements is installed and baseline reading sets have been taken.
3.
Perform excavation continuously from ground surface to the required depth. Excavate
in a manner that minimizes movement and loss of ground.
4.
Excavate panels to the dimensions indicated on the Contract Drawings, within

allowances for vertical and horizontal tolerances.
02310 - 13
C.
5.
The depth of panel excavation shall extend to the toe level over the full plan area of
the panel. The contractor must account for any additional excavation required as a
result of the equipment selected.
6.
Perform excavation through the slurry, adding slurry as necessary to maintain slurry
level no more than 3 feet below the top of the guide wall. Slurry level should be at
least 1 foot above the bottom of the guide wall.
7.
Do not commence excavation of a new panel until the concrete in the adjacent panels
has been in place for a minimum of 72 hours and has achieved sufficient strength, and
not less than 1000 psi, to enable it to withstand the effects of the excavation.
Reinforcement
1.
Fabricate reinforcing assemblies in accordance with the Shop Drawings, ensuring they
are free from distortion. Assemblies fabricated off site are to be checked for distortion
prior to use. Add additional bars, stiffeners and struts as required to resist distortion
loads associated with transporting and erecting the assemblies.
2.
Install guides and spacers to ensure minimum cover is maintained between reinforcing
steel and face of excavation. Maximum spacing of spacers: 8.0 ft vertical; 2.0 ft
horizontal.
3.
Check location of, secure and protect blockouts to prevent damage and displacement
by flotation.
4.
Use lap splice couplers to connect reinforcement assemblies when both assemblies are
in the vertical position. Use sufficient number of couplers to ensure a factor of safety
of five against slippage under the dead weight of the reinforcing assembly or flotation
where fiber reinforced polymer reinforcement is used. Ensure correct vertical
alignment and lap lengths are maintained.
5.
Reinforcement shall be designed and erected to enable concrete placement by tremie

pipe without honeycombs, slurry-filled voids, or other defects.
6.
Clean the bottom of the trench of all loose material and inspect the trench to determine
that the required depth and width of excavation has been achieved utilizing the
following sequence or modified methodology approved by the RE. Each step shall be
executed to the satisfaction of the RE:
a.
One hour before placement of the reinforcing steel clean the bottom of the
excavation by air lifting or pumping.
b.
Verify that the required trench width and depth has been met.
c.
Verify that the trench is clean and the slurry at excavation bottom has the
required density and contains no impurities such as sand or soil contamination
by testing of the recirculated slurry from the base of the trench.
d.
Place reinforcing as soon as practicable after cleaning the excavation bottom

and testing requirements have been successfully met.
e.
The reinforcing assembly shall be placed no later than four hours after
excavation completion otherwise steps (a) through (d) shall be repeated.
02310 - 14
D.
Instrumentation: Shall be installed within the slurry wall panels as shown on the Contract
Drawings and sufficient baseline readings taken prior to commencing shaft excavation in
accordance with Section 02495 Instrumentation and Monitoring.
E.
Concreting
3.04
1.
Begin placing concrete by means of tremie pipe within 12 hours of completing

excavation, and within two hours of completion of installation of reinforcing in the
trench. If the two hour limit is exceeded remove the reinforcing, clean the reinforcing,
re-clean the excavation bottom, and re-install the reinforcing in accordance with
Article 3.03C.
2.
Tremie pipe shall remain embedded in the concrete at all times. The pipe shall be kept
no less than 7 ft below the concrete level when the concrete level reaches 10 feet
above the slurry wall toe. Equip the tremie pipe with a ball check valve or other device
to prevent mixing of the slurry with concrete inside the tremie pipe.
3.
Use a minimum of one tremie pipe for each 8 ft of panel length.
4.
Concrete shall be placed in such a manner that the concrete displaces the slurry
progressively from the bottom and rises uniformly to the surface, and that concrete
and slurry do not intermix. Ensure concrete/slurry interface remains horizontal.
5.
Place concrete in a continuous operation until the slurry wall panel is completely
concreted to the required elevation.
6.
The tremie pipe shall have an internal diameter of not less than six (6) inches for
concrete with 0.75 inch maximum size aggregate and not less than eight (8) inches for
concrete with a 1.25 inch maximum size aggregate. The tremie pipe shall have no
internal projections and external projections shall be minimized. The receiving hopper
for the tremie pipe shall have a capacity at least equal to that of the tremie pipe.
7.
At all times the end of the tremie pipe shall be kept clear of the reinforcement, any
embedded steel section and box out and the side of the foundation, to prevent
segregation of the concrete.
8.
Concrete shall be placed continuously to ensure that entrapment of air within the
tremie pipe is minimized and at all times a sufficient quantity of concrete shall be
maintained within the tremie pipe to ensure that the pressure from it exceeds that from
the slurry or support fluid.
SLURRY WALL FIELD INSPECTION
A.
Perform inspection as excavation progresses. Immediately inform the RE of any overexcavation, obstructions, out-of-tolerance excavation, or slurry loss.
B.
Upon completion of excavation, use inspection devices in the presence of the RE to demonstrate
that the trench has been excavated to the specified width, depth and verticality, the cleanliness
of the trench bottom and that concrete from previous pours does not encroach on the panel or
into the joint.
02310 - 15
C.
Immediately prior to placing concrete in any panel, sample the slurry 1 foot from the bottom of
the trench and test it for compliance with the requirements for in-trench slurry properties,
defined herein. Modify or replace slurry if tests indicate non-compliance and re-test. Perform
additional tests such as measurement of fluid loss if requested by the RE.
D.
Prepare Slurry Panel Summary Report sheets using a proforma similar to that shown in
Figure 02310.1 and 02310.2. Complete a Slurry Panel Summary Report for each panel and
submit to the RE within 24 hours of completion.
3.05
REPAIR AND RESTORATION
A.
The slurry wall panels will be considered defective if the panels are installed beyond the
tolerance limits specified or have defective concrete as described below. The contractor shall
prepare and submit proposed corrective measures for review by the RE. Corrective measures to
remediate or replace defective wall sections shall be at no additional cost to the Corporation.
B.
A panel shall be considered as having defective concrete when:

1.
There are areas of voids, honeycomb, excessive laitance accumulation, aggregate runs,
segregated aggregate, or exposed reinforcement.
2.
There are cold joints in a panel.
3.
Areas of concrete are contaminated with bentonite slurry or dried bentonite.
4.
Under-strength concrete is used.
02310 - 16
SLURRY PANEL SUMMARY REPORT

CONTRACT
Element
PANEL No.
CONTRACTOR
Foreman
Supt.
C710 Beacon Hill Station
Main Shaft
MS-1
Date Excavation Started

Date Excavation Completed
Panel Type
DIMENSIONS
14/06/2004
17/06/2004
18/06/2004
19/06/2004
Date Steel Placed in Excavation

Date Concrete Placed
220X-163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
Y
Y
Y
Y
Y
Y
Lean
Lean
Lean
Lean
Lean
Lean
8.0
8.0
8.5
10.0
10.0
10.0
10.0
12.0
12.0
12.0
10.0
10.0
10.0
10.0
10.0
12.0
12.0
12.0
12.0
12.0
0.0
0.0
0.0
12.0
11.0
12.0
11.0
11.0
12.0
12.0
12.0
11.0
11.0
10.5
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
21
4
181
111
233
292
Width
Depth
Bottom Elev.
Strl Top Elev.
Grade Elev.
Approx 2CY sand removed from base - possible cave-in.

Hydrofraise breakdown afternoon of 6/14. Repaired in
1 hr. Operator reports alignment good.
4-pc rebar cage. Add'l bracing added.
Slurry SG checked at bottom - OK. 12 Baker tanks full.
2 Tremies w/ 10 ft pcs.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
Primary/Closure
DESIGN AS-BUILT
Length
CONSTRUCTION REMARKS (equip., obstructions, delays, etc.)
CONCRETE PLACEMENT DETAILS

QA?
Load Ticket No.
Quantity, CY
ABC Foundations, Inc.
20.83
3.94
181.8
110.2
235
292
ft
ft
ft
ft
ft
ft
VOLUME
Structural Conc.
Lean Conc.
380
184
Tremie Tip Depth
Concrete Depth, ft
End Time
178
178.0
175.0
173.0
170.0
168.0
166.0
162.0
159.0
156.0
153.0
150.0
147.0
145.0
143.0
140.0
137.0
134.0
130.0
127.0
123.0
123.0
123.0
123.0
117.0
113.0
110.0
105.0
103.0
98.0
93.0
87.0
84.0
80.0
76.0
73.0
70.0
66.0
62.0
59.0
55.0
51.0
47.0
43.0
39.0
9:40
9:45
9:45
10:15
10:20
10:22
10:40
11:15
11:20
11:22
11:40
12:15
12:20
12:22
12:40
13:15
13:20
13:22
13:40
14:15
14:20
14:22
14:40
15:15
15:20
15:22
15:40
16:15
15:50
15:52
16:10
16:45
16:20
16:22
16:40
17:15
16:50
17:22
17:40
18:15
17:50
18:22
18:40
19:15
168
158
148
138
128
118
108
98
88
78
68
58
48
Figure 02310.1 Slurry Panel Report Example - Page 1

02310 - 17
384 CY
196 CY
Notes
Truck Rejected
Truck Rejected
Truck Rejected
CONCRETE PLACEMENT DETAILS, CONTINUED

QA?
Load Ticket No.
Quantity, CY
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
208
209
210
211
212
213
214
215
216
217
218
219
Lean
Lean
Lean
Lean
Lean
Lean
Lean
Lean
Lean
Lean
Lean
Lean
Tremie Tip Depth
Concrete Depth, ft
End Time
38
32.0
28.0
23.0
18.0
15.0
12.0
9.0
6.0
4.0
4.0
1.0
0.0
19:22
19:40
19:45
19:50
19:52
20:10
20:15
20:20
20:22
20:40
20:45
20:50
12.0
12.0
12.0
12.0
10.0
10.0
10.0
10.0
10.0
0.0
9.0
5.0
28
18
Notes
Truck Rejected
Concrete Volume Placed

0
50
100
150
200
250
300
350
400
450
500
450
500
200
180
Actual
160
Theoretical
Concrete Depth, ft
140
120
100
80
60
40
20
0
0
50
100
150
200
250
300
350
400
Concrete Volume, CY
REMARKS
Slurry Wall Supt
Contractor's Proj. Mgr
Resident Engineer
Figure 02310.2 Slurry Panel Report Example - Page 2

END OF SECTION
02310 - 18
SECTION 02315
EARTH PRESSURE BALANCE TUNNEL BORING MACHINE
PART 1 GENERAL
1.01
A.
B.
1.02
SCOPE OF WORK
The Work specified in this Section includes, but is not limited to: design, manufacture,
assembly and testing at the manufacturers facility, disassembly, and preparation for transport to
site of a tunnel boring machine (TBM) including backup gantries and ancillary equipment
capable of operating as an Earth Pressure Balance (EPB) TBM, as defined below, and capable
of performing the Work:
1.
In all subsurface conditions expected to be encountered and as described in the GBR.
2.
At progress rates necessary to complete the work within the specified time period.
3.
Within tolerances specified for the line and grade.
The design requirements defined in these Specifications are the minimum design requirements
that shall be met in the design and supply of the TBM.
RELATED SECTIONS
A.
B.
C.
Precast Concrete Tunnel Lining is included in Section 02340.
D.
Compressed Air Working is included in Section 02416.
E.
F.
G.
H.
I.
1.03
REFERENCE STANDARDS
A.
ASTM A36
Standard Specification for Carbon Structural Steel
B.
ASTM A572
Standard Specification for High-Strength Low-Alloy Columbium-Vanadium

Structural Steel
02315 - 1
C.
AWS D1.1
Structural Welding Code
D.
AWS 5.1
Specification for Carbon Steel Electrodes for Shielded Metal Arc Welding
E.
EFNARC
Specification and Guidelines for the Use of Specialist Products for

Mechanised Tunnelling (www.efnarc.org)
F.
NEMA 1WC-3
Rubber Insulated Wire and Cable for the Transmission and Distribution of
electrical energy
G.
NEMA WC-8
Ethylene-Propylene-Rubber-Insulated Wire and Cable for the Transmission

and Distribution of Electrical Energy
H.
NFPA 70
National Electrical Code (NEC)
I.
OSHA
U.S. Department of Labor, Occupational Safety and Health Administration,

Construction Standards and Interpretations, 29 CFR Part 1926 Safety and
Health Regulations for Construction.
1.04
DEFINITIONS
A.
See Section 02330 for general definitions.
B.
Earth Pressure Balance (EPB) type Tunnel Boring Machine (EPB TBM): A TBM with a
pressure bulkhead located behind the face to form an plenum chamber under pressure. The
pressurized medium in the plenum chamber is the ground and groundwater which are modified
by the injection of soil conditioners at the face that are mixed with the contents of the plenum
chamber. The mixture is extracted by means of a screw conveyor in an operation integrated with
the TBM advance to ensure continuous support of the face.
C.
Screw Conveyor: A cased, rotating auger which transports the excavated material and
groundwater, either with or without soil conditioners, from the plenum chamber through the
pressure bulkhead while dissipating pressure at the plenum chamber to atmospheric pressure at
the discharge end of the screw and maintaining pressurization of the excavated material in the
plenum chamber.
D.
Soil Conditioners: Materials such as foam, bentonite slurry, polymers, and supplementary fines,
injected into the TBM plenum chamber to improve the workability of the excavated ground and
groundwater, improve face stability, and reduce wear.
1.05
A.
SUBMITTALS
Submit the following information within 30 days of receipt of the Notice to Proceed (NTP):
1.
TBM Manufacturer qualifications as specified herein.
2.
TBM diameter, excavated diameter, shield length.
3.
Schedules for the design, manufacturing, factory fabrication and testing, dismantling,
and shipment to Site of the TBM and all ancillary systems required to make the
machine fully operational.
02315 - 2
B.
1.
Manufacturer's technical specifications, description, and shop drawings for the TBM
and all ancillary systems. Include the design loads used for the main components,
including cutterhead, main bearing, and propulsion systems, and submit design
calculations including assumptions and maximum load-rating of these components.
The shop drawings shall be to scale and at a scale showing sufficient detail to clearly
demonstrate that all requirements of this Specification are met. There shall be
sufficient vertical and horizontal longitudinal sections at tunnel axis and cross sections
to clearly identify the different components of the TBM, including trailing gear.
Include, as a minimum, the following information:
a.
Name of TBM Manufacturer and model number of TBM.
b.
TBM cutterhead, cutterhead openings, with cutterhead tools, size and

arrangement of tools.
c.
TBM cutterhead drive system. Submit design cutterhead power and torque.
d.
Thrust and steering system. Submit proposed total thrust and jacking
arrangement.
e.
Articulation.
f.
Soil conditioning systems.
g.
Muck extraction and removal systems including methods for dealing with
boulders. Include details of screw conveyor.
h.
Bearings and bearing sealing systems.
i.
Shield tail seals and grease injection system.
j.
Trailing gear arrangement.
k.
TBM guidance system and data acquisition systems including sample display
screens, sample data output, and details of data feed, internet-based systems,
and backup systems.
l.
Segment handling system including segment erector, method of gripping

segments, and the interface of the TBM with the precast segmental lining
system elements.
m.
Equipment for annular grouting of the precast segments.
n.
Drilling, probing and grouting equipment.
o.
Spoil handling areas at the surface.
p.
Compressed air lock systems.
q.
Fire suppression system.
r.
Gas monitoring system.
s.
Services and utilities, such as:

1)
Local TBM Ventilation and equipment.
2)
Electrical equipment and cable.
3)
Piping for water and air supply, and water discharge.

02315 - 3
C.
4)
Construction track.
5)
All other facilities employed in the performance of the work.
2.
Documentation of main bearing and main bearing seal design including calculations
and drawings to demonstrate the design procedure used. The calculations shall contain
the design assumptions used for calculating the specified main bearing life. Include
qualifications of independent design reviewer and statement from bearing
manufacturer that the main bearing is rated for the specified loads and life.
3.
Detailed report with narrative and supporting sketches demonstrating the suitability of
the TBM for tunneling in the ground conditions described in the Contract Documents.
4.
Details of TBM built-in limitations that may automatically trigger a shutdown of the
machine and/or cutterhead rotation.
5.
List and description of required spare parts, giving storage location and condition.
6.
Detailed electrical power characteristics required for the TBM drive and other service
activities including supply facilities and backup supply for power outages.
7.
Description of equipment and methods for replacement of cutterhead seal, tail seal,
and cutterhead tools from within tunnel.
8.
Details of any planned modifications to be made to the cutterhead, cutting tool

configuration, mucking system, or other major equipment modifications to deal with
the ground conditions described in the GBR.
9.
Program for fire prevention and mitigation.
10.
Means and methods for drilling holes for probing ahead of TBM.
11.
Means and methods for drilling holes for ground treatment (pre-excavation grouting)
or spiling.
12.
Written certification from TBM manufacturer of full and complete design

coordination between TBM (shield) manufacturer, trailing gear, lining (segment)
erector manufacturer, and lining manufacturer. Include a written certification by
Contractor and manufacturer(s) affirming the compatibility of TBM with lining,
segment erector, and annular grout injection system.
Submit the following information at least 120 days prior to startup of the TBM:
1.
Soil Conditioners:
a.
Types and quantities of conditioners anticipated to be used in various ground

conditions to be encountered, including treated ground.
b.
Procedures to be used in determining type and quantity of conditioner to be

used and when.
c.
Handling and disposal requirements including impacts on muck handling and

treatment at the surface.
02315 - 4
d.
Mixing methods.
e.
Proposed injection rates.
f.
Quality control program, including quality control tests to be used in the field.
Include a description of those tests and the range of values considered
acceptable for ground conditions anticipated.
2.
Screw conveyor operation and volumetric control of screw conveyor discharge to

maintain target EPB pressures.
3.
Methods for monitoring the rate at which material is excavated and removed from the
face. Method of continuously correlating mucking rate measurements with volumetric
advance rate and recording the results by station.
4.
Description of methods and detailed procedures for replacement of cutterhead seal,

tail seal, and cutterhead tools from within tunnel.
5.
Annular grouting:
a.
Detailed description of grouting systems and operation, including capability for

complete, immediate, and uniform filling of the annular tail void as the TBM
advances.
b.
Description of how the TBM is prevented from advancing when primary

backfill grouting is not being carried out.
c.
Method of measuring grout volumes and pressures.
d.
Equipment and methods to avoid blocking of grout lines.
e.
See additional submittal requirements in Section 02330.
6.
Details of cutterhead tool configurations to be used for mining through shaft walls,
full face rock, mixed-face, soft ground, treated ground, and through other ground
conditions.
7.
Details of the TBM gas detection system, its equipment interlocks, alarms, set points,
and operating logic network diagram. In addition, provide description of calibration
data for gas detection instruments to be provided and procedures for operation.
8.
Details of the mechanisms by which the load distribution pads and the thrust jacks will
be kept in their intended positions on the lining segments to prevent eccentric or
excessive loads being applied to the segments or gaskets creating a potential for
damage.
9.
Details of the air locks, their locking and bulkhead designs, the sealing arrangements,
the life support requirements, and the mechanisms supporting the locks inside the
tunnel. Include a detailed description of procedures for operating the air locks,
effecting compression and decompression, and operating details. See Section 02416
for additional requirements.
10.
Calibration methods for pressure cells in plenum chamber.
11.
Product data and injection system means and methods for tail seal grease.
02315 - 5
D.
E.
F.
1.06
Four weeks prior to shipment of TBM and back-up system:

1.
A report including video footage demonstrating that, in the factory, a fully bolted and
gasketted precast concrete tunnel lining ring can be erected within 30 minutes. The
test shall be performed using a minimum of two full rings.
2.
Preassemble TBM at factory and conduct test of all TBM systems before
disassembling and shipping to Site. Provide Preliminary Testing Certificate following
successful factory testing of the TBM and all subsystems, signed by the TBM
Manufacturer. Inform RE at least 30 days prior to testing of major systems and permit
RE to witness these tests.
3.
Description and detailed procedures for transporting, unloading, and initial assembly
of the TBM at the launching shaft. Launch/start-up, testing and on-site training period
planned to reach routine tunneling progress rates for execution of the work.
4.
Description and detailed procedures for decommissioning, disassembling, and

removing TBM, backup plant, and equipment from the receiving shaft and
demobilization and removal from the site.
Submit the following information, at least 21 days before start of tunneling:

1.
A maintenance plan and schedule for the TBM.
2.
Three complete sets of TBM Manufacturers operations and maintenance manuals and
TBM drawings.
Submit the following information, at least 1 day before start of tunneling:

1.
TBM commissioning report detailing TBM Manufacturers certification that the TBM,
as assembled, meets specification requirements, has been successfully tested, and is
ready for operation.
2.
Manufacturer certification that TBM Operators are qualified to operate, and TBM
Mechanics/Electricians are qualified to maintain and repair the TBM and ancillary
systems, before tunnel excavation commences. Any substitute or additional operators
or mechanics shall also be certified as qualified by the manufacturer.
DELIVERABLES
A.
During manufacture of TBM and back-up system: Weekly progress reports including future
action required to maintain delivery date.
B.
Provide continuous internet access to data acquisition system.
C.
Prior to the commencement of tunnel excavation, and as required during operations, provide
calibration certificates for: gas detection system; pressure cells in plenum chamber; verification
of the TBM Guidance System data performed by means of independent conventional survey;
thrust jacks; and annular grout pressure gauges. Provide these certificates every 30 days during
which TBM tunneling is taking place.
02315 - 6
D.
1.07
A.
B.
Submit all certifications and test results in accordance with Article 1.07 herein.
Qualifications and Training:
1.
TBM Manufacturer: A minimum of ten years experience (or as approved by the RE)
in the design and manufacture of pressurized-face TBMs. It shall have supplied at
least six pressurized-face TBMs of a comparable size (or greater) and type required
for this Project in the last six years.
2.
The TBM Manufacturer shall provide an on-site training course and certification for
all operators and mechanics of the TBM based on the TBM operation and
maintenance manual. Manufacturers recommendations for preventive maintenance
and repairs, and instructions on steering and operating the TBM in the ground
conditions indicated in the GBR and Contract Documents, and ground conditions
disclosed in the GDR shall be covered in the training course.
3.
TBM drawings and calculations shall be signed by an engineer with a minimum prior
experience in responsible design of two TBMs of the type and size to be used in the
Work.
4.
Main bearing and main bearing sealing system design and calculations shall be
independently reviewed and signed by a Professional Engineer licensed in the State of
New York who has been in charge of at least five similar designs.
Access for the Corporation and its Representatives

1.
The Corporation and the RE reserve the right to attend progress meetings between the
Contractor and the TBM Manufacturer.
2.
The Contractor shall ensure that the Corporation and the RE will have unrestricted
access to inspect the TBM and TBM elements.
3.
The Contractor shall make due allowance to permit the Corporation and the RE to
attend the final factory trials and to witness the performance of the segment erector.
C.
Conduct a demonstration test on-site in the presence of Contractor and RE, before launch of the
TBM. Test shall demonstrate functionality of all major hydraulic, mechanical, electrical, soil
conditioning and safety systems. Contractor may choose to demonstrate grout and soil
conditioning systems using water in place of actual construction fluids.
D.
Configure and certify all TBM electrical systems in accordance with the NEC and the
requirements of OSHA 29 CFR 1926, Class I, Division 2.
E.
Certify that hydraulic fluids used on the machine and backup systems are non-flammable or
flame-resistant.
PART 2 PRODUCTS
02315 - 7
2.01
GENERAL
A.
The TBM shall be new.
B.
The TBM shall be capable of excavating and constructing a single pass, gasketted, precast
concrete segmentally lined tunnel of the size, length, and alignment specified in the Contract
Documents. The TBM shall be designed to perform excavation and support successfully within
tolerances specified for line and grade and at progress rates necessary while maintaining face
stability and minimizing ground settlement in the geological conditions described in the GBR
and Contract Documents, during both excavation and stoppages, including sudden loss of
power. The Contractor, based on construction requirements for erecting the specified precast
concrete lining, shall determine the excavated size of the tunnel.
C.
EPB TBM Pressure: The TBM shall be capable of operating in closed mode and maintaining
the range of face pressures in the plenum chamber as calculated by the Contractor in accordance
with the GBR. In any case the TBM shall be capable of operating at a maximum face pressure
of 65 psi. The TBM shall be capable of maintaining the required operating pressure to within
plus or minus 3 psig of the target pressure.
D.
Safety:
E.
1.
A safe working environment shall be provided with visual, and where appropriate,
audible warnings of potential hazards.
2.
Equip the TBM and backup gantries with a pumping and discharge system of
sufficient capacity to handle all water inflows and construction water to maintain safe
working conditions within the TBM and completed tunnel, in particular the segment
erection area. A separate independent backup pumping system that does not operate
from the main TBM power supply shall also be installed for use in emergency
situations.
3.
Provide the TBM and trailing backup with fire detection, alarm, and suppression
systems to extinguish fires, and allow safe egress for all persons from the TBM and
trailing backup. Provide hand-operated fire extinguishers.
4.
Provide emergency stop pull wire along conveyors at all points of hazard.
5.
The TBM shall be equipped with suitable safety systems in accordance with
applicable OSHA requirements for underground construction equipment, including
equipment classified as a Rapid Excavation Machine, and as a minimum that
defined in Section 13000 Tunnel and Shaft Safety.
Access to the plenum chamber: Provide compressed air locks and associated compressed air
equipment designed for the maximum hydrostatic pressure to which the tunnel is exposed but
not less than 3.8 bar (55 psi) air pressure, in accordance with Section 02416 and the following
requirements:
1.
Install a two-man air lock (minimum).
2.
Install at least one separate lock for tools and equipment. Provide feed-throughs into
plenum chamber independent of air lock(s) for electrical power, water supply, fire
02315 - 8
suppression system, high- and low-pressure air, welding and any other service lines
required.
3.
Supply air in sufficient volume to maintain pressure in both the plenum chamber and
ahead of the face during all anticipated operations both.
4.
Provide efficient means of purging the plenum chamber of hazardous gases before
entry. Provide means and methods of verifying such gases are purged before any
personnel are allowed to enter that chamber.
5.
At no time shall cables, hoses or other service lines be trained through air lock
doorways or through unsealed openings in the bulkhead.
6.
The compressed air locks shall be designed either as part of the TBM or to be installed
within the tunnel. If installed within the tunnel, details of special tunnel linings shall
be provided as required in the submittals described herein.
F.
TBM and tunnel lining segments shall be fully compatible, including equipment design and
operation of thrust jacks, annular grouting, shield tail seal and segment erector.
G.
Exterior of TBM shield and cutterhead shall be painted at the TBM Manufacturers facility.
Text, logos and TBM name shall be determined by the RE.
2.02
CUTTERHEAD AND EXCAVATING TOOLS
A.
The TBM cutterhead shall be designed and constructed to withstand all loads and pressures
likely to be encountered during tunneling operations for the required rates of advance along the
tunnel length.
B.
Design TBM to be capable of handling boulders of the sizes indicated in the Contract
Documents, or disclosed in the reference documents.
C.
Design the TBM cutterhead openings to be sized, or to incorporate welded grizzly bars, to limit
the maximum size of boulders and rock/boulder cuttings entering the plenum chamber to the
size that can be dealt with by the screw conveyor.
D.
The TBM cutterhead shall incorporate suitable interchangeable cutting and excavation tools
such as durable disc cutters and ripper teeth/drag bits. Disc cutters shall be capable of cutting
and removing hard materials including boulders, hard layers, rock, and other hard materials as
described in the Contract Documents. Design disc cutter seals and bearings to perform in the
full range of ground conditions indicated in the Contract Documents. Cutterhead tools shall be
replaceable from the rear of the TBM cutterhead i.e. back-loading.
E.
The cutterhead face and rim shall be designed with abrasion resistant features to avoid the need
for majors repairs or re-armoring before completion of the tunnel drive. Design cutting tools for
high abrasion resistance and durability based on anticipated conditions.
F.
The main bearing shall be peripheral and adequately sealed to resist the entry of water and fine
material. The TBM cutterhead shall incorporate a system to permit continuous monitoring of
the lubricant pressure and purity in the main bearing and main bearing seals, with the facility to
totally purge and replace the lubricants should they become contaminated. Loss of pressure
02315 - 9
from the main bearing seal shall immediately initiate an automatic shutdown of the TBM. The
design life of the main bearing shall be not less than 10,000 hours with a sealing system
providing protection for the same period. The bearing seals shall be designed for all tunneling
conditions and maximum pressures anticipated from the sum of all forces acting on the seals
simultaneously and shall be replaceable from the rear of the machine.
G.
Equip TBM with a minimum of five pressure cells to monitor pressure in plenum chamber.
Pressure cells are to be located at the invert, springline (or axis), and at the crown. Provide a
minimum of four pressure cells to monitor pressure along the screw conveyor. Pressure cells
shall be replaceable during TBM stoppages. When the pressure drops below a level determined
in the submitted method statement (see Section 02330), the TBM Operator shall receive an
audible and visual alarm, and the event shall be recorded by the data acquisition system.
H.
Soil Conditioners:
2.03
1.
Provide conditioners to stabilize face and improve muck workability under all
conditions described in the Contract Documents. Water shall not be considered a
conditioner.
2.
Provide TBM with conditioner injection system to condition the muck as required, and
to prevent excavated material from adhering to and clogging the plenum chamber,
muck passages, or other parts of the TBM. Locate at least five ports on the cutterhead
for injection into the face. Provide additional ports in the plenum chamber and at least
four ports along the screw conveyor. Each port shall be protected from abrasion, and
shall be fed by an independent pump line.
3.
Provide conditioners capable of providing a minimum four-inch slump for working

consistency of material in plenum chamber at the point of discharge onto the
conveyor.
SHIELDS
A.
The TBM shield shall be designed and constructed to withstand all loads and pressures likely to
be encountered during the tunneling operations. All metal work shall be protected to minimize
deterioration due to abrasion based on anticipated conditions.
B.
The TBM shall be provided with ports to enable pressurized injection of bentonite or other
lubricants full-circle through the shield to reduce skin friction, if needed.
C.
A minimum of three rows of grease-fed wire-brush tail seals shall be provided between the last
ring built and the rear shield and shall be effective over the full range of grout injection and
hydrostatic pressures. The rear shield shall have sufficient length to give an adequate overlap on
the last ring built, to provide enough space in the ring-build area to install segments with dowels
in the circumferential joints, and to ensure that the tail seals are fully engaged on the last ring
built after advancing. Tail seals other than the rear seal shall be replaceable from within the
tunnel.
D.
The shield shall be designed to accommodate annular grouting system through the tail shield as
specified in this Section. Seals shall be provided on the outside of the rear shield to prevent
grout moving forwards towards the TBM cutterhead.
02315 - 10
E.
Provide anti-rolling system to prevent rotation of shield.
F.
If the shield incorporates an articulation joint to aid in steering:
2.04
1.
Equip the articulation joint with a seal, replaceable from within the TBM, to prevent
the entry of soil conditioners, grout, fines, or other foreign material at the maximum
anticipated hydrostatic and earth pressures. Provide a means for cleaning the
articulation joint from within the TBM to maintain its full range of articulation.
2.
Record extension of articulation cylinders via data acquisition system.
THRUST AND DRIVE SYSTEM
A.
Provide adequate drive motor horsepower so that the machine is not torque limited while
operating in all ground conditions expected as described in the GBR.
B.
The machine shall be capable of applying 1.5 times full rated torque at startup, or after
shutdown for any reason, during possible jammed or stalled cutterhead conditions. Provide
clutches or a hydraulic assist for an electric drive or use a variable speed hydraulic drive system.
C.
Provide a thrust system that can advance the machine by thrust cylinders that react against the
installed segmental liner to achieve the required instantaneous penetration rates necessary to
complete the tunnel within the scheduled time under the combined reaction from maximum
earth and hydrostatic pressure, shield friction, maximum face stabilization load, and loading
caused by discs or other excavation tools.
D.
Provide jack shoes or partial jack rings, articulated shoes, or pads consistent with the segmental
lining design and as required to distribute the thrust loads to the segmental lining without
damaging the liner. Thrust pads shall not bear on or damage segmental liner gaskets. The
maximum thrust contact pressure at any point and at any time on the liner system shall not
exceed 3000 psi (measured by dividing the thrust of the jack by the area of bearing surface on
the concrete segment).
E.
Provide thrust cylinders capable of individual actuation, synchronized actuation, and individual
thrust pressure control. Thrust cylinders shall incorporate displacement monitors and shall not
permit displacement when idle, or during a loss of power. The thrust cylinder stroke must allow
the installation of segments with dowel connectors on the circumferential joints.
F.
TBM drive system shall operate the cutterhead equally in either direction of rotation (bidirectional).
2.05
A.
MUCK SYSTEM
Fit and operate a screw conveyor to remove excavated material from the plenum chamber.
Design the screw conveyor with abrasion resistant features for operation in soil conditions as
described in the GBR and the GDR, and for efficient replacement from within the tunnel. Belt
conveyor feeding from the plenum chamber will not be acceptable for operating in pressurized
mode.
02315 - 11
B.
The front of screw conveyor shall project into chamber when operating. The screw shall be
capable of being withdrawn for maintenance and the front bulkhead door closed against
maximum hydrostatic and earth pressure.
C.
Design the screw conveyor to be capable of being closed and sealed against maximum
hydrostatic and earth pressure at each end (both front and rear). Fit the rear end with a positive
displacement pump device that can be activated immediately when pressurized spoil reaches the
discharge end of the screw conveyor, and works reliably for the ground conditions detailed in
the Contract Documents. The positive displacement pump device shall be readily maintained or
replaced from within the tunnel. Also fit the discharge end of the screw with a hydraulically
controlled gate that can be closed when required, including in the event of a power failure.
D.
While face pressure is to be generated by the thrust system, design the screw conveyor to
maintain the required face pressure within the plenum chamber and the entrance to the screw
conveyor. The EPB TBM shall be capable of controlling face pressure to within plus or minus
3-psi of the desired pressure at all times. Reduce pressure to atmospheric at the screw exit by
proper soil conditioning, control of the screw conveyor, and the pressure lock out device.
E.
Equip TBM with two weight-scales and a volumetric scanner integrated into the discharge (nonextendable) conveyor. Weight scales and scanner shall be linked into data acquisition system,
which shall give audible and visual warning if extracted weight or volume for any ring advance
exceeds a value determined in the submitted Work Plan. Install a closed circuit television
(CCTV) system on the discharge conveyors (screw and belt). Use the CCTV system to
continuously monitor and record the quantity and consistency of the excavated material from
the TBM operation control center and from Contractors TBM performance monitoring surface
location.
F.
Provide multiple mixing bars within the plenum chamber to condition muck uniformly. Arms
shall be spaced to avoid any jamming.
G.
Calibrate pressure cells as recommended by supplier or as needed to assure accuracy of pressure

measurements.
H.
Use a conveyor or rail system for muck transport in the tunnel. Design the system selected for
materials with abrasive fines and high water content, rock fragments, cobbles and other
conditions as described in the GBR and the GDR.
2.06
A.
2.07
COMPRESSED AIR FACILITIES

See section 02416.
SEGMENT ERECTOR AND SEGMENT FEEDER
A.
Design segment erector and segment feeder to be compatible with one another and the TBM
and lining system to ensure safe and efficient segment installation.
B.
The segment erector mechanism shall be capable of picking up, accurately locating, and placing
the segments used safely in the required orientation to the tolerances stated in the Specifications
without damage to the segments or gaskets. The segment erector mechanism shall be designed
to provide sufficient force to compress the gaskets.
02315 - 12
C.
The erector mechanism shall be capable of removing damaged or misaligned or incorrect

segments prior to completion of the ring and within the first 12-inches of shove. The erector
shall be capable of being actuated in the axial, radial, and circumferential directions and in the
three articulation angles corresponding to the six degrees of freedom.
D.
Segment lifting operations shall be either by vacuum or by engaging embedded lifting sockets.
A safety device to ensure that segments cannot be released during handling shall be
incorporated. Segment lifting and handling systems must be capable of holding a segment
securely in position in the event of a power failure.
E.
The segment feeder system shall be designed and constructed so that the segments are supplied
at the rate and orientation to suit the erector.
2.08
TBM GUIDANCE SYSTEM AND DATA ACQUISITION SYSTEM
A.
Equip and operate the TBM with a computerized guidance system capable of accurately
following the planned alignment and continuously recording TBM position, elevation, and
attitude.
B.
Design the guidance system to calculate and provide continuous data in real-time for every
segment ring along the tunnel centerline including:
1.
Design centerline station, coordinates, and elevation.
2.
As-driven station, coordinates, elevation, and attitude (yaw, tilt, and roll).
3.
Horizontal and vertical offsets from design tunnel centerline to the driven tunnel
centerline.
4.
Horizontal and vertical attitude of TBM.
5.
Forecast position of the TBM for each of the next ten rings.
6.
Forecast ring orientation for each of the next ten rings.
7.
As-built ring orientation.
C.
The information shall be graphically displayed to the TBM Operator at all times on an
electronic display terminal. Display modes shall read to 0.05 inch and 0.01 degrees accuracy.
D.
Equip the guidance system with an alarm to alert the TBM Operator in the event that the driven
tunnel exceeds or is projected to exceed tolerances and provide the capability to forecast the
composition and orientation of the subsequent ten rings to get back on target.
E.
Design guidance system to interface with: individual controls for thrust ram pressures and
extensions; cutterhead; and shield articulation (if installed).
F.
Provide data acquisition system that shall transmit and record data in real-time to an internetbased system which shall be accessible to the RE, for unlimited users. Real-time shall mean that
the time lag from which the data is generated to being accessible on the internet-based system is
no greater than one minute. Process and generate, automatically by computer, separate plots of
all parameters of TBM performance that shall be available on the internet-based system. Use
02315 - 13
automatic recording systems for data collection that provide access to all historical data. The
data feed, generated output, and the database shall be in a format to be approved by the RE.
G.
Data acquisition system shall continuously collect and store information for each shove or
stroke of the TBM, including but not limited to:
1.
Date, time, and tunnel station at start of shove, and duration and length of shove.
2.
Time lining erection started and finished and ring orientation.
3.
All TBM guidance system data as specified herein.
4.
TBM cutterhead direction, torque, and speed
5.
Screw conveyor torque and speed and discharge gate position.
6.
Drive motor power consumption.
7.
Total thrust force and extension of thrust rams.
8.
Instantaneous advance rate of TBM during shove.
9.
Mucking rate, volume, and weight of excavated material.
10.
Main bearing lubrication pressure, flow, and temperature.
11.
Segment grouting pressures and volumes by port.
12.
Electrical power consumption and motor temperature.
13.
Pressures on the cutterhead, in the plenum chamber, and in the screw conveyor,
measured by each installed pressure cell.
14.
Conditioning agent injection rates, pressures and volumes.
15.
Annular bentonite injection pressures, volumes and injection rates, per injection port.
16.
Mode of operation.
17.
Opening angle and location of maximum opening of articulation joint (if installed).
H.
Data shall be backed up to a remote location at least once every 24 hours. Backup system shall
permit all historical data to be retrieved.
I.
Repair or replace the data acquisition system within 24 hours should it not be functioning
correctly.
2.09
A.
PROBE DRILLING AND GROUND TREATMENT CAPABILITIES

Provide drilling ports and drilling and grouting equipment capable of probing, spiling, and
ground treatment to a minimum of 50 feet ahead of the excavation face at maximum hydrostatic
and earth pressure, including:
02315 - 14
1.
Drilling and ground treatment through the cutterhead.
2.
Drilling and ground treatment through the shield.
3.
Means and equipment to control ground and groundwater inflow during drilling,
spiling and grouting operations and to seal the ports when not in use.
B.
Provide sufficient number of ports around the TBM shield to permit a zone of ground ahead of
the TBM to be stabilized.
C.
Provide drilling equipment which can be mounted in the TBM rear shield.
2.10
ANNULAR GROUTING EQUIPMENT
A.
Provide equipment for mixing, transporting, and injecting a suspension grout into the void
between lining and ground in a continuous flow at a rate that will keep the annular gap
completely filled concurrent with the maximum expected advance rate of the TBM while
maintaining the required grout pressure.
B.
The grout shall be injected through the TBM tail shield unless otherwise approved by the RE.
The number of grout pipes shall be compatible with the mobility of the grout mix. The system
shall include flushing capability and/or redundancy in the number of pipes to account for pipe
blockages.
C.
Grouting equipment shall include an accurate measuring device capable of measuring volume of
grout injected in cubic yards to the nearest one-hundredth of a cubic yard. Annular grouting
equipment shall be capable of measuring the amount of grout per injection port and the
cumulative total per ring.
D.
Provide suitable stop valves at each grout injection port to maintain pressure in grouted zone as
required until grout has set. Provide an automatic bypass valve to avoid exceeding the design
grout pressure. Install pressure gauges to indicate pressure at pump and at point of injection.
Provide pressure, volume-sensing, and transmission equipment for connection to TBM data
acquisition system.
E.
Provide automatic interlock to prevent advance of the TBM until the annular grout system is
operational and is providing the required grout during the advance.
F.
Provide drilling equipment and staging off the TBM trailing gear capable of drilling holes
through the segments to enable proof grouting through the lining at any position around the
ring.
G.
Provide proof grouting equipment compatible with the proof drilling equipment to allow
mixing, storing, and pumping of grout through the lining at the pressures given in Section
02330.
2.11
A.
GAS DETECTION AND VENTILATION EQUIPMENT

Provide the TBM with local auxiliary ventilation to allow a continuous and sufficient supply of
fresh air to the areas of the TBM that are occupied by personnel. Provide airflow quantities that
conform to OSHA 29 CFR 1926. The main tunnel ventilation and local auxiliary ventilation
02315 - 15
shall overlap so that fresh air is provided right up to the back of the TBM bulkhead. Provide
ventilation systems with reversible fans for fresh air supply and exhausting to meet the
requirements specified herein.
B.
Provide built-in equipment to continuously monitor noxious gases, explosive gases and oxygen
concentrations as required by OSHA 29 CFR 1926 and to give audible and visual warning of if
gas levels are outside threshold limits. Monitoring point positions shall include the TBM
plenum chamber and the discharge systems.
C.
Equip the TBM with a power interruption system that will automatically shut down power to
the TBM drive system upon detection of levels of hazardous and/or explosive gasses in excess
of OSHA standards. Design this power interruption system so that TBM maintains face
pressure and so that power for lighting, compressed air, pumping, ventilation and other safety
critical systems are not shut down.
2.12
A.
ESSENTIAL SPARES
Provide replacement parts or maintenance materials for all systems. One of each item (or group
of items) is required to be stored on-site, unless a greater number is recommended by the TBM
manufacturer. Items stored on Site shall include all items with lead times greater than two days,
and the following:
1.
Parts and materials in accordance with the Contractors maintenance plan, and TBM
and ancillary systems manufacturers recommendations. Maintain an inventory and a
location for all such parts and materials shall be maintained.
2.
One complete set of excavation tools (discs, picks/drag bits, and other cutters) on Site
and at all times. One set consists of complete replacement of all tools on one
cutterhead for all remaining configurations of excavation tools indicated in the
Contractors submittals.
3.
Hydraulic jacks, hydraulic hoses, and components.
4.
Seals, o-rings, and gaskets.
5.
Electrical and mechanical components.
6.
Two spare main drive units including pinions, gearboxes, and motors.
7.
Spare parts or a replacement system for the TBM Guidance System.
8.
Grout pump for annular grouting.
9.
One spare screw conveyor.
B.
Immediately reorder and replace into storage any replacement part that is used, lost, or is no
longer fit for purpose without delay.
C.
One spare main bearing assembly and seals shall be available for replacement of the
corresponding parts provided with each TBM. These spares shall be available for the duration
of TBM excavation, and shall be deliverable to the Work Site within one week. The spare parts
02315 - 16
may be previously used provided they are rebuilt, in as-new condition, fully compatible with the
TBM, and so certified in writing by original TBM Manufacturer.
PART 3 EXECUTION
3.01
A.
GENERAL
Execution is covered under Section 02330 Tunneling by Tunnel Boring Machine.
END OF SECTION
02315 - 17
SECTION 02316
SLURRY TUNNEL BORING MACHINE
PART 1 GENERAL
1.01
A.
SCOPE OF WORK
The Work specified in this Section includes, but is not limited to: design, manufacture,
assembly and testing at the manufacturers facility, disassembly, and preparation for transport to
site of a tunnel boring machine (TBM) including backup gantries and ancillary equipment
capable of operating as slurry TBM, as defined below, and capable of performing the Work:
1.
In all subsurface conditions expected to be encountered and as described in the GBR.
2.
At progress rates necessary to complete the work within the specified time period.
3.
Within tolerances specified for the line and grade.
B.
Design and furnishing of slurry treatment plant.
C.
The design requirements defined in these Specifications are the minimum design requirements
that shall be met in the design and supply of the TBM.
1.02
RELATED SECTIONS
A.
B.
C.
D.
Compressed Air Working is included in Section 02416.
E.
F.
G.
H.
I.
1.03
REFERENCE STANDARDS
A.
ASTM A36
B.
ASTM A572
Standard Specification for High-Strength Low-Alloy Columbium-Vanadium

Structural Steel
02316 - 1
C.
AWS D1.1
D.
AWS 5.1
Specification for Carbon Steel Electrodes for Shielded Metal Arc Welding
E.
EFNARC

F.
NEMA 1WC-3
Rubber Insulated Wire and Cable for the Transmission and Distribution of
electrical energy
G.
NEMA WC-8
Ethylene-Propylene-Rubber-Insulated Wire and Cable for the Transmission

and Distribution of Electrical Energy
H.
NFPA 70
National Electrical Code (NEC)
I.
OSHA

Health Regulations for Construction.
1.04
DEFINITIONS
A.
See Section 02330 for general definitions.
B.
Slurry type Tunnel Boring Machine (Slurry TBM): A TBM with a pressure bulkhead located
behind the face to form an plenum chamber under pressure. Bentonite slurry and/or or other
liquid medium is introduced into the plenum chamber under controlled pressure to stabilize the
face and to be mixed with material excavated by the rotary cutterhead. The resultant slurry,
with cuttings, is removed by pumping in an operation integrated with TBM advance. At the
surface a slurry separation plant removes the excavated material from suspension in the slurry
for disposal and cleans the slurry for reuse.
1.05
A.
B.
SUBMITTALS
1.
TBM Manufacturer qualifications as specified herein.
2.
TBM diameter, excavated diameter, shield length.
3.
Schedules for the design, manufacturing, factory fabrication and testing, dismantling,
and shipment to Site of the TBM and all ancillary systems required to make the
machine fully operational.
1.
Manufacturer's technical specifications, description, and shop drawings for the TBM
and all ancillary systems. Include the design loads used for the main components,
including cutterhead, main bearing, and propulsion systems, and submit design
calculations including assumptions and maximum load-rating of these components.
The shop drawings shall be to scale and at a scale showing sufficient detail to clearly
demonstrate that all requirements of this Specification are met. There shall be
sufficient vertical and horizontal longitudinal sections at tunnel axis and cross sections
02316 - 2
to clearly identify the different components of the TBM, including trailing gear.
Include, as a minimum, the following information:
2.
a.
Name of TBM Manufacturer and model number of TBM.
b.
TBM cutterhead, cutterhead openings, with cutterhead tools, size and

arrangement of tools.
c.
TBM cutterhead drive system. Submit design cutterhead power and torque.
d.
Thrust and steering system. Submit proposed total thrust and jacking
arrangement.
e.
Articulation.
f.
Slurry injection, control and handling systems.
g.
Spoil and slurry extraction and removal systems including methods for dealing
with boulders.
h.
Bearings and bearing sealing systems.
i.
Shield tail seals and grease injection system.
j.
Trailing gear arrangement.
k.
TBM guidance system and data acquisition systems including sample display
screens, sample data output, and details of data feed, internet-based systems,
and backup systems.
l.
Segment handling system including segment erector, method of gripping

segments, and the interface of the TBM with the precast segmental lining
system elements.
m.
Equipment for annular grouting of the precast segments.
n.
Drilling, probing and grouting equipment.
o.
Spoil and slurry treatment facility including separation plants.
p.
Compressed air lock systems.
q.
Fire suppression system.
r.
Gas monitoring system.
s.
Services and utilities, such as:

1)
Local TBM Ventilation and equipment.
2)
Electrical equipment and cable.
3)
Piping for water and air supply, and water discharge.
4)
Construction track.
5)
All other facilities employed in the performance of the work.
Documentation of main bearing and main bearing seal design including calculations
and drawings to demonstrate the design procedure used. The calculations shall contain
the design assumptions used for calculating the specified main bearing life. Include
qualifications of independent design reviewer and statement from bearing
manufacturer that the main bearing is rated for the specified loads and life.
02316 - 3
C.
3.
Detailed report with narrative and supporting sketches demonstrating the suitability of
the TBM for tunneling in the ground conditions described in the Contract Documents.
4.
Details of TBM built-in limitations that may automatically trigger a shutdown of the
machine and/or cutterhead rotation.
5.
List and description of required spare parts, giving storage location and condition.
6.
Detailed electrical power characteristics required for the TBM drive and other service
activities including supply facilities and backup supply for power outages.
7.
Description of equipment and methods for replacement of cutterhead seal, tail seal,
and cutterhead tools from within tunnel.
8.
Details of any planned modifications to be made to the cutterhead, cutting tool

configuration, mucking system, or other major equipment modifications to deal with
the ground conditions described in the GBR.
9.
Program for fire prevention and mitigation.
10.
Means and methods for drilling holes for probing ahead of TBM.
11.
Means and methods for drilling holes for ground treatment (pre-excavation grouting)
or spiling.
12.
Written certification from TBM manufacturer of full and complete design

coordination between TBM (shield) manufacturer, trailing gear, lining (segment)
erector manufacturer, and lining manufacturer. Include a written certification by
Contractor and manufacturer(s) affirming the compatibility of TBM with lining,
segment erector, and annular grout injection system.
Submit the following information at least 120 days prior to startup of the TBM:
1.
2.
Description and detailed procedures for Slurry Treatment Plant including:

a.
Details of slurry treatment plant and of treatment plant operations. Include

processing rate of the slurry treatment plant for various ground conditions to be
encountered.
b.
Disposal of slurry and conditioners.
c.
Plant capabilities relative to anticipated ground conditions including treated

ground.
d.
Use and treatment of bentonite, polymers, chemical flocculants, and other

additives.
e.
Quality control testing program for slurry including a description of required

tests and range of values considered acceptable for ground conditions
anticipated for each tested parameter.
Methods for monitoring the rate at which material is excavated and removed from the
face. Method of continuously correlating mucking rate measurements with volumetric
advance rate and recording the results by station.
02316 - 4
D.
3.
Description of methods and detailed procedures for replacement of cutterhead seal,

tail seal, and cutterhead tools from within tunnel.
4.
Annular grouting:
a.
Detailed description of grouting systems and operation, including capability for

complete, immediate, and uniform filling of the annular tail void as the TBM
advances.
b.
Description of how the TBM is prevented from advancing when primary

backfill grouting is not being carried out.
c.
Method of measuring grout volumes and pressures.
d.
Equipment and methods to avoid blocking of grout lines.
e.
See additional submittal requirements in Section 02330.
5.
Details of cutterhead tool configurations to be used for mining through shaft walls,
full face rock, mixed-face, soft ground, treated ground, and through other ground
conditions.
6.
Details of the TBM gas detection system, its equipment interlocks, alarms, set points,
and operating logic network diagram. In addition, provide description of calibration
data for gas detection instruments to be provided and procedures for operation.
7.
Details of the mechanisms by which the load distribution pads and the thrust jacks will
be kept in their intended positions on the lining segments to prevent eccentric or
excessive loads being applied to the segments or gaskets creating a potential for
damage.
8.
Details of the air locks, their locking and bulkhead designs, the sealing arrangements,
the life support requirements, and the mechanisms supporting the locks inside the
tunnel. Include a detailed description of procedures for operating the air locks,
effecting compression and decompression, and operating details. See Section 02416
for additional requirements.
9.
Calibration methods for pressure cells in plenum chamber.
10.
Product data and injection system means and methods for tail seal grease.
Four weeks prior to shipment of TBM and back-up system:

1.
A report including video footage demonstrating that, in the factory, a fully bolted and
gasketted precast concrete tunnel lining ring can be erected within 30 minutes. The
test shall be performed using a minimum of two full rings.
2.
Preassemble TBM at factory and conduct test of all TBM systems before
disassembling and shipping to Site. Provide Preliminary Testing Certificate following
successful factory testing of the TBM and all subsystems, signed by the TBM
Manufacturer. Inform RE at least 30 days prior to testing of major systems and permit
RE to witness these tests.
02316 - 5
E.
F.
1.06
3.
Description and detailed procedures for transporting, unloading, and initial assembly
of the TBM at the launching shaft. Launch/start-up, testing and on-site training period
planned to reach routine tunneling progress rates for execution of the work.
4.
Description and detailed procedures for decommissioning, disassembling, and

removing TBM, backup plant, slurry separation plant, and equipment from the
receiving shaft and demobilization and removal from the site.
Submit the following information, at least 21 days before start of tunneling:

1.
A maintenance plan and schedule for the TBM.
2.
Three complete sets of TBM Manufacturers operations and maintenance manuals and
TBM drawings.
3.
Three complete sets of manufacturers operations and maintenance manuals and

drawings for the slurry treatment plant.
Submit the following information, at least 1 day before start of tunneling:

1.
TBM commissioning report detailing TBM Manufacturers certification that the TBM,
as assembled, meets specification requirements, has been successfully tested, and is
ready for operation.
2.
Manufacturers certification that the slurry treatment plant, as assembled, meets

specification requirements, has been successfully tested, and is ready for operation.
3.
Manufacturer certification that TBM Operators are qualified to operate, and TBM
Mechanics/Electricians are qualified to maintain and repair the TBM and ancillary
systems, before tunnel excavation commences. Any substitute or additional operators
or mechanics shall also be certified as qualified by the manufacturer.
DELIVERABLES
A.
During manufacture of TBM and back-up system: Weekly progress reports including future
action required to maintain delivery date.
B.
Provide continuous internet access to data acquisition system.
C.
calibration certificates for: gas detection system; pressure cells in plenum chamber; verification
of the TBM Guidance System data performed by means of independent conventional survey;
thrust jacks; and annular grout pressure gauges. Provide these certificates every 30 days during
which TBM tunneling is taking place.
D.
Submit all certifications and test results in accordance with Article 1.07 herein.
1.07
A.
Qualifications and Training:
02316 - 6
B.
1.
TBM Manufacturer: A minimum of ten years experience (or as approved by the RE)
in the design and manufacture of pressurized-face TBMs. It shall have supplied at
least six pressurized-face TBMs of a comparable size (or greater) and type required
for this Project in the last six years.
2.
The TBM Manufacturer shall provide an on-site training course and certification for
all operators and mechanics of the TBM based on the TBM operation and
maintenance manual. Manufacturers recommendations for preventive maintenance
and repairs, and instructions on steering and operating the TBM in the ground
conditions indicated in the GBR and Contract Documents, and ground conditions
disclosed in the GDR shall be covered in the training course.
3.
TBM drawings and calculations shall be signed by an engineer with a minimum prior
experience in responsible design of two TBMs of the type and size to be used in the
Work.
4.
Main bearing and main bearing sealing system design and calculations shall be
independently reviewed and signed by a Professional Engineer licensed in the State of
New York who has been in charge of at least five similar designs.
Access for the Corporation and its Representatives

1.
The Corporation and the RE reserve the right to attend progress meetings between the
Contractor and the TBM Manufacturer.
2.
The Contractor shall ensure that the Corporation and the RE will have unrestricted
access to inspect the TBM and TBM elements.
3.
The Contractor shall make due allowance to permit the Corporation and the RE to
attend the final factory trials and to witness the performance of the segment erector.
C.
Conduct a demonstration test on-site in the presence of Contractor and RE, before launch of the
TBM. Test shall demonstrate functionality of all major hydraulic, mechanical, electrical, slurry
and safety systems. Contractor may choose to demonstrate grout and slurry systems using water
in place of actual construction fluids.
D.
Configure and certify all TBM electrical systems in accordance with the NEC and the
requirements of OSHA 29 CFR 1926, Class I, Division 2.
E.
Certify that hydraulic fluids used on the machine and backup systems are non-flammable or
flame-resistant.
PART 2 PRODUCTS
2.01
GENERAL
A.
The TBM shall be new.
B.
The TBM shall be capable of excavating and constructing a single pass, gasketted, precast
concrete segmentally lined tunnel of the size, length, and alignment specified in the Contract
02316 - 7
Documents. The TBM shall be designed to perform excavation and support successfully within
tolerances specified for line and grade and at progress rates necessary while maintaining face
stability and minimizing ground settlement in the geological conditions described in the GBR
and Contract Documents, during both excavation and stoppages, including sudden loss of
power. The Contractor, based on construction requirements for erecting the specified precast
concrete lining, shall determine the excavated size of the tunnel.
C.
Slurry TBM Pressure: The TBM shall be capable of operating in closed slurry mode and
maintaining the range of face pressures in the plenum chamber as calculated by the Contractor
in accordance with the GBR. In any case the TBM shall be capable of operating at a maximum
face pressure of 65 psi. The TBM shall be capable of maintaining the required operating
pressure to within plus or minus 3 psig of the target pressure.
D.
Safety:
E.
1.
A safe working environment shall be provided with visual, and where appropriate,
audible warnings of potential hazards.
2.
Equip the TBM and backup gantries with a pumping and discharge system of
sufficient capacity to handle all water inflows and construction water to maintain safe
working conditions within the TBM and completed tunnel, in particular the segment
erection area. A separate independent backup pumping system that does not operate
from the main TBM power supply shall also be installed for use in emergency
situations.
3.
Provide the TBM and trailing backup with fire detection, alarm, and suppression
systems to extinguish fires, and allow safe egress for all persons from the TBM and
trailing backup. Provide hand-operated fire extinguishers.
4.
The TBM shall be equipped with suitable safety systems in accordance with
applicable OSHA requirements for underground construction equipment, including
equipment classified as a Rapid Excavation Machine, and as a minimum that
defined in Section 13000 Tunnel and Shaft Safety.
Access to the plenum chamber: Provide compressed air locks and associated compressed air
equipment designed for the maximum hydrostatic pressure to which the tunnel is exposed but
not less than 3.8 bar (55 psi) air pressure, in accordance with Section 02416 and the following
requirements:
1.
Install a two-man air lock (minimum).
2.
Install at least one separate lock for tools and equipment. Provide feed-throughs into
plenum chamber independent of air lock(s) for electrical power, water supply, fire
suppression system, high- and low-pressure air, welding and any other service lines
required.
3.
Supply air in sufficient volume to maintain pressure in both the plenum chamber and
ahead of the face during all anticipated operations both.
02316 - 8
4.
Provide efficient means of purging the plenum chamber of hazardous gases before
entry. Provide means and methods of verifying such gases are purged before any
personnel are allowed to enter that chamber.
5.
At no time shall cables, hoses or other service lines be trained through air lock
doorways or through unsealed openings in the bulkhead.
6.
The compressed air locks shall be designed either as part of the TBM or to be installed
within the tunnel. If installed within the tunnel, details of special tunnel linings shall
be provided as required in the submittals described herein.
F.
TBM and tunnel lining segments shall be fully compatible, including equipment design and
operation of thrust jacks, annular grouting, shield tail seal and segment erector.
G.
Exterior of TBM shield and cutterhead shall be painted at the TBM Manufacturers facility.
Text, logos and TBM name shall be determined by the RE.
2.02
CUTTERHEAD AND EXCAVATING TOOLS
A.
The TBM cutterhead shall be designed and constructed to withstand all loads and pressures
likely to be encountered during tunneling operations for the required rates of advance along the
tunnel length.
B.
Design TBM to be capable of handling boulders of the sizes indicated in the Contract
Documents, or disclosed in the reference documents.
C.
Design the TBM cutterhead openings to be sized, or to incorporate welded grizzly bars, to limit
the maximum size of boulders and rock/boulder cuttings entering the plenum chamber to the
size that can be dealt with by the rock crusher.
D.
The TBM cutterhead shall incorporate suitable interchangeable cutting and excavation tools
such as durable disc cutters and ripper teeth/drag bits. Disc cutters shall be capable of cutting
and removing hard materials including boulders, hard layers, rock, and other hard materials as
described in the Contract Documents. Design disc cutter seals and bearings to perform in the
full range of ground conditions indicated in the Contract Documents. Cutterhead tools shall be
replaceable from the rear of the TBM cutterhead i.e. back-loading.
E.
The cutterhead face and rim shall be designed with abrasion resistant features to avoid the need
for majors repairs or re-armoring before completion of the tunnel drive. Design cutting tools for
high abrasion resistance and durability based on anticipated conditions.
F.
Provide a compressed air reservoir that controls slurry pressure in the plenum chamber and
automatically compensates for fluctuations in support pressure.
G.
The main bearing shall be peripheral and adequately sealed to resist the entry of water and fine
material. The TBM cutterhead shall incorporate a system to permit continuous monitoring of
the lubricant pressure and purity in the main bearing and main bearing seals, with the facility to
totally purge and replace the lubricants should they become contaminated. Loss of pressure
from the main bearing seal shall immediately initiate an automatic shutdown of the TBM. The
design life of the main bearing shall be not less than 10,000 hours with a sealing system
providing protection for the same period. The bearing seals shall be designed for all tunneling
02316 - 9
conditions and maximum pressures anticipated from the sum of all forces acting on the seals
simultaneously and shall be replaceable from the rear of the machine.
H.
2.03
Equip TBM with a minimum of five pressure cells to monitor pressure in plenum chamber.
Pressure cells are to be located at the invert, springline (or axis), and at the crown. Pressure
cells shall be replaceable during TBM stoppages. When the face pressure drops below a level
determined in the submitted method statement (see Section 02330), the TBM Operator shall
receive an audible and visual alarm, and the event shall be recorded by the data acquisition
system.
SHIELDS
A.
The TBM shield shall be designed and constructed to withstand all loads and pressures likely to
be encountered during the tunneling operations. All metal work shall be protected to minimize
deterioration due to abrasion based on anticipated conditions.
B.
The TBM shall be provided with ports to enable pressurized injection of bentonite or other
lubricants full-circle through the shield to reduce skin friction, if needed.
C.
A minimum of three rows of grease-fed wire-brush tail seals shall be provided between the last
ring built and the rear shield and shall be effective over the full range of grout injection and
hydrostatic pressures. The rear shield shall have sufficient length to give an adequate overlap on
the last ring built, to provide enough space in the ring-build area to install segments with dowels
in the circumferential joints, and to ensure that the tail seals are fully engaged on the last ring
built after advancing. Tail seals other than the rear seal shall be replaceable from within the
tunnel.
D.
The shield shall be designed to accommodate annular grouting system through the tail shield as
specified in this Section. Seals shall be provided on the outside of the rear shield to prevent
grout moving forwards towards the TBM cutterhead.
E.
Provide anti-rolling system to prevent rotation of shield.
F.
If the shield incorporates an articulation joint to aid in steering:
2.04
1.
Equip the articulation joint with a seal, replaceable from within the TBM, to prevent
the entry of slurry, grout, fines, or other foreign material at the maximum anticipated
hydrostatic and earth pressures. Provide a means for cleaning the articulation joint
from within the TBM to maintain its full range of articulation.
2.
Record extension of articulation cylinders via data acquisition system.
THRUST AND DRIVE SYSTEM
A.
Provide adequate drive motor horsepower so that the machine is not torque limited while
operating in all ground conditions expected as described in the GBR.
B.
The machine shall be capable of applying 1.5 times full rated torque at startup, or after
shutdown for any reason, during possible jammed or stalled cutterhead conditions. Provide
clutches or a hydraulic assist for an electric drive or use a variable speed hydraulic drive system.
02316 - 10
C.
Provide a thrust system that can advance the machine by thrust cylinders that react against the
installed segmental liner to achieve the required instantaneous penetration rates necessary to
complete the tunnel within the scheduled time under the combined reaction from maximum
earth and hydrostatic pressure, shield friction, maximum face stabilization load, and loading
caused by discs or other excavation tools.
D.
Provide jack shoes or partial jack rings, articulated shoes, or pads consistent with the segmental
lining design and as required to distribute the thrust loads to the segmental lining without
damaging the liner. Thrust pads shall not bear on or damage segmental liner gaskets. The
maximum thrust contact pressure at any point and at any time on the liner system shall not
exceed 3000 psi (measured by dividing the thrust of the jack by the area of bearing surface on
the concrete segment).
E.
Provide thrust cylinders capable of individual actuation, synchronized actuation, and individual
thrust pressure control. Thrust cylinders shall incorporate displacement monitors and shall not
permit displacement when idle, or during a loss of power. The thrust cylinder stroke must allow
the installation of segments with dowel connectors on the circumferential joints.
F.
TBM drive system shall operate the cutterhead equally in either direction of rotation (bidirectional).
2.05
MUCK SYSTEM
A.
Provide and use a closed circuit system capable of discharging spoil through the slurry pipelines
and discharge pumps. Use slurry lines with diameter, wall thickness and abrasion resistance
suitable for muck materials with abrasive fines and high water content, rock fragments, cobbles
and other conditions as described in the Contract Documents or disclosed in the GDR.
B.
Equip the TBM with a crusher capable of crushing boulders and rock fragments of a size that
can pass through the TBM cutterhead and with a strength described in the Contract Documents.
The rock crusher shall be accessible for maintenance in free air while the TBM face pressure is
maintained.
C.
Calibrate pressure cells as recommended by supplier or as needed to assure accuracy of pressure

measurements.
D.
Design, provide and use a slurry separation plant that is:
E.
1.
Capable of processing the anticipated volume rates, types, and quantities of materials
anticipated as described in the Contract Documents and for treated ground.
2.
Capable of removing solids from suspension at a sufficiently fast rate to ensure that
slurry treatment does not limit the Slurry TBM advance rate.
3.
Equipped with a means of replacing or reconditioning slurry as required when slurry

properties are unsatisfactory.
Provide and use flow, density and other meters in the supply and discharge slurry lines on a
continuous real time basis connected to the TBM data acquisition system. The meters shall:
1.
Monitor excavation progress and excavated volumes.

02316 - 11
2.
Detect and control conditions of the working face.
3.
Ensure smooth transportation of slurry.
4.
Detect and notify of slurry leakage.
F.
Equip TBM with means of extending slurry lines with minimal loss of slurry.
G.
Provide ability to increase slurry density at the heading to suspend all type of ground anticipated
for transport, to counter slurry leakage and to prevent face collapses.
H.
A hydraulic power supply to the bulkhead door to close off the slurry system shall be provided
with a hydraulic accumulator in case of power failure.
2.06
A.
2.07
COMPRESSED AIR FACILITIES

See section 02416.
SEGMENT ERECTOR AND SEGMENT FEEDER
A.
Design segment erector and segment feeder to be compatible with one another and the TBM
and lining system to ensure safe and efficient segment installation.
B.
The segment erector mechanism shall be capable of picking up, accurately locating, and placing
the segments used safely in the required orientation to the tolerances stated in the Specifications
without damage to the segments or gaskets. The segment erector mechanism shall be designed
to provide sufficient force to compress the gaskets.
C.
The erector mechanism shall be capable of removing damaged or misaligned or incorrect

segments prior to completion of the ring and within the first 12-inches of shove. The erector
shall be capable of being actuated in the axial, radial, and circumferential directions and in the
three articulation angles corresponding to the six degrees of freedom.
D.
Segment lifting operations shall be either by vacuum or by engaging embedded lifting sockets.
A safety device to ensure that segments cannot be released during handling shall be
incorporated. Segment lifting and handling systems must be capable of holding a segment
securely in position in the event of a power failure.
E.
The segment feeder system shall be designed and constructed so that the segments are supplied
at the rate and orientation to suit the erector.
2.08
TBM GUIDANCE SYSTEM AND DATA ACQUISITION SYSTEM
A.
Equip and operate the TBM with a computerized guidance system capable of accurately
following the planned alignment and continuously recording TBM position, elevation, and
attitude.
B.
Design the guidance system to calculate and provide continuous data in real-time for every
segment ring along the tunnel centerline including:
1.
Design centerline station, coordinates, and elevation.

02316 - 12
2.
As-driven station, coordinates, elevation, and attitude (yaw, tilt, and roll).
3.
Horizontal and vertical offsets from design tunnel centerline to the driven tunnel
centerline.
4.
Horizontal and vertical attitude of TBM.
5.
Forecast position of the TBM for each of the next ten rings.
6.
Forecast ring orientation for each of the next ten rings.
7.
As-built ring orientation.
C.
The information shall be graphically displayed to the TBM Operator at all times on an
electronic display terminal. Display modes shall read to 0.05 inch and 0.01 degrees accuracy.
D.
Equip the guidance system with an alarm to alert the TBM Operator in the event that the driven
tunnel exceeds or is projected to exceed tolerances and provide the capability to forecast the
composition and orientation of the subsequent ten rings to get back on target.
E.
Design guidance system to interface with: individual controls for thrust ram pressures and
extensions; cutterhead; and shield articulation (if installed).
F.
Provide data acquisition system that shall transmit and record data in real-time to an internetbased system which shall be accessible to the RE, for unlimited users. Real-time shall mean that
the time lag from which the data is generated to being accessible on the internet-based system is
no greater than one minute. Process and generate, automatically by computer, separate plots of
all parameters of TBM performance that shall be available on the internet-based system. Use
automatic recording systems for data collection that provide access to all historical data. The
data feed, generated output, and the database shall be in a format to be approved by the RE.
G.
Data acquisition system shall continuously collect and store information for each shove or
stroke of the TBM, including but not limited to:
1.
Date, time, and tunnel station at start of shove, and duration and length of shove.
2.
Time lining erection started and finished and ring orientation.
3.
All TBM guidance system data as specified herein.
4.
TBM cutterhead direction, torque, and speed
5.
Drive motor power consumption.
6.
Total thrust force and extension of thrust rams.
7.
Instantaneous advance rate of TBM during shove.
8.
Operational parameters of slurry recharge and discharge systems including quantities,

inbound density, outbound density, pressure, volume ratio, flow rates, weight of
excavated material, and leakage indications.
02316 - 13
9.
Main bearing lubrication pressure, flow, and temperature.
10.
Segment grouting pressures and volumes by port.
11.
Electrical power consumption and motor temperature.
12.
Pressures on the cutterhead and in the plenum chamber measured by each installed
pressure cell.
13.
Annular bentonite injection pressures, volumes and injection rates, per injection port.
14.
Mode of operation.
15.
Opening angle and location of maximum opening of articulation joint (if installed).
H.
Data shall be backed up to a remote location at least once every 24 hours. Backup system shall
permit all historical data to be retrieved.
I.
Repair or replace the data acquisition system within 24 hours should it not be functioning
correctly.
2.09
A.
PROBE DRILLING AND GROUND TREATMENT CAPABILITIES

Provide drilling ports and drilling and grouting equipment capable of probing, spiling, and
ground treatment to a minimum of 50 feet ahead of the excavation face at maximum hydrostatic
and earth pressure, including:
1.
Drilling and ground treatment through the cutterhead.
2.
Drilling and ground treatment through the shield.
3.
Means and equipment to control ground and groundwater inflow during drilling,
spiling and grouting operations and to seal the ports when not in use.
B.
Provide sufficient number of ports around the TBM shield to permit a zone of ground ahead of
the TBM to be stabilized.
C.
Provide drilling equipment which can be mounted in the TBM rear shield.
2.10
ANNULAR GROUTING EQUIPMENT
A.
Provide equipment for mixing, transporting, and injecting a suspension grout into the void
between lining and ground in a continuous flow at a rate that will keep the annular gap
completely filled concurrent with the maximum expected advance rate of the TBM while
maintaining the required grout pressure.
B.
The grout shall be injected through the TBM tail shield unless otherwise approved by the RE.
The number of grout pipes shall be compatible with the mobility of the grout mix. The system
shall include flushing capability and/or redundancy in the number of pipes to account for pipe
blockages.
02316 - 14
C.
Grouting equipment shall include an accurate measuring device capable of measuring volume of
grout injected in cubic yards to the nearest one-hundredth of a cubic yard. Annular grouting
equipment shall be capable of measuring the amount of grout per injection port and the
cumulative total per ring.
D.
Provide suitable stop valves at each grout injection port to maintain pressure in grouted zone as
required until grout has set. Provide an automatic bypass valve to avoid exceeding the design
grout pressure. Install pressure gauges to indicate pressure at pump and at point of injection.
Provide pressure, volume-sensing, and transmission equipment for connection to TBM data
acquisition system.
E.
Provide automatic interlock to prevent advance of the TBM until the annular grout system is
operational and is providing the required grout during the advance.
F.
Provide drilling equipment and staging off the TBM trailing gear capable of drilling holes
through the segments to enable proof grouting through the lining at any position around the ring.
G.
Provide proof grouting equipment compatible with the proof drilling equipment to allow
mixing, storing, and pumping of grout through the lining at the pressures given in Section
02330.
2.11
GAS DETECTION AND VENTILATION EQUIPMENT
A.
Provide the TBM with local auxiliary ventilation to allow a continuous and sufficient supply of
fresh air to the areas of the TBM that are occupied by personnel. Provide airflow quantities that
conform to OSHA 29 CFR 1926. The main tunnel ventilation and local auxiliary ventilation
shall overlap so that fresh air is provided right up to the back of the TBM bulkhead. Provide
ventilation systems with reversible fans for fresh air supply and exhausting to meet the
requirements specified herein.
B.
Provide built-in equipment to continuously monitor noxious gases, explosive gases and oxygen
concentrations as required by OSHA 29 CFR 1926 and to give audible and visual warning of if
gas levels are outside threshold limits. Monitoring point positions shall include the TBM
plenum chamber and the discharge systems.
C.
Equip the TBM with a power interruption system that will automatically shut down power to
the TBM drive system upon detection of levels of hazardous and/or explosive gasses in excess
of OSHA standards. Design this power interruption system so that TBM maintains face
pressure and so that power for lighting, compressed air, pumping, ventilation and other safety
critical systems are not shut down.
2.12
A.
ESSENTIAL SPARES
Provide replacement parts or maintenance materials for all systems. One of each item (or group
of items) is required to be stored on-site, unless a greater number is recommended by the TBM
manufacturer. Items stored on Site shall include all items with lead times greater than two days,
and the following:
1.
Parts and materials in accordance with the Contractors maintenance plan, and TBM
and ancillary systems manufacturers recommendations. Maintain an inventory and a
location for all such parts and materials shall be maintained.
02316 - 15
2.
One complete set of excavation tools (discs, picks/drag bits, and other cutters) on Site
and at all times. One set consists of complete replacement of all tools on one
cutterhead for all remaining configurations of excavation tools indicated in the
Contractors submittals.
3.
Hydraulic jacks, hydraulic hoses, and components.
4.
Seals, o-rings, and gaskets.
5.
Electrical and mechanical components.
6.
Two spare main drive units including pinions, gearboxes, and motors.
7.
Spare parts or a replacement system for the TBM Guidance System.
8.
Grout pump for annular grouting.
9.
Two spare slurry pumps (one for feed line, one for return line).
B.
Immediately reorder and replace into storage any replacement part that is used, lost, or is no
longer fit for purpose without delay.
C.
One spare main bearing assembly and seals shall be available for replacement of the
corresponding parts provided with each TBM. These spares shall be available for the duration
of TBM excavation, and shall be deliverable to the Work Site within one week. The spare parts
may be previously used provided they are rebuilt, in as-new condition, fully compatible with the
TBM, and so certified in writing by original TBM Manufacturer.
PART 3 EXECUTION
3.01
A.
GENERAL
Execution is covered under Section 02330 Tunneling by Tunnel Boring Machine.
END OF SECTION
02316 - 16
SECTION 02330
TUNNELING BY TUNNEL BORING MACHINE
PART 1 GENERAL
1.01
A.
SCOPE OF WORK
The Work specified in this Section includes, but is not limited to the following:
1.
Tunnel Excavation: Excavation of the tunnel to the line and grade as shown on Contract
Drawings within specified tolerances and in the ground described in the Geotechnical
Baseline Report (GBR), using a pressurized face tunnel boring machine (TBM) that
complies with the requirements of the TBM specified in either Section 02315 Earth
Pressure Balance TBM, or Section 02316 Slurry TBM.
2.
Precast Lining Erection: Erection of precast concrete gasketted segmental lining rings
within the tail shield of the TBM.
3.
Tunnel Grouting: Provision and injection of grout to fill the annular space between the
precast concrete tunnel lining and the cavity excavated by the TBM, including proof
grouting.
4.
Probing and advance ground treatment capability ahead of tunnel face and around the
periphery of the TBM shield.
5.
Support Equipment and Services: Installation and operation of machine tunneling support
equipment and services including tunnel ventilation, TBM auxiliary ventilation,
temporary tunnel drainage, temporary tunnel lighting, temporary tunnel walkways, TBM
power supply cables, communication cables, water supply and discharge and muck
removal facilities.
6. Transportation and delivery of TBM to launching shaft, assembly and testing and
commissioning of TBM, launching of TBM, mining by TBM, receiving and
disassembly of TBM at receiving shaft, and removing TBM from Site.
7. Primary and secondary control surveys and as-built survey of the completed tunnel.
1.02
RELATED SECTIONS
A.
Field Engineering and Surveying is included in Section 01050.
B.
Temporary Utilities is included in Section 01510.
C.
D.
E.
Earth Pressure Balance TBM is included in Section 02315.
02330 - 1
F.
Slurry TBM is included in Section 02316.
G.
H.
Tunnel Cleaning is included in Section 02400.
I.
Compressed Air Work is included in Section 02416.
J.
K.
L.
Backfill Concrete in Shafts and Tunnels is included in Section 03301.
M.
Concrete for Precast Tunnel Lining is included in Section 03360.
N.
Reinforcement for Precast Tunnel Lining is included in Section 03370.
O.
P.
Q.
R.
S.
T.
1.03
REFERENCE STANDARDS
A.
ACI 224.1
Causes, Evaluation, and Repair of Cracks in Concrete Structures
B.
ACI 306R
Cold Weather Concreting
C.
ASTM C31
Making and Curing Concrete Test Specimens in the Field
D.
ASTM C39
Compressive Strength of Cylindrical Concrete Specimens
E.
ASTM C150
Portland Cement
F.
EFNARC

1.04
A.
DEFINITIONS
Air Lock: A personnel air lock with separate materials air lock which allows manned
interventions if required under compressed air into the plenum chamber for cutterhead and
cutter maintenance and also for the removal of obstructions if encountered.
02330 - 2
B.
Birdsmouthing: The opening or closing of a radial joint between two segments relative to the
nominal width of the gap when segments are fully seated and compressed.
C.
Cutterhead: The forward rotating section of the TBM on which the cutting tools are mounted to
excavate the ground.
D.
Lipping: The deviation of adjacent segments from one another measured at right angles
(normal) to the tunnel axis at the radial joints.
E.
Main Bearing: The large diameter bearing on which the cutterhead is mounted and which
includes the main drive gear, driven by a number of drive pinions connected to the drive motors.
F.
Manufacturer: The Tunnel Boring Machine Manufacturer.
G.
Plenum Chamber (also known as cutterhead chamber or excavation chamber): The enclosed
space between the pressure bulkhead and the excavation face where excavated material is mixed
and pressurized to resist ground and hydrostatic loads, with or without the addition of soil
conditioners.
H.
Pressure Bulkhead: A partition wall within the shield on which the main bearing is mounted and
which resists the loads exerted by the pressurized excavated material in the plenum chamber
and the forces required to bury the cutting tools and operate the machine.
I.
Pressurized Face Tunnel Boring Machine (TBM) or TBM: A TBM which is able to pressurize
the medium in the plenum chamber to resist the external ground and hydrostatic pressures at the
tunnel face while excavating the ground, to maintain face stability and minimize ground
movements. The TBM includes backup gantries that house ancillary equipment to support the
operation of the TBM. Refers to either Earth Pressure Balance (EPB) Tunnel Boring Machine
as specified in Section 02315, or Slurry Tunnel Boring Machine as specified in Section 02316,
as determined by the Contractor.
J.
psig (pounds per square inch gauge): A measure of pressure relative to the surrounding
atmosphere, measured in pounds per square inch at the gauge.
K.
Segment Erector: The mechanical device mounted within the tailshield that is used to place the
precast concrete lining segments to build a complete ring.
L.
Stepping: The deviation of adjacent liners from one another measured at right angles (normal)
to the tunnel axis at circumferential joints.
M.
Tailseal: A series of grease-fed wire brush seals mounted on the intrados of the rear end of the
TBM tailshield which seal the annular space between the tailshield and the extrados of the
precast concrete liner and prevent inflow of groundwater or grout into the TBM.
N.
Thrust Jacks: The main jacks that push against the previously erected precast tunnel lining in
order to propel the TBM shield through the ground.
1.05
A.
SUBMITTALS
Qualifications: Submit qualifications of the Project Manager, Tunnel Superintendent, TBM
Operators, and TBM Mechanics and Electricians at least 60 days before commencement of
02330 - 3
tunnel excavation for review and approval by the RE. Affirm each persons sole commitment to
this project.
B.
At least 60 days before delivery of the TBM to the launching shaft, submit in agreed formats the
following method statements, shop drawings, procedures, and durations:
1.
2.
3.
Details including plans and sections of the laydown area and launch structure including:
a.
Segment storage area.
b.
Muck or slurry treatment and handling plant and areas.
c.
Stockpiles.
d.
Silos (cement, bentonite, other).
e.
Cranes.
f.
Conveyors, slurry pipelines, ventilation equipment, pump lines, and sump

locations.
g.
Locations and routing of temporary services and utilities.
h.
Site offices and welfare facilities.
i.
Construction rail systems within the launching shaft.
j.
Means of personnel access and egress through the shaft to the tunnel.
Transportation of TBM:
a.
Details, equipment, and haulage routes for transportation and movement of the
TBM and TBM elements including backup gantries to, from and within the Site,
including initial delivery to the launching shaft site and final removal from the
receiving shaft site.
b.
Copies of necessary permits including abnormal loads, oversized vehicles, and

Maintenance and Protection of Traffic schemes.
Hoisting of TBM:
a.
Details of hoisting and lifting equipment required to install or remove the TBM
and TBM elements into or out of the launching and receiving shafts, including:
b.
4.
Location of hoists and lifting equipment during lifts.
2)
Temporary construction platforms or mats.
3)
Strutting or modification of existing structures, facilities, or utilities.
Calculations and shop drawings demonstrating that loads on shaft structures, the
tunnel, and any surrounding structures or utilities do not exceed safe structural
capacities. Include details of any temporary support measures required.
Assembly of TBM:
a.
5.
1)
Schedule, sequence, and details of TBM assembly, testing and commissioning.
Disassembly of TBM:
a.
Schedule, sequence, and details of TBM decommissioning and disassembly.
02330 - 4
C.
At least 60 days prior to the commencement of tunnel excavation, submit in agreed formats the
following method statements, shop drawings, procedures, and durations together with all
relevant manufacturers information sheets. Calculations and shop drawings shall be signed and
sealed by a Professional Engineer licensed in the State of New York:
1.
2.
3.
Detailed tunnel construction cycle and associated logistics, including:

a.
Details of ring build time and mining time, per cycle.
b.
Details of all resources to be utilized (personnel, locomotives, muck cars, etc.) and
hours and shifts to be worked.
TBM Launch and Initial Mining:

a.
Details and calculations for invert support, thrust frame, and blocks required for
launching the TBM, including calculations to verify the integrity of the shaft
structure during launch.
b.
Details and calculations for ground treatment outside launching shaft to be

undertaken prior to launching the TBM.
c.
Stepwise details of TBM launch and initial mining sequence, including procedure
for mining through shaft wall and treated ground and for engaging fully
pressurized mining mode.
d.
Details of measures to prevent loss of ground, groundwater, slurry, or annular

grout around the TBM and liner at the interface with the shaft.
e.
Details of the mechanical TBM launch seal system to be provided inside the
launching shaft.
f.
Details of special training, supervision, and other procedures to be employed for

the first 300-feet of the bored tunnel drive to minimize the risk of ground
movements during the learning curve as the crew become familiar with the
operation of the TBM.
TBM Reception:
a.
Re-establishment of the receiving shaft construction Site.
b.
Details and calculations for invert supports and any other structures needed to
facilitate reception and removal of the TBM, including calculations to verify the
integrity of the shaft structure during reception.
c.
Details and calculations for ground treatment outside receiving shaft to be

undertaken prior to receiving the TBM.
d.
Stepwise details of TBM reception sequence, including procedure for mining

through treated ground and shaft wall and alterations to TBM operational
parameters to be made prior to termination of mining.
e.
Details of measures to prevent loss of ground, groundwater, slurry, or annular

grout around the TBM and liner at the interface with the shaft.
f.
Details of the mechanical TBM reception seal system to be provided inside the
receiving shaft.
g.
Decommissioning and disassembly
02330 - 5
4.
TBM Operation Plan:

a.
Operational procedures for the TBM and components, including airlocks. Include
details of critical TBM systems to ensure required TBM performance and sample
TBM Condition Report.
b.
5.
Details of the intended machine operating procedures and controls to achieve

and maintain the face pressures as determined in the TBM Face Pressure and
Settlement Control method statement for the range of ground conditions
described in the GBR and other Contract Documents and disclosed in the GDR;
and for each of the conditions listed below. Include for each condition target
ranges for cutterhead rotation speed and torque, thrust, instantaneous
penetration rate, and muck conditioning materials and volumes. Include
inbound and outbound slurry densities for the Slurry TBM, if used.
1)
Soil excavation.
2)
Rock excavation.
3)
Mixed face excavation.
4)
Mining through and exiting walls.
5)
Mining through and exiting treated ground.
c.
Details of activities requiring access through the TBM cutterhead including but
not limited to cutterhead maintenance, obstruction removal activities and any
other intervention. Include a sample TBM Cutterhead Condition Report.
d.
Procedure and initial schedule for inspection and replacement of cutting tools.
Adjust and resubmit schedule based on actual tool wear.
e.
Identification of sources of consumable materials such as tail seal grease etc.

and methods of handling of such materials.
f.
Procedures for extending utilities and logistical supply in the tunnel and shaft
and integration into the mining cycle.
g.
Health and Safety Plan and Tunnel and Shaft Ventilation Plan, in accordance
with Sections 13000 and 13130, respectively. These shall include details of
tunnel and TBM atmospheric monitoring and ventilation under normal working
conditions, and details of procedures to be implemented when contaminated
soil, water or harmful/explosive gases are encountered.
TBM Face Pressure and Settlement Control:

a.
Calculations for determining face pressures required to maintain face stability,

and to keep settlement within specified limits. Submit a tabulated summary of
pressures at maximum 50 foot intervals along the tunnel, indicating maximum,
minimum and target working pressures. Include excavation chamber pressures
at which the TBM Operator shall receive an alarm requiring the TBM to stop.
b.
Calculations of estimated settlements along the tunnel drive and measures to be

taken to control movements within limits given in Section 02495.
c.
Describe how settlement monitoring and other instrumentation data will be used
to modify the target face pressures and machine operating procedures.
02330 - 6
6.
7.
8.
d.
Response Plan: Describe in detail plan(s) for corrective measures and responses
to be implemented should the orange trigger review level or red trigger alert
level be reached, or any new cracks or concrete defects occur in the erected
tunnel lining, or an existing crack or defect becomes enlarged. The Response
Plan shall be in accordance with Section 02495.
e.
Face pressure look-ahead calculations: Calculations of face pressures shall be

provided on a weekly basis to the RE for review. The calculations shall estimate
face pressures on a look-ahead basis for the anticipated progress over the
following two weeks.
TBM Guidance System: Detailed description of TBM Guidance System, including:

a.
TBM alignment input data: format, translation, and input of design alignment data
into guidance system. Submit spreadsheet tabulation detailing Easting, Northing,
and Elevation, in relation to the project coordinate system and datum, at each
proposed ring centerline.
b.
Operation of TBM Guidance System including: information available to TBM

operator; interfaces with other TBM systems; selection of ring orientation and how
it will be used to avoid and correct misalignment; and format of output data to be
provided to the RE.
c.
Details of: survey equipment; how the survey control is brought underground;
frequency and methodology of independent verification surveys; support of control
points in tunnel; transition of survey control along tangents and around curves;
communications between survey equipment, guidance system, and surface;
coordinating advance of survey system with that of TBM; location of target; and
methods to preserve and protect all survey monuments and related marks.
TBM Cutterhead Access:

a.
Details for effecting worker entry into the plenum chamber, including safety
procedures, methods of supporting the ground and methods of preventing ingress
of fines and water, in accordance with Section 13000.
b.
Procedures for access ahead of the TBM cutterhead, including face support,
ground stabilization methods and any additional safety measures to be
implemented.
c.
Details for effecting cutterhead access using compressed air shall be submitted in
accordance with Section 02416.
Muck Removal and Handling:

a.
For an EPB TBM, a method statement detailing the weight and volumetric
measurement of extracted muck and the methodology for calculating the
anticipated weight and volume for each ring of advance, including allowance for
conditioners. Details of how predicted quantities will be compared with results
from monitoring devices and muck car counts (if muck cars used), and the level at
which the TBM Operator will receive an alarm requiring the TBM to stop.
b.
For a Slurry TBM, a method statement detailing the measurement of the quantity
of extracted muck, including use of flow and density meters, and the methodology
for calculating the anticipated quantity of muck for each ring of advance. Details
02330 - 7
of how predicted quantities will be compared with measured results, and the level
at which the TBM Operator will receive an alarm requiring the TBM to stop.
c.
9.
10.
11.
12.
Submit details of muck handling systems from the TBM through the tunnel to the
surface at the TBM launch area, including any surface handling and environmental
controls required prior to loading muck for removal from site.
Ground Investigation and Ground Treatment: Details of probing and ground treatment
ahead of tunnel face through the cutterhead and around the periphery of TBM shield,
including:
a.
Equipment and procedure for drilling exploratory probe holes.
b.
Planned frequency and location of exploratory probe holes.
c.
Logging procedures, drilling parameter recording system, and sample reports.
d.
Analysis of recovered soil material and methodology for assessment of soil type
and condition.
e.
Drilling fluids, blow-out preventers, back-flow preventers, and valves.
f.
For ground treatment:

1)
Specifications and procedures for drilling and ground treatment

equipment.
2)
Details and patterns of ground treatment.
TBM Stoppages:
a.
Details of any special precautions and related inspection procedures to be taken

when stopping the machine for repair, weekends, holidays, and other scheduled
and unscheduled stoppages to ensure that face stability is maintained during the
shutdown.
b.
Include contingency measures to be implemented if problems develop in ground

control or groundwater control or if electric power supply is interrupted.
c.
Details of re-starting the tunneling operations following a stoppage.
Water Inflow:
a.
Details and procedures for controlling groundwater inflows through the TBM or
tunnel lining, including sudden high water inflows.
b.
Details of methods for measuring water leakage through the tunnel lining.
c.
Details and procedures for rectifying water leakage through the tunnel lining to
satisfy water ingress criteria, including sealing of leaks occurring through:
1)
Segmental gasketted joints.
2)
Lifting and grout holes.
3)
Cracks.
Daily Meeting: Sample form for recording minutes of Daily Meeting between Contractor
and RE.
02330 - 8
13.
Contingency Plans: Detailed action plans, calculations, and criteria addressing:

a.
b.
c.
Machine unable to advance:

1)
Possible obstructions as defined in the GBR, including: boulders.
2)
Machine entrapment.
3)
Jammed TBM cutterhead due to insufficient torque or boulders or other

obstructions.
4)
Insufficient jacking capacity.
For an EPB TBM, soil conditioning problems:

1)
Excavated muck is difficult to handle on conveyors.
2)
Excavated muck is too sloppy to remove from the storage area.
3)
Screw conveyor fails to hold water pressure in plenum chamber.
For a Slurry TBM:

1)
14.
15.
Difficulty controlling slurry density.
d.
Replacing muck removal and handling system components.
e.
TBM Guidance System laser is distorted by heat, humidity or other physical

conditions.
Erection of Precast Concrete Lining:

a.
The procedure and calculations to determine the next ring type and orientation and
the interface with the TBM Guidance System.
b.
Details and procedures for attaching segment packers and gaskets prior to delivery
to the TBM.
c.
Details of handling, storing, and delivery of segments to the TBM including

segment stacking sequence.
d.
Procedure for erection and bolting of segments for each ring type.
e.
Ring build measuring and recording procedures and corrective measures to be

taken should tolerances specified be exceeded.
f.
Corrective measures to be taken if segment damage or gasket damage occurs prior

to installation of segment, including procedure to remove and replace rejected
segments.
g.
Segment repair procedures for erected lining to include description of type,

location, and extent of damage and their associated repair procedure.
h.
Details of Ring Build Report which shall include all details as specified herein.
i.
Estimated average ring erection rate in minutes per complete ring.
Annular Grouting: Details and procedures for annular and proof grouting, including:
a.
Details of annular and proof grouting operations and integration into the mining
cycle.
02330 - 9
16.
17.
D.
b.
Grout mix designs, including additives and sources and properties of all
components.
c.
Preconstruction test reports for proposed grout mixes.
d.
Location of mixing plant.
e.
Grout delivery system.
f.
Grout pumping system.
g.
Testing procedures.
h.
Grout volume and pressure measurement, and sample grout record sheets per
injection port and totalized per ring.
i.
Location and sequence of injection.
j.
Methods of proof drilling.
k.
Pressure measurement.
l.
Accelerator dosing and control devices.
m.
Flow and directional control.
n.
Temporary storage vessels.
o.
Interlocks with other TBM functions including: tail seal grease injection and
pressure control; and shove ram activation.
p.
Grouting for leak sealing grout holes or between segment joints.
q.
Sample of Ring Grouting Report.
Technical Data: Submit data on construction materials, including:

a.
Tail seal grease, main bearing grease and other lubricants.
b.
Products to remain in contact with the ground or exposed at the tunnel interior
surface.
c.
Soil conditioning and slurry materials including mix designs, injection rates and
pressure, and environmental acceptance certification.
Sample TBM Shift Report, Stroke Report, and Survey Report.
Surveys:
1.
30 days prior to the commencement of tunnel excavation, submit:

a.
2.
Results of checking that control line monuments established by the Corporation are
correct and satisfactory for correctly setting out Work.
30 days prior to as-built surveying, provide details of methods and equipment to be used
for:
a.
Conducting a closed traverse survey through the completed tunnel to close to the
specified accuracy.
b.
As-built tunnel surveys, information to be obtained in survey, and graphical

representation of the data.
02330 - 10
E.
1.06
If during TBM operations it becomes necessary to revise a method statement, such revised
method statements shall be submitted to the RE at least 14 days in advance of implementing any
changes. If operations are required to be modified prior to the implementation of a revised
method statement, notify the RE immediately with all available details and submit the revised
method statement as soon as possible, and always within five working days of changes being
implemented.
DELIVERABLES
A.
During assembly of TBM and back-up systems: Provide weekly progress reports including
details of commissioning.
B.
Prior to the commencement of tunnel excavation, provide results of independent verification

survey check of TBM Guidance System and measurements demonstrating shield circularity.
C.
Continuous Monitoring Data of TBM Performance: Provide to the RE on a real-time basis for
the duration of TBM excavation via the internet, as specified in Section 02315 and Section
02316.
D.
Prepare, maintain, and provide a TBM Shift Report for each shift including periods when the
TBM is not excavating. Prepare reports commencing on the first day of TBM assembly and
continue for every shift until the TBM is removed from the receiving shaft. Provide one hard
copy of the TBM Shift Report, signed by the Tunnel Superintendent, to the RE before 12:01pm
the following workday. Times shall be recorded to the nearest five minutes, or more precisely.
As a minimum the following information shall be included in a format acceptable to the RE:
1.
Name of Tunnel Superintendent, TBM operator, and other key personnel.
2.
Number of workers employed categorized by union trade, idle equipment, active

equipment, and visitors.
3.
TBM position at start and end of shift, including:
4.
a.
Reference station.
b.
TBM position and attitude.
c.
Offsets from the tunnel designed alignment.
Stroke Report:
a.
Ring number and stationing.
b.
Start and finish time.
c.
Volume of muck removed including number and size of muck skips or automatic
conveyor weight and volume measurements or slurry flow and density
measurements, depending on the system used.
d.
Planned face pressure, actual face pressure, and reason for any deviation.
e.
Summary of all other data automatically recorded by the TBM Guidance System,
including results of before and after comparison each time the system has been
moved or reconfigured, and TBM Monitoring Data Systems.
02330 - 11
f.
Description of ground being excavated: soil, rock, presence of boulders,

obstructions, mixed face, etc.
g.
Record of soil conditioning (for EPB TBM), including:
h.
5.
1)
Total volume pumped by location.
2)
Volumes per shove.
3)
Mix constituents, ratios and injection pressures.
Record of slurry operations (for slurry TBM), including:

1)
Quality control tests.
2)
Volumes.
3)
Inflow density and outflow density.
Ring build and survey records:

a.
Provide a Survey Report each time a ring is surveyed, including lining survey and
ring build data as specified herein.
b.
Non-conformance reports for out-of-tolerance lining.
c.
Provide weekly as-built survey record in paper and electronic spreadsheet formats
showing centerline of tunnel lining and comparison with the design tunnel
centerline. The comparison shall include plans, longitudinal sections, and cross
sections illustrating vertical deviation of the installed lining from the designed
location.
d.
Completed quality control sheet indicating inspection and serial number for each
segment and gasket in a ring, before installation.
6.
Non-conformance reports for all damaged segments including cause of damage and
description of all repairs.
7.
Ring Grouting Report.
8.
Time, duration, and description of all activities in the tunnel including TBM and nonTBM activities. Any delay or stoppage shall be recorded with an explanation of the
reason for the delay or stoppage for individual or cumulative durations greater than 15
minutes.
9.
Problems encountered, including quantitative description, cause, and corrective measures

implemented. Include incidence of water inflow during excavation or through completed
lining, ground loss, surface settlement, loss of grout or slurry to surface, excessive heat in
motors or muck, unusual noises or vibrations, deviation from approved method
statement, or other unusual events.
10.
TBM Condition Report on a daily basis.
11.
TBM Cutterhead Condition Report: including current condition of cutterhead and other
components, and description of repairs and component changes. State position number
of repaired/replaced cutting tools or component, degree of wear, reason for change(s),
and existing condition of all remaining tools.
02330 - 12
12.
Planned TBM alignment and ring orientations (and selections) for this shift, compared
with actual alignment and orientations.
13.
Planned TBM alignment and ring orientation (and selections) for next ten rings following
end of shift.
14.
Probe hole records as specified herein.
15.
Air Quality Reports: Records of air quality and gas monitoring. Test and monitoring
reports as required by OSHA and other Federal, State, and local regulations. Settings or
air flows of ventilation system.
16.
Based on the instrumentation readings provided by the RE and instrumentation readings

taken by the Contractor, review and determine potential causes of highlighted or other
abnormal movement, and correlate with significant events such as TBM performance,
stoppages, face instability, face interventions, backfill grouting performance or other
events or problems, and describe what improvements to tunneling procedures will be
implemented. Indicate instrument faults, and durations.
17.
Details and type of all consumable materials used during the shift.
E.
Provide maintenance records of the TBM, the mucking system, and all associated equipment
every 30 days. Provide calibration certificates specified as deliverables in Section 02315 and
Section 02316.
F.
Provide the final Primary survey control network diagram for the tunnel and Post-Grouting
Survey Report as specified herein within 30 days after hole-through. Provide the updated
Primary survey monuments list update, including data sheet for each newly established
monument with coordinates and elevation values, location, Order, Class, and other data.
G.
Provide permits for disposing of excavated muck, contaminated muck, muck containing
bentonite slurry, construction materials (including tail seal grease, cement, and accelerator),
dewatering fluids, and tunnel drainage. See Section 13140.
H.
Provide all required health and safety reports, as and when required by authorities having
jurisdiction and provide a copy of each such report to the RE at the same time that each is sent
to the appropriate public authorities.
I.
certifications for individuals authorized to perform hazardous gas testing including gas
monitoring instruments and procedures to be used.
J.
CCTV System: A CCTV system shall be provided to the RE containing four separate viewing
stations, each in different locations on the project site. Each viewing station shall as a minimum
have a camera clearly viewing: the front TBM conveyor; a camera viewing backwards from the
rear of the TBM backup system; a camera viewing the entire ring build area; and a camera at the
launch shaft. If a continuous conveyor is used, then an additional camera shall view the
continuous conveyor belt beyond the TBM backup. The viewing stations can consist of separate
stand-alone video displays displaying all camera views simultaneously or a single unit with a
manual control that allows the viewer to manually select a camera view of choice.
02330 - 13
1.07
A.
Personnel Qualifications and Duties:
1.
2.
Project Manager:
a.
A minimum of ten years experience with tunnel construction at least five of which
shall have been within the preceding ten years;
b.
A minimum of five years as a Project Manager on projects that entailed the

operation pressurized face TBMs (either EPBMs or Slurry TBMs).
c.
Duties of the Project Manager shall include but not be limited to the following:
1)
Overall managerial responsibility for the execution of the Works under

this Contract shall ensure safety, quality, conformance with the Contract
Documents and timely completion of the Works.
2)
Be located on-site full time for at least one 8-hour shift per day for a
minimum of five days per week, when tunnel construction is taking
place.
3)
Provide technical supervision of excavation to help maintain safety of

construction at shaft excavations and the tunnel heading.
4)
Coordinate preventative and remedial measures when ground loss at

shaft excavations or the tunnel heading or instability of the shafts or
tunnel occurs or appears likely.
5)
Consult with RE regarding ground conditions encountered, data from

probing ahead of the face, and operating face pressures.
6)
Prepare and maintain daily written interpretation of instrumentation

measurement readings during construction.
7)
Attending the Daily Meeting with the RE.
8)
Preparation, submission, review and modifying/updating of procedures,

method statements, shop drawings, etc.
9)
Coordination with TBM Tunnel Superintendents and RE.
TBM Tunnel Superintendent:

a.
A minimum of ten years experience with TBM construction at least five of which
shall have been within the preceding ten years;
b.
A minimum of five years as a Project Superintendent on a TBM construction

project or projects; and
c.
A minimum of one project in soft ground (soils) by EPB TBM or Slurry TBM.
d.
Duties of TBM Tunnel Superintendents, which may be carried out by different

persons on different shifts, shall include but not be limited to the following:
1)
Overall supervisory responsibility for planning, coordinating and

reviewing all tunnel excavation by TBM, precast segmental lining,
grouting, monitoring data, protection of facilities, and other elements of
the tunnel works including operations in the TBM launching and
receiving shafts and surface, to ensure safety, quality, conformance with
02330 - 14
the Contract Documents, timely completion of the Works and the

keeping of accurate records of all work as required herein.
2)
Attending the Daily Meeting with the RE.
3)
Implementation of procedures, method statements, shop drawings and

overseeing remedial measures when specified limits are approached or
exceeded, or as directed by the RE.
4)
Being available at Site at all times during tunnel excavation activities.
5)
Coordination with other TBM Tunnel Superintendents, and RE.
3.
TBM Operators: Five years as a TBM operator including one year as a TBM machine
operator on a TBM machine type as selected for this project by the Contractor.
4.
TBM Technical Representative(s): TBM Technical Representative(s) from the TBM

Manufacturer, knowledgeable in the assembly, operation, maintenance and repair of
TBMs, and experienced with the use of bolted, gasketted precast concrete segments for
primary support shall be incorporated into the Contractors staff at Site, as detailed
herein.
5.
TBM Mechanic or Electrician: Five years as a TBM mechanic or electrician including a

minimum of one year on a TBM machine type as selected for this project by the
Contractor and with experience in the use, operation, and maintenance of the
Programmable Logic Controller (PLC) and Variable Frequency Drives (VFDs).
6.
Professional Engineer: At least ten years of experience of designing underground works

and at least five years of experience of designing tunnel linings and systems for
pressurized face TBMs including as a minimum three projects of a similar nature in the
preceding five years.
B.
Substitutions for the Project Manager, the TBM Tunnel Superintendents, or the TBM Operators
during the Contract period shall not be made without prior written acceptance by the RE.
Substitute personnel for these positions must have at least the same qualifications as those
specified herein.
C.
TBM Operators, TBM Mechanics and TBM Electricians shall be trained and certified by the
TBM Manufacturer before start-up of the TBM, in accordance with Section 02315 and Section
02316.
D.
Do not perform tunneling unless the Tunnel Superintendent, TBM Operators, TBM Mechanics
and TBM Electricians meeting the above experience requirements are on-site and in actual
control of work for the bored tunnel.
E.
Grouting
1.
Preconstruction testing of annular grout:

a.
Provide testing apparatus to demonstrate the strength gain and gel time
characteristics of the grout. Carry out parallel testing using a strength-monitoring
device suitable for use in the tunnel.
02330 - 15
b.
2.
F.
Provide test results demonstrating the attainment of specified minimum 28-day

compressive strength.
Production testing of annular grout:

a.
Measure early strength gain using the procedure developed in this Section, with at
least one test for every two rings grouted.
b.
Produce two cylinders each shift for grout strength testing.
Surveying:
1.
Each surveyor responsible for tunnel surveying shall have had previous experience with
the TBM guidance system or have attended instructional courses by the supplier of the
system.
2.
If monuments provided by the Corporation are damaged or moved, notify the RE

promptly. It is the contractors responsibility to secure, protect, maintain and recover any
control points and benchmarks outside and within the tunnel.
3.
Survey by the RE: For the purposes of tunnel survey by the RE, the Contractor shall
provide at its own expense any assistance required by the RE including locomotive time,
stable survey instrument support brackets, level benchmarks, access platforms and any
other assistance required by the RE.
4.
The Contractor shall perform gyro surveys every 1000-ft for verification purposes. These
surveys shall be at the Contractors expense.
G.
Do not deliver TBM elements to the Site until all required submittals have been made, TBM has
been factory tested, and all permits and approvals have been secured and copies provided to the
RE, unless agreed otherwise with the RE.
H.
Do not commence TBM tunnel excavation until the following conditions have been met:
1.
Installation of geotechnical instrumentation has been completed in accordance with

Section 02495.
2.
Ground treatment at launching and receiving shafts has been completed and efficacy
verified in accordance with Section 02432.
3.
All health and safety requirements have been met and all submittals have been made in
accordance with OSHA requirements, Section 13000, and other applicable codes,
regulations, and requirements of Federal, State and local agencies having jurisdiction.
4.
Temporary utilities and ventilation systems have been installed and tested in accordance
with Section 01510 and Section 13130 and the backup power supply has been installed as
specified herein.
5.
Survey Control has been established in TBM launching shaft for TBM drive.
6.
Independent verification survey for the TBM Guidance System has been performed and
the results have been reviewed by the RE.
02330 - 16
7.
I.
Project staff has been trained to ensure understanding of method statements and response
requirements when instrumentation and monitoring data reach orange trigger review level
or red trigger alert level.
Do not move or reconfigure TBM Guidance System setup while TBM is advancing.
PART 2 PRODUCTS
2.01
GENERAL
A.
Provide a new pressurized face TBM together with all backup gantries and other appurtenant
equipment in accordance with Section 02315 or Section 02316.
B.
Grout, slurry, slurry additives, soil conditioners, and tail seal grease shall meet the material and
testing requirements of Part 2 of the EFNARC Specification and Guidelines, except where
otherwise specified in the Contract Documents.
C.
Tail seal grease shall be inert, shall not contaminate the ground or groundwater and shall not in
any way cause long term deterioration of the liner concrete, the joint connectors, the gaskets,
seals or packers.
D.
Use only such TBM products, including spare parts, as supplied by, or approved by the TBM
manufacturer.
E.
Use only fire retardant products.
F.
All products remaining in contact with the ground or exposed at the tunnel interior surface shall
be non-hazardous and either inert or biodegradable. Verify compatibility of products utilized in
tunneling operations with requirements for cleaning specified in Section 02400 Tunnel
Cleaning.
G.
The products or materials selected shall perform satisfactorily for the specified service life of
the tunnel under the groundwater conditions as described in the Contract Documents.
H.
Probe drilling equipment shall be carefully selected such that if a drill string becomes detached
ahead of the face it does not impede the advance of the TBM.
2.02
A.
ANNULAR AND PROOF GROUT

Grout:
1.
Portland cement-based.
2.
Backfill grout mix designs shall be compatible with TBM advance rates and exhibit a
minimum compressive strength in accordance with ASTM C39 of:
a.
25 psi at initial set;
b.
50 psi within 24 hours; and
c.
100 psi within 7 days.
02330 - 17
2.03
A.
2.04
A.
2.05
3.
The above strength requirements are the minimum required values. It is the Contractors
sole responsibility to design and adjust the annular grout mixtures for the sufficient
strength gain needed to constrain the precast lining in its erected position and to be
compatible with the planned TBM advance rates. Sufficient support shall be provided to
resist self-weight and buoyancy forces. Such support shall be required at a minimum
distance of two ring lengths back from the leading edge of the tunnel lining.
4.
Pumpability: Flow characteristics such that complete filling of the annular space between
the excavated ground and the erected lining are easily achieved.
SOIL CONDITIONING AGENTS

Soil conditioning agents may be one or more of the following:
1.
Water.
2.
Bentonite slurry.
3.
Surfactant foam.
4.
Carboxy Methyl Cellulose (CMC) Polymer.
5.
Others as submitted to and approved by the RE.
PRECAST CONCRETE LINING AND ACCESSORIES

Refer to Section 02340 - Precast Concrete Tunnel Liners.
POWER SUPPLY
A.
The Contractor shall supply and install below-ground and above-ground power and control
packages and cables transforming high voltage electrical power to the necessary voltage for the
TBM, back-up plant and equipment.
B.
Provide backup power supply from on-site generators for lighting, compressed air, breathing air
in airlock, ventilation, pumping, and other essential systems.
2.06
A.
MECHANICAL LAUNCH AND RECEPTION SEALS

Each of the launch and reception seals shall comprise at least two independent seal components:
1.
One seal shall engage the body of the TBM.
2.
The other seal shall engage the precast concrete tunnel lining.
PART 3 EXECUTION
3.01
A.
GENERAL
TBM tunneling shall be carried out from the Staten Island Shaft (the launching shaft) to the
Brooklyn Shaft (the receiving shaft).
02330 - 18
B.
Probe drilling ahead of the face shall be carried out to provide continuous coverage of probe
drilling for the entire length of the tunnel drive.
C.
Perform Work in a manner that minimizes safety hazards and exposure of personnel and
equipment to hazardous and potentially hazardous conditions in accordance with specified
safety requirements and Contractors Health and Safety Plan.
D.
Maintain clean working conditions inside the tunnel. Remove slurry spills, muck spills, grout
spills, and any other material not to be used for tunneling.
E.
Provide a clear and continuous walkway from the TBM launching shaft to the tunnel face, to
allow access and egress for normal and emergency conditions. The walkway shall be free of
slipping and tripping hazards, and maintained in good repair at all times.
F.
Daily Meeting: Commencing when power is connected to the TBM the Project Manager,
Tunnel Superintendent and other personnel as required shall meet daily with the RE. Present
and discuss information about recent activities and upcoming work, including the following
items:
1.
2.
3.
4.
General:
a.
Review TBM Shift Reports.
b.
Status of Submittals and Deliverables, and issues arising.
c.
Any other issues.
Instrumentation and Monitoring:

a.
Review geotechnical and structural monitoring data.
b.
Settlement events, including monitoring data exceeding orange trigger review level
or red trigger alert level. Present causes, consequences and corrective actions.
c.
Instrument problems, data availability, erroneous readings and reliability issues,

and corrective actions.
Health and Safety:

a.
Reportable accidents or near-misses.
b.
Actions taken to improve and maintain health and safety.
TBM Operation Parameters, including:

a.
Current TBM station and daily advance rates.
b.
TBM deviations from alignment, and corrective actions.
c.
Ground conditions, face control, over-excavation events, grout takes, and grouting
events.
d.
Modifications to method statements in response to geotechnical and structural

monitoring data or other events.
e.
TBM and construction team performance, including stoppages and delays
f.
Review actual performance in comparison with planned operational parameters.
02330 - 19
5.
Tunnel Liner:
a.
Ring build quality, including any damage and repairs.
Presentation and discussion of issues at the Daily Meeting shall not relieve the Contractor of
Submittal, Deliverable and other Contract requirements. Minutes produced during the
meeting shall be signed by all attendees.
G.
Provide all labor, materials, tools and equipment, including TBM, slurry treatment plant, muck
handling systems, segment storage and handling facilities, cranes, tracks and ancillary
equipment necessary for excavating and constructing tunnels by TBM, and for performing all
other operations described herein.
H.
Prevent unauthorized entry into the tunnels and shafts using physical barriers and surveillance.
Maintain continuously up-to-date record of all personnel in the tunnels.
3.02
TUNNEL BORING MACHINE OPERATION AND MAINTENANCE
A.
Operate and maintain the TBM in accordance with the manufacturers guidelines and
recommendations and submitted method statements. Method statements and tunnel excavation
procedures shall be continually reviewed, updated, and improved based on back-analyzed
monitoring data and TBM parameters. After each ring build and shove cycle, record any
deviation from the method statement and provide details in the TBM Shift Report.
B.
Arrange for the TBM Manufacturer to have experienced TBM Technical Representatives on
Site that meet the qualification requirements of this section:
1.
2.
On a full-time basis:
a.
To supervise and assist with assembly, commissioning, and launch of the TBM;
b.
To provide hands-on training for all Contractor-designated TBM Operators; and
c.
As a minimum: for the first 1,000 ft of tunneling.
As a minimum: attendance thereafter every two weeks for testing and inspecting of the
TBM during normal tunneling operations or maintenance shifts.
C.
Operate TBM using a minimum face pressure at invert level equal to groundwater pressure plus
the effective active soil pressure, and maximum face pressure at invert level equal to
groundwater pressure plus effective at-rest soil pressure, in accordance with the method
statement. Face pressures shall account for any hydrostatic pressure as determined at the tunnel
invert. Adjust pressures as necessary to meet requirements herein for face control and to
maintain ground deformation within allowable limits.
D.
As the TBM advances, continuously inject tail seal grease under pressure to minimize risk of
groundwater or grout intrusion into the TBM.
E.
Excavate for a length sufficient only for the erection of one ring after the previous ring has been
erected and grouted. Do not mine forward until the lining has been grouted up to the TBM
shield.
02330 - 20
F.
Interventions and inspection of the cutterhead and forward shield are discussed in the GBR. To
prevent damage to the TBM cutterhead, perform inspection and replacement of worn cutting
tools on the TBM cutterhead in accordance with approved method statements. All access into
the excavation chamber shall be in accordance with the approved method statement. The
Contractor must evaluate the ground conditions, selected TBM, and means and methods of
operation to determine the appropriate number and location of interventions required, and
perform ground treatment if necessary.
G.
Whenever there is an incident or stoppage of Work that, in the opinion of the RE, is likely to
cause excessive settlement or endanger stability of excavation or adjacent structures or
pipelines, or endanger the public, maintain sufficient personnel on the Site for 24 hours a day,
including weekends and holidays, to cope with the incident or hazardous condition until the
incident or stoppage is rectified.
H.
During periods of stoppage and shutdown, maintain positive support of the tunnel face. Ensure
the plenum chamber is filled prior to the restart of tunneling.
I.
During periods of extended stoppage, prevent TBM entrapment by positive means such as
injection of bentonite slurry around the TBM shield, or other applicable measures required.
J.
Provide suitable shaft wall or temporary ground support to prevent ground loss during launch
and reception of TBM. Provide suitable mechanical seals to the extrados of the tunnel lining at
these locations to prevent loss of soil, groundwater and annular grout. Prior to removal of the
TBM ensure that all rings in the vicinity of the receiving shaft wall are fully grouted and
secured.
3.03
A.
3.04
A.
SOIL CONDITIONING
Inject appropriate soil conditioning agents as required to optimize the consistency of excavated
muck in the plenum chamber, to facilitate control of pressures during pressurized face
operation, to facilitate muck removal through the muck removal system and to reduce
cutterhead and mucking system wear.
ALIGNMENT CONTROL
The Contractor shall determine and advise the RE of the steering tolerances to be utilized for the
control of the tunnel alignment to ensure the Works are completed to the specified tolerances
defined herein. The center of the TBM shield in the ring-build area shall not deviate from the
designed center of the segmental tunnel lining shown on the Contract Drawings by more than 4
inches. Positive steps to return the tunnel drives to the design alignment shall be taken before
the tunnel excavation deviates by more than 50 percent of the steering tolerance. Such action
shall not relieve the Contractor of responsibility to ensure that segments are constructed within
tolerance and shall not be detrimental to joints and gaskets. When deviations are in excess of
50 percent of the steering tolerance, the Contractor shall immediately inform the RE and submit
a corrective action report. The Contractor shall continue to monitor the corrective action and
shall submit further proposals to limit further deviation should it increase to 75 percent of the
steering tolerance. Should the deviation reach 100% of the maximum tolerance the Contractor
shall cease TBM operation, secure the tunnel, and resubmit revised proposals for corrective
action to the RE. In addition if at any time during the excavation of the tunnel, it is evident that
the alignment of the tunnels will lead to the Permanent Works alignment deviating outside the
specified tolerance then, before proceeding with the excavation, the RE and the Contractor shall
02330 - 21
agree the necessary corrections to the alignment and the Contractor shall immediately make
such corrections.
B.
Check accuracy of guidance system by performing check surveys in accordance with reviewed
method statement. Perform independent verification survey of the TBM shield by means of
conventional survey to determine shield position and attitude (station, horizontal and vertical
offsets from the design alignment, pitch, yaw and roll), compare results with TBM Guidance
System data, and submit to RE as required herein.
C.
Immediately stop the TBM and secure the tunnel when the TBM Guidance System fails or is
not functioning correctly. Do not resume advance of the TBM until the TBM Guidance System
is functioning correctly.
D.
Validate tunnel line and grade continuously as specified herein with survey control being
undertaken by qualified survey personnel in accordance with Section 01050 Field Engineering
and Surveying.
3.05
PROBE HOLES
A.
Prepare logs of all probe holes. The logs shall include the following minimum information:
date; time (start and finish); drilling supervisors name; location of hole; horizontal and vertical
orientation; length; drill penetration rate (and changes in penetration rates); thrust; torque; feed
rate; location, nature, color and quantity of any water inflows including drill water inflow
pressure, drill water inflow rate, and back-flow rate through drill string; loss of drilling water;
indications of any soft zones; description of cuttings and any other drilling or geological
anomalies.
B.
Prepare logs of all holes drilled for ground treatment from the TBM in accordance with
requirements for probe holes.
C.
Where ground treatment is performed, record grout injection pressure, grout injection flow rate,
grout volume injected, and injection time.
3.06
A.
PRECAST CONCRETE LINING ERECTION

Tunnel Lining Handling:
1.
Handle segments during transportation and erection processes so as to prevent damage

and in accordance with Section 02340 Precast Concrete Tunnel Lining.
2.
Inspect concrete segments, joint connection assemblies, compression packers and gaskets
before taking segments underground and just prior to erection. Complete quality control
sheet, recording the following:
a.
Verify that no damage has occurred to the lining gaskets during shipment and prior
to lining erection. If only superficial (i.e. cosmetic) damage is noted, the damage
shall be repaired prior to erection in accordance with agreed procedures to the
approval of the RE. If structural damage (e.g. reinforcement exposed, segment
cracked, or gasket groove damage) is noted, the RE is to be notified and the
segment shall be removed from the tunnel and replaced with an undamaged
segment. Such damaged segments are not to be installed.
02330 - 22
B.
b.
Ensure all accessories such as packers are properly positioned and attached. Insert
dowels into circumferential joint holes immediately prior to liner erection in
accordance with the manufacturers recommendations.
c.
Non-conformance reports shall be prepared for all damaged segments.
Ring Build:
1.
Erect rings within the protection of the TBM tail shield in the order and with the taper
orientation required to follow the TBM and negotiate horizontal and vertical curves and
to correct for line and level. Do not use shims or packing for this purpose.
2.
Ensure the invert of the tunnel in the ring assembly area is clear of water, soil, grout, oils
and associated debris prior to commencement of the ring build cycle. Clean joint surfaces
of previously installed segments and new segments immediately prior to erection.
3.
Lubricate gaskets using a product recommended by the gasket manufacturer prior to

erection. Do not apply ram loads or ram shoe loads directly onto gaskets. If any damage
or displacement of the gasket occurs during erection, the segment is to be removed and
either an undamaged gasket shall be fitted or the segment shall be replaced.
4.
Prior to engaging the dowels in their sockets ensure correct alignment of each segment.
No lubrication is to be applied to these connectors.
5.
Fully tighten bolts on radial joints at the time each segment is positioned to maintain joint
faces in contact and gaskets in compression. The circumferential joints shall be closed by
the thrust rams, this force shall be sufficient to adequately compress the gaskets, and the
pullout resistance of the dowel system shall be sufficient to maintain the gasket
compression prior to the release of the thrust rams.
6.
Locate radial joints in adjacent rings so that there are no continuous radial joints.
7.
Thrust rams shall be kept in contact with the segments at all times. Retract only the rams
necessary to install a single segment and reapply contact before proceeding to the next
segment.
8.
Do not apply eccentric loads to the segments or gaskets that are detrimental to the liner
system during the erection sequence or force segment ring out of circular geometry.
9.
Maintain sufficient clearance between the shield and segmental rings to ensure that
alignment control is not compromised, that segments are not overstressed or displaced,
and tail seal brushes work effectively. Measure clearance at top, bottom, and both sides
of the shield.
C.
Segment bolts shall not be utilized for temporary support of services in the tunnel. Dimples on
the intrados surface of segments shall be provided to identify locations where holes may be
drilled into the lining for attachments as indicated on the Contract Drawings. Design anchors so
that the maximum drill-hole depth shall not exceed 4 inches.
D.
Clearly number every fifth ring following erection using stenciled paint or similar with 4-inch
high characters.
02330 - 23
E.
On completion of tunneling and prior to installation of the steel water main or placing the
backfill concrete thoroughly clean and wash the tunnel lining in accordance with Section 02400
Tunnel Cleaning.
F.
Refer to Section 02340 Precast Concrete Tunnel Lining for additional requirements.
3.07
DAMAGED SEGMENTS
A.
Any segment with defects existing prior to erection shall be repaired or rejected in accordance
with Section 02430 Precast Concrete Tunnel Lining.
B.
Segments with visible damage to concrete or gasket during erection or during the first 12-inches
of shove shall be disassembled and removed, and will be rejected.
C.
At any time after 12-inches of shove, should any new cracks or concrete defects occur, or an
existing crack or defect become enlarged, then:
3.08
1.
Immediately provide a non-conformance report. Should RE deem that an installed

segment cannot be repaired in accordance with accepted Contractors repair procedures,
or that the damage is sufficient to compromise the integrity of the lining, the segment will
be rejected. Propose remedial works to the RE for acceptance.
2.
Investigate and provide to RE potential reasons for damage or defect. Submit any
proposed modifications to method statement to avoid recurrence. Review the following
with the RE:
a.
Grout records.
b.
Thrust records and thrust ram selection.
c.
TBM operational parameters.
d.
Proposed changes to method statements.
3.
Repair segments with minor damage or defects in accordance with the reviewed
Contractors method statement and ACI 224.1 to maintain the structural integrity of the
segmental lining system.
4.
Record all repairs and report them to the RE.
MONITORING AND CONTROL FOR TUNNEL LINING
A.
Perform surveying in accordance with Section 01050 Field Engineering and Surveying, and as
specified herein.
B.
Advance and verify all underground tunnel control after every 500 feet of tunnel advance.
C.
Conduct daily walk-through to visually identify new or worsening cracks, leakage or other
defects. If such defects are identified, use suitable monitoring devices to measure crack widths,
defect size and inflows, and survey the segments as described below, until measurements
improve or stabilize for at least 30 days. Work in accordance with reviewed method statement.
D.
Not used.
02330 - 24
E.
F.
Survey a segmental ring(s), as described in Article 3.08F, when any of the following occur:
1.
Immediately following the installation of the ring, before starting to assemble the
subsequent ring.
2.
Within one shift of the ring clearing the end of the trailing gear.
3.
At least once every shift if in-tunnel surveys or observations indicate ongoing movement.
4.
After completion of all proof grouting in the tunnel. This Post-Grouting Survey shall
locate every third lining ring through the tunnel. Where the survey shows that a section of
tunnel is outside specified tolerances, survey shall be carried out at every ring throughout
that section plus a length of ten rings on each side. This survey shall be based on the
Primary survey control network once it has been adjusted and finalized after TBM holethrough.
For each ring surveyed, perform the following tasks and provide Ring Survey Report to the RE.
Provide paper and electronic spreadsheet copies of survey data on the day the measurements are
taken:
1.
Survey the location of eight points around circumference. The points surveyed shall be
one in the crown, one in the invert, one at each end of the horizontal axis, and one at each
end of the diagonals at 45 degrees to the vertical axis. All measurements shall be taken
on the trailing edge of the ring and at the inside face of the linings. Provide coordinates
(station, offset, Easting, Northing, and elevation) relative to the design tunnel alignment,
and diametric dimension between opposing points.
2.
Calculate tunnel centerline from a best-fit circle through the surveyed points and provide
as coordinates (station, offset, Easting, Northing, and elevation).
3.
The following surveys/records are required for all ring surveys except the Post-Grouting
Survey:
4.
a.
Measure the steps at radial joints between each segment in the ring.
b.
Measure the maximum steps at circumferential joints between the surveyed ring
and the next. Measure the maximum step at the trailing edge of each segment in
the leading ring.
c.
Measure the width of the caulking groove at the radial joint between each segment
in the ring.
d.
Measure the width of the caulking groove at the circumferential joints between the
surveyed ring and the next. Measure the maximum width at the trailing edge of
each segment in the leading ring.
The following surveys/records are only required for the survey immediately following the
installation of each ring:
a.
Planarity of the leading edge of the ring.
b.
Key position.
c.
Date, time and shift built.
02330 - 25
G.
If any measurements indicate excessive deformations are occurring, advise the RE immediately
and take corrective measures as approved by the RE. Take additional readings on affected
sections on a daily basis or more frequently, if required. Deformation shall be considered
excessive if diameter changes by more than 1 inch from that measured at the time of completion
of ring build or if contract-specified tolerances are exceeded.
H.
Within two weeks of the final segmental ring in the tunnel being assembled, and prior to
performing the Post-Grouting Survey, perform a closed traverse through the completed tunnel
returning at surface level to verify the accuracy of the Primary survey control network. Tie the
survey into the Primary survey control monuments. Establish Primary survey monuments along
the tunnel, spaced in accordance with Primary survey requirements. Prepare the final Primary
survey control network diagram accompanied by an updated Primary survey monuments list
based on the overall least square network adjustment.
I.
Assessment by the RE of any length of tunnel cannot be completed until as-built survey data
have been supplied for at least 250 feet into adjacent lengths of tunnel. The RE may design and
adopt an amended pipe alignment at the RE or the Corporations sole discretion. Contractor
shall pay all of the costs that are associated with designing and adopting an amended pipe
alignment. A time extension shall not be granted for any delays associated with the evaluation
of realignment possibilities.
J.
If an amended pipe alignment is adopted, carry out all subsequent work in accordance with that
amended alignment.
3.09
TUNNEL GROUTING
A.
Only use procedures, mixes and equipment that have been approved by the RE.
B.
Continuously backfill grout the annular gap between the excavated tunnel and the extrados of
the precast tunnel lining through the TBM tail shield as the TBM advances. Maintain sufficient
grout to fill voids produced by advance including for wastage. Inject the grout such that the
annular space between the tunnel lining and the excavated profile is kept completely filled as
the TBM advances and that the designed grout pressure is maintained until the grout has set.
C.
Provide an automatic computer operated grouting system linked to the TBM Programmable
Logic Controller (PLC) system to calculate grout quantities and continuously adjust grout
injection rate and pressures and other data. Provide an interlock system so that the TBM cannot
be advanced unless the tail grouting systems are operational and capable of providing the
required grout.
D.
The minimum grout pressure at point of injection shall be 10 psig above the hydrostatic
pressure at the point of injection.
E.
The TBM shall not advance when grouting equipment is not fully functioning.
F.
The Ring Grouting Report shall include records of all tunnel lining grouting operations,
including:
1.
Total volume pumped at each grouting location.
2.
Average take volume per ring grouted compared to theoretical.
02330 - 26
G.
H.
3.10
A.
B.
3.
Pressures used at start and end of grouting operations.
4.
Grout mixes used, volume of grout batched, the actual quantities of grout mix
constituents per batch, the date and time of batching, and the name of the batch plant
operator.
5.
10-ring rolling average of grout takes compared against the theoretical quantity.
Proof Grouting:
1.
Proof grouting shall be undertaken in selected rings in areas where the 10-ring rolling
average grout take indicates takes below the theoretical for more than three consecutive
rings or in areas where voids may be present as a result of over excavation or loss of face
support, or as required by the RE. Proof grouting shall be performed by means of
removing grout plugs from the tunnel lining and drilling a hole to the back of the existing
grout. This shall be undertaken as soon as practicable but within 14 days of the annular
grouting operation or when the face has advanced 300 feet from the location of the
annular grouting whichever first occurs.
2.
Drill-through blow-out-preventers must be used for drilling proof grouting holes and for
proof grouting.
3.
Each hole shall be grouted at a pressure equivalent to approximately two thirds of the
overburden pressure, up to a maximum of 50 psig or as determined by the RE.
Temperature: Maintain contact surfaces above freezing for the minimum period called for in
ACI Committee 306, Cold Weather Concreting or the grout manufacturers specifications.
LINING INSTALLATION TOLERANCES
Erect segmental tunnel linings such that they conform to the following tolerances:
1.
As shown on Contract Drawings.
2.
The center of the segmental ring, calculated from the surveyed points, shall not deviate
from its design position by more than 3 inches, including all cumulative effects of
fabrication, survey, setting out, steering, excavation alignment, and building errors.
3.
The variation of the measured internal liner diameter from the design diameter measured
vertically and horizontally across the axis shall not deviate by more than plus or minus
0.5% of internal diameter.
4.
The plane of the leading face of the leading ring shall not depart at any point from plane
surface by more than 0.125 inches.
5.
Stepping or lipping on the internal surface between abutting segments on radial and
circumferential joints shall not be greater than 0.3 inches.
6.
The width of any radial joint shall not vary by more than 0.1 inch along the length of the
joint (birdsmouthing).
Out-of-Tolerance Lining:
02330 - 27
C.
3.11
1.
Submit a non-conformance report immediately for any segment or ring that is found to be
out-of-tolerance. State proposed remedial actions.
2.
Implement remedial actions for out-of-tolerance linings in accordance with submitted

method statement.
3.
Identify cause of out-of-tolerance segment or ring and state measures to prevent

recurrence.
Any requirements of this Section shall not be taken to imply any relaxation of the requirement
to install all required bolts or dowels.
WATER LEAKAGE
A.
Water leakage into the tunnel through the bolted, gasketed, precast concrete segments after
segment installation and annular grouting, but prior to the installation of the pipeline, shall be
limited to a maximum of 1 gallon per minute over any 1000 lineal feet of tunnel at any location.
B.
Leakage into the completed tunnel shall be restricted to damp patches on the face of the
concrete and to minor weeping of joints. Damp patches shall have no visible film of water.
Minor weeping is limited to a maximum of one drip per second per ring.
C.
Inspect all locations of water leakage daily for signs of ground loss. In the event that soil is
noted to be leaking through the lining grout the leak immediately until water and soil are no
longer entering the tunnel.
D.
Where water leakage rates into the tunnel exceed the specified limits, Contractor shall rectify
this prior to installation of the pipeline in accordance with submitted method statement.
Remediation may be performed by grouting, injection of cracks, or by other approved means.
Caulking of caulking grooves is not permitted.
E.
Establish grout injection pressures by means of an on-site demonstration. Do not damage the
lining.
3.12
A.
3.13
A.
DISPOSAL OF MUCK
Remove and dispose of muck (excavated material) from the bored tunnel in accordance with
Section 13140.
VENTILATION AND UTILITIES DURING TUNNELING
Refer to Section 13130 - Temporary Tunnel and Shaft Ventilation and Utilities.
END OF SECTION
02330 - 28
SECTION 02338
SHAFT SUPPORT GROUND FREEZING (Optional)
PART 1 GENERAL
1.01
DESCRIPTION
A.
This Section specifies requirements for the provision of all labor, supervision, equipment,
materials, testing, design, installation, operations and monitoring of a ground freezing system (if
selected) for the excavation support for the Staten Island or Brooklyn TBM launching and
receiving shafts. Ground freezing shall be used as excavation support for the duration
necessary.
B.
Perform a design of the ground freezing system, including the power supply, freeze plant, type
of coolant used, coolant distribution system, location and details of freeze pipes, connections
and all components required to freeze the ground including estimated time for initial freeze,
maintenance phase freeze and time for thawing. Provide a written design report for the REs
approval.
C.
Provide the equipment, materials and labor; install; and operate the ground freezing system to
establish a structurally stable excavation and groundwater cut-off prior to the installation of
shotcrete support. Provide groundwater cut-off for the TBM break-in/out at intersection of shaft
and tunnel through saturated ground to prevent the flow and seepage of groundwater from
entering the excavation.
D.
Maintain ground freezing after completing the shaft excavation and TBM break-out and breakin operation period or until such time as the permanent shaft support has been installed.
E.
Provide the equipment, materials and labor; install; operate; and monitor ground temperature
measuring devices and the ground freezing system. Provide and operate an automatic data
collection readout and presentation system for ground and freeze plant temperature
measurements. Start monitoring ground conditions at least one week prior to the start of
freezing and continue monitoring through the end of the thaw.
F.
Dismantle and remove the ground freezing system. For brine coolant, purge system with air to
remove brine. Dispose of all fluid gases (ammonia, brine) in accordance with applicable
regulations and remove ground freezing distribution system, fill abandoned pipes with grout and
cut below grade. Restore wall penetrations and all other disturbed components related to ground
freezing and thawing to its original condition and the satisfaction of the RE.
1.02
RELATED WORK
A.
Control of Ground Water and Surface Water is included in Section 02145.
B.
Tunnel by Tunnel Boring Machine is included in Section 02330.
C.
Geotechnical Instrumentation and Monitoring is included in Section 02495.
D.
Shotcrete is included in Section 03380.

02338-1
1.03
DEFINITIONS
Bar Unit of pressure equal to 10 meters of water or 14.2 psi
Closure A freeze wall has closure when all of a freeze wall has been frozen completely
and to a sufficient thickness through all soil layers such that external groundwater is isolated
from and does not flow into an internal excavation as it advances.
Coolant Either a brine solution or liquid nitrogen used to freeze the groundwater.
Cool-down period when coolant is circulated to start the freezing process and continues
until the system has achieved closure, minimum wall thickness had been
attained and design average temperature of the frozen wall has been
attained.
Frozen Ground Ground with an average temperature of -2 C.
Freeze plant cooler plant used to circulate the coolant throughout the freeze system.
Freeze pipe conduit used to move the coolant throughout the freeze system
Freeze system Entire system to operate the freezing operation including plant, all
supply and return lines, freeze casing pipes, freeze pipes, manifold
system.
Freeze Wall Frozen ground formed by circulation of chilled brine or liquid nitrogen through
freeze pipes forming a generally circular that provides ground support for an
internal excavation and that isolates groundwater from the excavation.
Temperature pipe brine filled pipe used to encase thermocouples to monitor the ground
temperature
Thaw cycle time period when reduced or no coolant passes through the freeze pipes
thereby allowing the ground to warm.
1.04
A.
REFERENCES
All work and materials shall comply with applicable rules, regulations, codes, ordinances and
standards of the following ASTM requirements:
ASTM C33
ASTM D421 or D422
ASTM D784 or ASTM F480
ASTM D1784
1.05
A.
Filter Sand
Grain Size Analysis
PVC Pipe
PVC and CPVC Compounds
QUALIFICATIONS
The Ground Freezing Contractor shall be experienced in ground freezing with a minimum of
five project performed within the past ten years and shall have sufficient personnel competent in
using the ground freezing refrigeration plant, manifold distribution system, and monitoring
instrumentation to successfully complete the work.
02338-2
B.
Ground freezing Superintendent shall be available full time on-site individual responsible for all
ground freezing operations per shift. The Superintendent must be involved in at least five projects
within the last five years using brine freezing in ground freezing and competent in using the
ground freezing refrigeration plant, manifold distribution system, and monitoring
instrumentation.
C.
Shift Supervisors: shall have at least five years of experience in past ten years in charge of
ground freezing operations for groundwater cut-off and ground support. The assigned crews
working on the ground freezing system shall each have a minimum of two previous projects
working at similar tasks.
D.
1.06
The Ground Freezing Contractor or the drilling subcontractor, as a minimum shall:

1.
Have at least three (3) years experience drilling horizontal drill holes of the size and depth
proposed by the Contractor in the ground freezing plan.
2.
Show that they are experienced with the use of their proposed freeze-pipe survey
instrument.
QUALITY CONTROL
A.
Freeze pipe locations and elevations shall be surveyed after installation. The method of freeze
pipe installation selected by the Contractor shall be capable of installing freeze pipes with
minimal deviation from planned line and grade to prevent creating unequal separation between
freeze pipes with depth which may lead to insufficient freezing resulting in windows in the
frozen boundary.
B.
Closely spaced freeze pipes at the perimeter of the ground freezing areas shall be located in plan
and surveyed with proper equipment to define the position and spacing of the pipes below the
ground surface. .
C.
Temperature (monitoring) pipes and each adjacent freeze pipe shall also be surveyed as
described in Paragraph 1.06-A.
D.
Installed freeze pipes and temperature monitoring pipes shall be leak tested with water under
pressure as described in Part 3.05 of this specification before further connections to the freeze
system.
E.
All work shall comply with the applicable rules, regulations, codes and ordinances of State and
Federal authorities.
F.
Monitoring Instrumentation used for data acquisition shall include the following:
a. Ground temperature
b. Return coolant temperature for each pipe or grouped series of pipes
c. Coolant manifold pressure
d. Coolant manifold flow
e. Brine tank level or nitrogen storage tank level including amounts of back fill
f. Brine density
g. Ammonia concentrations inside and immediately adjacent to the freeze plant
h. Oxygen concentrations in shafts and tunnel (if liquid nitrogen is used).
i. Internal and external groundwater level.
02338-3
j. Pumping rates and amounts of any pumped water from pump tests.
G.
All data points except monitoring wells, piezometers, and brine density shall be connected to an
automatic monitoring device to allow acquisition of data a minimum of one reading per hour.
Data acquisition device shall have dial in/out capabilities for on line monitoring.
H.
Monitored data shall be prepared by Contractor and submitted to the RE in plotted format
showing:
a. Acquired value versus time
b. Temperature versus temperature pipe length ( ground temperature points)
c. Temperature versus distance from closest freeze pipe (ground temperature points)
I.
The Contractor shall perform quality control monitoring during installation of the freeze pipes,
during ground freezing to closure and development of the wall, and during excavation and
lining. Specific quality control activities and requirements are set forth in the following sections:
1.
Freeze Pipe Pressure Testing: after installation of the outer freeze pipe, the pipe shall be
pressure tested to 10 bars for 15 minutes. If a brine solution is used as coolant, second
pressure test shall be conducted after the initial cool-down of freeze system (brine not
warmer than -35C) each freeze pipe or group shall be pressure tested with the already
filled brine pressurized to 2 times the Contractors planned operation pressure. Freeze pipe
must hold this pressure for a minimum of 15 minutes.
2. Freeze Pipe Installation Survey: after completion of the pressure test, each freeze pipe shall
be surveyed at the ground surface, to obtain the as-built surface location, and down-hole
surveyed to determine the pipes location at depth, particularly in relation to adjacent pipe
locations.
3
Temperature Measurements of the Frozen Soils: ground temperatures shall be monitored

throughout the depth of frozen wall..
4. Groundwater Monitoring During Freezing: in addition to an open standpipe well,

piezometers shall be installed at locations. Water level readings shall be taken frequently
throughout the freezing period. Prior to excavation, the water level within the shaft shall be
pumped down from the open standpipe well, and readings will be taken at the piezometers
outside the wall to verify that no continuity between internal and external wells exists.
5. Refrigeration Plant Performance: the performance of the refrigeration plant, brine flow
volume and temperature in circulation and possible leakage of brine or refrigerant shall be
monitored to ensure efficient cooling. The Contractor shall carry sufficient spare parts to
ensure that the refrigeration plant functions as designed by the Contractor.
1.07
A.
CONTRACTOR SUBMITTALS
Company experience using ground freezing. A minimum of three (3) projects performed within
the past seven (7) years shall be presented including date of project, location, excavation type,
responsible personnel, client and contact address and phone number, size of job in dollars, and
performance. Calculations and drawings shall be prepared, stamped, and signed by a registered
Professional Engineer in the state of New York.
02338-4
B.
Report summarizing the detailed ground freezing design, testing, and modeling. Submit a work
plan, which describes the Contractors proposed freezing sequence.
Plans and manufacturers specifications, and off-site performance test results for the
refrigeration plant to be used at the site. This information should include the type of coolant, the
size and power capacity of the compressor, the size and type of condenser, the size, type, and
temperature drop of the chiller / evaporator, the type and expected temperature range of the
brine, and the volume capacity of brine circulation pump. Include projected maximum and
average operating ranges.
D.
Submit the details of the freeze pipe installation procedures and equipment. This submittal shall
include:
1.
A freeze pipe layout plan, which includes location of each pipe and installation sequence.
2. Schematic details of the freeze pipe including drill hole, outer and inner freeze pipe
diameter, and type size and construction of the outer and inner freeze pipes.
3. As-installed surveyed location drawings showing sections of freeze pipes, temperature pipes
and thermocouples.
4. Method of drilling and supporting the drill holes. Include type of temporary casing or
drilling fluid, and outer freeze pipe backfill details.
5. Methods and criteria for pressure testing of each freeze pipe.
6. Methods and equipment to be used for down-hole surveys.
7. A schematic detail of the freeze pipe header assembly at the top of the freeze pipe.
8. A schematic detail of the brine circulation manifold.
9. Manifold and head insulation details.
10. Calibration test of temperature monitoring device to be used.
E.
Plan drawing of planned freeze pipes indicating planned tip elevation, diameter, and wall
thickness of pipes to be installed. Assignment of a unique identification number to each freeze
pipe.
F.
Plan drawing of supply and collection headers, connection piping, pumps and valves for
circulating and controlling chilled brine. Include flow diagram and valve / pipe schematic.
Details of means for placing and protection of pipes below grade (where required).
G.
Plan drawing of temperature measurement devices, locations, indicating depths, and showing
data collection board and communication cable arrangement. Example of data summary and
presentation formats, with descriptive statement of the data collection and assembly system.
Provide analysis demonstrating area coverage of frozen ground with freeze pipe layout
proposed.
H.
Calculations for design of the freeze plant system, including estimates of energy required for
initial freezing and freeze maintenance phases, brine pump requirements and circulation, time
02338-5
estimates for freezing. Provide calculations demonstrating the temperature criteria for the frozen
ground that will be provided by the proposed system within the proposed construction schedule.
I.
A written methods statement and the details of equipment, including manufacturers

specifications, for the groundwater and temperature monitoring instrumentation used for
monitoring formation and continuity of the ice wall.
J.
Health and Safety Plan for operation of the plant, coolant distribution system, and freeze pipe
headers. The Plan shall address handling chilled liquid, and provision of Material Safety Data
Sheets (MSDS) information and contingency measures for the catastrophic rupture of the
pressurized systems.
K.
Work plan for operation of the cooling plant, distribution system, and if brine is used as coolant
handling and disposal of coolant.
L.
Documentation that brine has been disposed of in an approved manner at completion of the
project.
M. Records of temperature measurements daily.

N.
Schedule of work by task for the construction period.
O.
All field and laboratory test results performed on the soil and groundwater for the design of the
temporary frozen excavation support. These results shall include among others the following:
1. Freeze pipe pressure testing and freeze pipe survey results at the completion of drilling
as defined and required in the Quality Control section below.
2. Groundwater monitoring and temperature monitoring results, as defined in the Quality
Control section listed below, weekly during initial freezing, daily as the wall
approaches closure, and as requested during excavation of the shaft to the RE for
review.
P.
Calculations for design of the frozen earth excavation support with all design assumptions
including average temperature to be maintained of the freeze wall, anticipated frozen earth wall
movements, strength of frozen soil at the average temperature of the freeze wall, and
confirmatory testing results and minimum required frozen wall thickness.
Q.
Calculations for design of the frozen earth excavation support at interface of tunnel and shafts
for safe break-out and break-in operation with all design assumptions including, average frozen
soil temperature within the freeze zone, strength of frozen soil, and confirmatory testing results
and minimum required frozen wall thickness.
R.
The construction schedule in real time for the completion of each shaft.
S.
The freeze-thaw cycle of the frozen soil, the shotcrete curing time, and the shotcrete strength.
T.
Shotcrete mix design with strength test and shotcrete placement requirements for shotcrete to
meet the design strength.
U.
Method, if required, to saturate the soil above the water table.
02338-6
V.
Method of drilling and installing the freeze pipes and the procedure and the tolerance of
maintaining the line and grade of the freeze pipes.
PART 2 PRODUCTS
2.01 MATERIALS
A. Freeze pipes (Brine solution for coolant) 3.5-inches or greater O.D. Schedule 40 seamless steel
pipe, with welded base plates.
B. Freeze pipes (Liquid nitrogen for coolant) 2.5-inches O.D. copper pipe.
C. Coolant Calcium chloride water solution with rust inhibitor and pH neutralized, range of
specific gravity is Contractors option.
D. Distribution System Manifolds and Pipe Connections Materials used for piping and connections
shall be designed for safe operation at temperatures appropriate for the chosen coolant and freeze
system selected by the Contractor. Provide documentation by pipe / connection manufacturer, or
demonstrate by testing.
E. Filter Sand Washed concrete sand meeting ASTM C33.
F. Sand Fill Fine to coarse sand, trace silt and clay, placed with compaction, and moistened to
promote freezing. Suitable for freezing with minimal heave and without secondary frost heave
ice jacking properties. Grain size analysis meeting ASTM D421 or D422 shall be submitted to
the RE for approval prior to use on this project.
G. PVC Pipe and Slotted PVC Intake PVC Type 1, Grade 1 Schedule 40 material as described in
ASTM F480 and ASTM D1784, Class 1245B, to include soundness, ovality and straightness.
2.02
EQUIPMENT REQUIREMENTS
A.
Refrigeration Plant The refrigeration plant shall be a self contained, fully enclosed, sound
proofed plant of sufficient volume to freeze the earth to the limits indicated on the Contractors
Shop Drawings and maintain the frozen soil during the excavation and final lining of the shaft.
Equipment shall be designed and sized by Contractor. Plant shall be modular refrigeration units,
as electrically powered. Plant shall include a stand-by unit to provide uninterrupted service in
the event of an emergency situation. Stand-by units may be used to accomplish initial freeze.
B.
Distribution System Equipment shall be sized by the Contractor. System shall include a brine
balance tank, insulated flow and return mains, and appropriate pumps, valves air release valves,
and temperature and flow measurement instruments. Critical mechanical components shall be
duplicated in order that chilled brine is continuously provided to the freeze pipes throughout the
work. Each freeze pipe shall have an air bleed valve, and each series of freeze pipes shall have
isolation control valves at the headers. Any distribution piping which crosses overhead shall be
double walled for leak containment. The brine circulation system shall have an automatic shutoff control when there is a sudden drop in brine pressure to limit loss if a leak develops. Each
series of freeze pipes arranged in a loop between the supply and return manifolds shall contain
provision for brine temperature measurements for both supply and return, and the temperature
split between these two shall be determined during initial freezing and maintenance.
02338-7
H. Drilled Temperature Pipe 4/5 O.D. Schedule 40 seamless pipes or equivalent with welded base
plate. Installed with and without drainage. Temperature monitoring pipes to be installed through
and across the full width and depth from top to the base of frozen soil mass. Temperature pipes
shall be filled with brine after installation of thermocouples
PART 3 EXECUTION
3.01
GENERAL REQUIREMENTS
A.
Provide both primary and stand-by freeze plants capable of initial freezing and maintaining the
ground frozen. The stand-by plant may be used to assist initial freezing, but shall be held in
reserve during freeze maintenance. The stand-by plant and any other duplicate systems shall be
ready and connected to the brine distribution system at all times.
B.
Obtain and pay for all required permits and certificates where required.
3.02
PREPARATION
A.
Depress freeze pipes and conveyance lines where necessary to provide grade-level access, as
needed. Shore sides and deck over depressed area; maintain access to freezing system for
maintenance and adjustment.
B.
Protect and insulate utilities within the frozen ground areas.
C.
Decking for depressed freeze pipes in the public way shall include a non-skid surface and the
surface maintain free of ice, snow, and standing water.
D.
Construct temporary platform and leak containment structure for ground freezing plant and
related distribution equipment and support facilities.
3.03
DESIGN
A.
The Contractor shall design a ground freezing system to provide and maintain average ground
temperatures at the criteria defined in the approved submittal within the proposed construction
schedule. System design shall include freeze pipes, coolant circulation, control valving, and
distribution system, refrigeration plant, brine, and temperature monitoring of the brine.
Minimum frozen wall thickness shall be 6 feet or calculated wall thickness whichever value is
greater. Thickness shall be measured from the -2 C thermals of the frozen wall from the
monitored thermocouples.
B.
The Contractor shall select pipe spacing, and additional pipes, to accomplish temperature
criteria.
C.
The Contractors coolant piping distribution system design shall include a piping layout that
allows alternating the brine circulating system piping between alternating freeze pipes. The
system design shall have the ability to turn on and turn off every other adjacent freeze pipe
during the maintenance stage of freezing while maintaining a nearly constant operation of the
freeze plant.
D.
The method of controlling secondary ice growth in the event adverse deflection is occurring due
to secondary ice growth.
02338-8
E.
F.
The Contractor shall provide a Design Report to the RE for review that shall include a
description of the proposed ground freezing system. The report shall contain, as a minimum, the
following information:
1.
Statement of System with a description of each component.
2.
Details for installation of pipes and drains.
3.
Details of coolant distribution system and control valves.
4.
Operation details of freeze plant.
5.
Prediction of freezing rates and schedule for freezing.
The Contractor shall provide a calculation that demonstrates his design. The calculation shall
include the following as a minimum:
1.
Thermal capacity of the system to obtain the ground temperature criteria within the project
schedule.
2.
Capability of pumps, valves and conveyance system to circulate the brine in a balanced
manner with a small temperature differential between flow and return during freeze
maintenance.
3.
Capacity of refrigeration plant to cool the brine of primary freezing and to maintain the
brine cooled thereafter.
4.
Adequacy of power supply for refrigeration plant operation.
5.
Required initial freeze time
6.
Temperature development versus time at critical points (e.g. areas with largest freeze pipe
spacing)
7.
Temperature contour lines for initial freezing stage.
8.
Temperature contour lines for maintenance stage.
9.
Freeze wall thickness versus time for each soil stratum.
G.
The Contractor shall prepare shop drawings defining the planned systems for review and
approval of the Engineer.
H.
The Contractor shall develop a schematic profile of system showing interrelationship of freeze
pipe distribution header system with building foundation and other existing subsurface
components. Show all measures necessary to implement the ground freezing system.
3.04
PIPE INSTALLATION
A. Additional freeze pipes shall be installed, or pipes shall be relocated, to meet the maximum
allowable spacing and freeze pipe density criteria given on the Contractors approved Shop.
02338-9
B. Freeze pipes and temperature monitoring pipes shall be installed in accordance with the
requirements of the Contractors approved Shop Drawings.
C. Pipe spacing of the installed pipe shall be verified by survey using appropriate equipment.
3.05
A.
3.06
A.
3.07
A.
B.
3.08
COOLANT DISTRIBUTION SYSTEM

Materials and connections shall be pressure tested at the Contractors proposed pressure, based
upon the operating pressure of the system, for leak detection before brine salt is added.
POWER SUPPLY
Power supply for freeze plant and warming system shall be installed by a licensed electrician
and shall meet Code requirements for permanent works.
OPERATION OF FREEZING SYSTEMS
Ground freezing shall be controlled by the Contractor on a continuous basis including:
1.
Monitoring, operating, and maintenance of the freeze plant.
2.
Continuous operation of the freeze plant.
3.
Removal of air from brine circulation system.
4.
Monitoring ground temperature and evaluating brine temperature splits and trends for
sub-systems and brine loops to locate anomalies and areas drawing greater energy
indicating windows or openings in the frozen ground.
5.
Modifying system to close windows or openings, including installing additional freeze

pipes or cut-off grounding to preclude the flow of groundwater.
6.
Determining from brine temperature split trends and ground temperature monitoring when
closure has been reached.
7.
Estimating, determining, and confirming that the frozen ground temperature is low enough
to permit shaft excavation.
Tolerances The tolerances for elevations, dimensions, and extent of freezing shall be 1.0% of
the drilled length.
MONITORING
A.
Install calibrated ground temperature monitoring devices where indicated on the Contractors
approved Shop Drawings. Obtain base readings at least seven (7) days before ground freezing is
activated in any area.
B.
Monitor brine temperature and ground temperatures to determine progress of ground freezing
and freeze maintenance daily, and adjust the system to provide the ground temperatures
specified or lower temperatures. Submit weekly summary reports that include plots of
temperature versus time for ground temperature, brine temperature, temperature splits at the
freeze plants and each piping loop, brine flow rate, and changes in freeze plant operation.
02338-10
C.
Confirm elevation of freeze pipe and driven temperature points before ground freezing
commences, at five (5) day intervals during initial freezing period and at 20 day intervals during
thaw or more frequently if elevations are changing.
D.
Secure monitoring instruments during backfilling and the freezing plant demobilization, and
continue monitoring temperature, settlement, inclinometer / extensometer through thaw.
3.09
FREEZE SYSTEM REMOVAL
A.
Purge all lines and tanks of brine and evacuate brine from freeze pipes. Brine shall be disposed
off site in an approved manner; provide documentation for disposal.
B.
All coolant distribution pipes, manifolds, tubes and insulation, etc. shall be removed from the
site.
C.
Freeze pipes shall be removed or evacuated of salt brine, flushed with fresh water, filled with
non-shrink grout, cut off, and abandoned in place upon completion of the work.
3.10
RECORD DRAWINGS
A.
Record drawings shall be prepared by the Contractor and submitted for review and approval
after the freezing system is installed. The drawings shall show the surveyed location of freeze
pipes, warming pipes, and monitoring instruments. Provide ID number for freeze pipes,
temperature points, temperature pipe, pile cap drain and drain, show adjacent foundation
elements, and reference column locations.
B.
Summarize monitoring records for all instrumentation and elevation surveys.

1.
Provide plots of measured ground and brine temperatures with time from initiation of
ground freezing through completion of thaw. Submit final summary of items included in
Part 3.08 of this specification.
END OF SECTION
02338-11
SECTION 02340
PRECAST CONCRETE TUNNEL LINING
PART 1 GENERAL
1.01
SCOPE OF WORK
A.
The fabrication, supply and delivery of precast concrete tunnel lining segments, complete with
accessories, for use as a segmental lining ring support in the tunnel.
B.
The Contractor shall furnish a segmental precast concrete lining system, produced to the
specified tolerances, capable of:
1.02
1.
Rapid erection within the Tunnel Boring Machine (TBM).
2.
Providing a watertight barrier when erected within specified erection tolerances to

meet the water inflow criteria specified in Section 02330 Tunneling by Tunnel
Boring Machine.
3.
Resisting loads imposed during manufacturing, handling, storage, transport, erection,

and by soil and water during service life.
4.
Providing a 100-year service life with minimal maintenance requirements.
RELATED SECTIONS
A.
Earth Pressure Balance Tunnel Boring Machine is included in Section 02315.
B.
Slurry Tunnel Boring Machine is included in Section 02316.
C.
D.
Concrete for Precast Concrete Tunnel Lining is included in Section 03360.
E.
Reinforcement for Precast Concrete Tunnel Lining is included in Section 03370.
F.
1.03
REFERENCE STANDARDS
A.
ACI 224.1
Causes, Evaluation and Repair of Cracks in Concrete Structures
B.
ACI 305
Hot Weather Concreting
C.
ACI 306
D.
ACI 309
Guide for Consolidation of Concrete
E.
ACI 503.4
Standard Specification for Repairing Concrete with Epoxy Mortars
02340-1
F.
ACI 517
Accelerated Curing
G.
ASTM A325
Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi
Minimum Tensile Strength
H.
ASTM C1166
Standard Test Method for Flame Propagation of Dense and Cellular

Elastomeric Gaskets and Accessories
I.
ASTM D395
Test Methods for Rubber Property Compression Set
J.
ASTM D412
Test Methods for Vulcanized Rubber and Thermoplastic Elastomers

Tension
K.
ASTM D471
Test Methods for Rubber Property Effect of Liquids
L.
ASTM D573
Test Methods for Rubber Deterioration in an Air Oven
M.
ASTM D1149
Test Methods for Rubber Deterioration-Cracking in an Ozone Controlled

Environment
N.
ASTM D2240
Test Method for Rubber Property Durometer Hardness
O.
ASTM F436
Standard Specification for Hardened Steel Washers
P.
PCI MNL-116
Manual for Quality Control for Plants and Production of Structural Precast
Concrete Products
1.04
DEFINITIONS
A.
Precast Concrete Tunnel Lining System: A tunnel support system to provide ground support and
shall comprise bolted, gasketed, precast concrete segments.
B.
Bolted, gasketted, precast concrete segments: A support system comprising of bolted, gasketted,
reinforced precast concrete segments erected as a ring in the tail shield of the TBM. Radial
joints shall be connected by bolts and circumferential joints shall be connected by dowel
connectors. All segments shall be fitted with gaskets to maintain watertightness. Bolted,
gasketed, precast concrete segments shall also be referred to variously as precast concrete
segments, segment rings, and segments.
C.
Gap: The distance between load-bearing surfaces of precast segments at radial or

circumferential joints. The gap distance is dependant on the thickness of packers, the magnitude
of the compression forces acting upon the segment joint, the amount of gasket compression and
depth of gasket groove. Gap is used as a measure of prestress loading of gaskets during precast
lining erection, and is an indicator of the ability of the gaskets to seal the segmental lining joints
to prevent groundwater leakage.
D.
Birdsmouthing: The opening or closing of a radial joint between two segments relative to the
nominal width of the gap when segments are fully seated and compressed.
E.
Lipping: The deviation of adjacent segments from one another measured at right angles
(normal) to the tunnel axis at the radial joints.
02340-2
F.
Stepping: The deviation of adjacent liners from one another measured at right angles (normal)
to the tunnel axis at circumferential joints.
G.
Packers: A load-distributing element cut from plywood or other approved material to the
geometries of the circumferential and radial segment joints in which they are placed. The
purpose of the packers is to distribute the compressive forces across the segment joint.
H.
Shimming: Element cut from plywood or other approved material to the geometries of the
circumferential segment joints in which they are placed. The purpose of the shimming is to
maintain planarity of the individual segment ring circumferential joints.
1.05
A.
SUBMITTALS
The Contractor shall submit the following documentation to the RE at least 60 days prior to
commencement of precast concrete tunnel lining production:
1.
Method statements and quality control procedures covering all stages of the material
supply, manufacturing, shipping and repair.
2.
Shop Drawings: For each segment type, details of reinforcement, mechanical joint
connection assemblies (dowel connectors with sockets), caulking grooves,
grout/threaded lifting sockets with non-return valves, gasket grooves and gaskets,
bolts with hardware, and bolt inserts. No segments intended for inclusion in the
underground works shall be cast until shop drawings are approved.
3.
Two samples each of mechanical joint connection assemblies (dowel connectors with
sockets), joint gasket material, grout/threaded lifting sockets with non-return valves,
reinforcement spacers, bolts with hardware, bolt inserts, and packers.
4.
Product data for gaskets, gasket mounting equipment and adhesives, bolts and
hardware, and lifting inserts.
5.
Bolt and connector loads required to ensure segment faces are in contact, gasket
performance, and ring stability.
6.
Details of molds proposed.
7.
A detailed description of procedures for fabricating, handling, transporting, and

storing segments, including calculations of stresses during handling.
8.
Documentation by an independent testing laboratory demonstrating joint connector

and lifting inserts capacities.
9.
Methods, procedures and details of the curing process from segment casting to 28
days after casting, with test data including temperature gradient measurements from
trial segments to verify that curing requirements can be achieved.
10.
Methods of quality control to ensure consistency of material and dimensions of the

gaskets.
02340-3
11.
Data to show that the proposed consolidation and curing process will result in
uncracked segments with the strength, permeability and diffusion properties specified
and an acceptable air-void system.
12.
Data establishing the relationships between strength gain and curing time at the range
of temperatures anticipated during the curing process.
13.
Written notice, 14 days prior to the event, confirming the start of the precast concrete
lining production.
14.
Sources of all materials. Notification to occur a minimum of 30 days prior to ordering

materials.
15.
The Contractor shall submit a detailed Quality Control Plan in accordance with this
specification.
1.06
1.07
A.
Design Criteria:
1.
The Contractor is responsible for ensuring the compatibility of the precast concrete
tunnel lining used with the selected TBM and its segment handling, erection, and other
equipment. Should the Contractor propose an alternative segment design to that shown
on the Contract Drawings, the proposed alternative design must be submitted to the
RE for approval at least 60 days before production of the segments is due to
commence.
2.
The Contractor shall retain a licensed Professional Engineer registered in the State of
New York to undertake, stamp and seal such alternative design of the precast concrete
tunnel lining system together with any modifications to the permanent works that may
result from this alternative design.
3.
The selection and detailing of any alternative precast concrete tunnel lining design
will be subject to the provisions of this specification and should consider the effects
of, as a minimum requirement, the following:
a.
Ground units encountered (strength and deformation properties);
b.
Depth of overburden;
c.
Variable groundwater table elevations due to fluctuating harbor water

elevations up to and including the 100-year flood elevation;
d.
Timing of lining installation relative to excavation;
e.
Segment handling and erection loads, including stacking, lifting, erection and
TBM shove ram forces;
f.
Construction and building tolerances, including casting accuracy, ring-build

circularity, lipping, stepping, and birdsmouthing;
g.
Planned operating face pressures, TBM overcut and tail void (annulus) grout
pressure levels;
02340-4
B.
h.
Double or single taper ring required to follow the designed alignment;
i.
Provision of a suitable gasket and grouting methodology to satisfy the water

inflow criteria contained in the Contract Documents; and
j.
Provision for proof grouting.
Quality Control Plan:

1.
The Contractor shall submit a detailed Quality Control Plan that covers all aspects of
the material supply, fabrication, transportation, delivery, storage, protection,
secondary handling and transportation at site, and repair of precast concrete tunnel
linings.
2.
The individual responsible for the quality of the precast concrete tunnel linings shall
have a minimum of 10 years experience in the application of quality control
procedures to the production of precast concrete.
3.
Comply with specified standards as a minimum quality for the work except when
more stringent tolerances or codes indicate higher standards or more precise
workmanship.
4.
Work to be done away from the casting site is subject to inspection on behalf of the
Corporation during its fabrication, manufacture, or testing, or before shipment.
Provide notice to the RE of the place and time where such fabrication, manufacture,
testing or shipping is to be done. Such notice shall be in writing and delivered to the
RE at least 7 days prior to the requirement so that the necessary arrangements for
inspection and witnessing or shop tests can be made.
5.
Where tests or inspections are called prematurely and testing is delayed by the
Contractor, the Contractor shall pay all additional costs incurred.
6.
Where tests or additional tests show the Work does not conform to contractual
requirements, the Contractor shall dispose of the defective Work and replace with new
at the Contractors own expenses.
7.
Provide steel templates, gauges, or electronic measuring systems and testing

apparatus, as required to enable the measurement of tolerances to ensure that each
segment falls within two concentric volumes in space represented at the maximum and
minimum dimensions allowed. Keep such apparatus suitably protected from damage
and distortion, free from dirt and corrosion, and ready for use in checking the
segments as described hereinafter.
8.
The first segment cast in any mold shall be gauged. Thereafter, as a minimum, every
fiftieth segment from each mold shall be gauged. When variation in segment quality
has occurred, the number of segments gauged shall be increased to that required to reestablish the accuracy and consistency of production.
9.
A record shall be kept of all the units cast in each mold and all molds that become
distorted or that cast faulty units shall be withdrawn immediately from service until
they are proven to the satisfaction of the RE to have been corrected.
02340-5
1.08
10.
All units of the same type shall be interchangeable and the dimensions for each unit
shown on the Contract Drawings shall be accurately reproduced within the tolerances
indicated on the Contract Drawings. The accuracy of the orientation of the joint
surfaces is of great importance.
11.
At a minimum frequency of one of every three hundred castings from each mold,
segments picked at random or by the RE shall be built to form rings on the master
rings to ensure that tolerances and interchangeability of segments are being
maintained.
12.
Check formwork dimensions prior to each production pour to ensure tolerances of

each mold are being maintained. Check a minimum of two of every one hundred
segments of each segment type produced on each shift and, as a minimum, ensure that
one segment from each mold is checked weekly for dimensions and tolerances.
13.
Check reinforcement cages and other embedments within each mold.
14.
Minimum quality control requirements for concrete are specified in Section 03360
Concrete for Precast Concrete Tunnel Lining.
15.
Tests to determine the in-place strength of concrete prior to lifting and for proving the
attainment of design strength shall be in accordance with the protocol in the Quality
Control Plan.
16.
The Contractor shall ensure that the lifting insert, if used, has been designed with an
adequate factor of safety and be compatible with the segment erector system on the
TBM.
17.
Verify that the segments have attained the design strength prior to shipping through a
combination of in-place strength testing and comparison with strength gain-maturity
curves. Verify results with cylinder tests from concrete cured with segments.
Frequency of testing shall be established in the approved Quality Control Plan and be
subject to re-approval.
18.
The segments shall be delivered to the tunnel excavation site in undamaged condition.
19.
Provide details of segment storage facilities at the casting site and the tunnel
excavation site, and details of secondary handling and delivery of segments to the
TBM segment erector.
TOLERANCES
A.
Tolerances for segments are shown on the Contract Drawings.
B.
Reinforcing shall be placed within molds to provide the cover between steel and concrete
surface shown on Contract Drawings. The tolerance on concrete cover shall be plus or minus
0.375-inch.
C.
Threaded grout/lifting sockets shall be located within 0.25-inch of the theoretical location.
D.
Bolt inserts shall be located within 0.04-inch of the theoretical location.
02340-6
PART 2 PRODUCTS
2.01
A.
2.02
A.
B.
REINFORCING STEEL
See Section 03370 Reinforcement for Precast Concrete Tunnel Lining.
GASKETS
General:
1.
All segments shall be supplied with a waterproofing compression gasket on the

extrados of all mating faces at the locations shown on the Contract Drawings. The
grooves shown on the Contract Drawings are indicative only and the Contractor may
propose revised dimensions for approval by the RE.
2.
The gaskets shall be designed for a minimum working hydrostatic pressure of 9 bars
with any gap between adjacent segments up to 0.50-inch and parallel offset 0.50-inch
from the ideal position.
3.
The Contractor shall provide evidence to support the durability of the gasket for the
design life based on previous experience of the materials and on the results of
accelerated tests.
4.
The gasket material shall not suffer any adverse effects when exposed to the
groundwater at the working pressure.
5.
The gasket shall be self-extinguishing.
6.
The Contractor shall warrant that the gaskets shall not deteriorate when exposed to
sunlight or ozone for a period of 120 days. Gasket material shall not be affected by
exposure to TBM tail seal grease or to cementitious grout.
7.
The gaskets shall be designed to be kept fully compressed by the radial bolts in the
linings after removal of the erector. The load required in the bolts to ensure this
compression shall be stated. The Contractor shall confirm that the bolts proposed will
provide the full compression force required.
8.
The gasket shall be designed to withstand the TBM erector and thrust ram loads.
Gasket Material Testing: Material tests shall be performed on specimens prepared from
processed gasket compound to ensure that finished gaskets conform to the following minimum
requirements:
1.
Tensile Strength ASTM D412, greater than 1.45 ksi.
2.
Ultimate Elongation ASTM D412, greater than 300 percent.
3.
Hardness ASTM D2240, Type A durometer, 65 5.
4.
Compression Set ASTM D395, Method B.
02340-7
2.03
5.
Short Term Test less than 25 percent compression set after 25 percent vertical
compression for 22 hours at 158 degrees F.
6.
Long Term Test less than 15 percent compression set after 25 percent vertical
compression for 72 hours at 68 degrees F.
7.
Fire rating A concrete test rig shall be used to prove that the gaskets will be
unaffected by fire. The gaskets shall be installed in grooves in concrete blocks in a
manner to be used in the tunnel, with two opposing gasket profiles compressed to a
joint gap of 0.125-inch. Via a burner, a temperature of 1450 degrees F shall be
generated at the intrados for a period of 30 minutes. The distance between the intrados
and the grooves of the concrete test rig shall be the same as the distance between the
intrados and the grooves of the tunnel lining. The temperature generated during the
test shall be measured at the gasket and it shall be demonstrated that less than threequarters of the widths of the gasket profiles are adversely affected.
8.
Aging ASTM D573, 70 hours at 210 degrees F. Changes in material properties shall
comply with the following parameters:
a.
Hardness less than 6 units increase.
b.
Tensile Strength less than 15 percent decrease.
c.
Ultimate Elongation less than 30 percent decrease.
9.
Water Absorption ASTM D471, 70 hours at 158 degrees F, maximum 10 percent

increase by weight. Use distilled water for the standard test liquid.
10.
Oil Absorption ASTM D471, 70 hours at 158 degrees F, in ASTM Oil #3, maximum
change in weight 110 percent.
11.
Ozone Resistance ASTM D1149, by method described in ASTM D518 Method A,

with the stipulations that there shall be no surface cracking when immersed in 200
parts per hundred million (PPHM) ozone solution for 100 hours at room temperature
and 55 percent humidity.
12.
Stress Relaxation using two steel plates, a minimum of 4 inches in length, with
machined grooves, place two full gasket profiles, 4 inches in length, with no offset
condition, and compress to a minimum gap of 0.0625-inch. Measure reaction loads
over a period of three months at 158 degrees F. After three months, calculate by
engineering analysis, the stress relaxation that accrues after 100 years. After 100
years, the remaining stress shall be more than 50 percent of that originally applied.
THREADED GROUT/LIFTING INSERTS
A.
If proposed by the Contractor, the threaded grout/lifting inserts, shall be capable of mating with
the threaded lifting ball used to lift and place the segments by means of the TBM erector arm
and allow for grouting without overstress or cracking of the lining..
B.
Insert shall be cast from a material having a coefficient of thermal expansion similar to that of
concrete. If a material of dissimilar thermal expansion to concrete is chosen, the Contractor shall
take measures to reduce the incidence of microcracking around the insert.
02340-8
C.
Insert shall have triple thread matching the threads on the lifting balls, as detailed on the
Contract Drawings, or similar efficient threading system proposed by the Contractor.
D.
Inside surface of insert shall be furnished with temporary plug to exclude foreign matter until
such time as that segment is to be erected.
E.
Extrados surface of insert shall be furnished with a plastic one-way valve adaptor to permit
grouting from the inside, should tail skin grouting not be proposed, while preventing the inflow
of grout from the annulus.
F.
Intrados surface of insert shall be furnished with a polyurethane plastic plug, with screw thread
to suit, designed to effectively seal the insert from water leakage.
2.04
BOLTS AND WASHERS
A.
Steel Bolts: ASTM A325, hot-dipped galvanized, to dimensions shown on the Contract
Drawings.
B.
Steel Washers: ASTM F436, hot-dipped galvanized, to dimensions shown on the Contract
Drawings.
C.
Hemp Gel Grommets: To dimensions shown on the Contract Drawings. The hemp material
shall be dipped in a mineral gel with a melt index point of not less than 100F. The gel content
and volume shall be sufficient to ensure that when the nut is tightened a satisfactory seal around
the bolt is achieved.
2.05
BOLT ANCHORAGES
A.
The bolt anchorages, including the plastic insert, shall be capable of developing 12 kips in
tension and 12 kips in shear and shall use a 0.75-inch diameter, ASTM A325 bolt
B.
At the same time the bolt and the bolt anchorage pullout capacity must exceed the reaction force
produced by the tributary length of the compressed gasket system as shown on the drawings
with a safety factor of 1.6.
C.
The anchorage shall be a threaded plastic bolt insert as shown on the Contract Drawings, or
approved equal.
D.
Anchorages shall not be within one inch of concrete surface. Provide additional cover if needed
to provide proper anchorage without causing distress to concrete.
E.
Bolt anchorages shall use a straight bolt. Curved bolt systems will not be accepted.
2.06
CONNECTORS
A.
Connector self-locking assembly shall be a fit for purpose specialized product intended for use
with precast concrete segment.
B.
Connector assembly shall be made of stable engineered thermoplastic resistant to the ground
water chemicals and concrete and shall not degrade with time.
02340-9
C.
Connector assembly shall consist of two sockets, cast into segments, and a loose dowel which
self-locks after insertion into the sockets. The dowel may contain metallic core.
D.
The maximum required dowel insertion force shall not exceed 14 kips.
E.
The minimum ultimate load carrying capacity of the installed dowels shall be at as a minimum
equal to 12 kips in tension and 12 kips in shear.
F.
The deformation of the dowel assembly under the full gasket reaction load must be such that the
gap created between the concrete joint surfaces by the dowel slippage and/or extension under
the gasket reaction load does not degrade the gasket performance below the required water
tightness criteria. The effect of the TBM ram loads is to be neglected in these calculations.
G.
The dowel assemblies must be flexible and deformable enough to allow the full intended
closure of the circumferential joint gap even in the case of the dowel - socket position
misalignment of up to 0.25-inch without damaging the surrounding concrete and/or damaging to
the connector assembly that would prevent the intended closure of the joint (mushrooming of
the dowel material at joint faces).
H.
The maximum connector assembly diameter shall be one-third of the lining thickness where the
minimum assembly length is 7 inches.
I.
The proposed connectors must have been successfully used on at least 5 completed projects.
2.07
A.
2.08
CONCRETE
Refer to Section 03360 Concrete for Precast Concrete Tunnel Linings.
MOLDS
A.
Molds for precast segment production shall be specifically made for this purpose. The
manufacturer of such molds shall have a documented history of producing molds for the
manufacture of precast concrete tunnel segments.
B.
The molds for the precast concrete units shall be constructed with smooth casting faces so that a
true and sound concrete surface may be formed. Joints shall be watertight and mold surfaces
shall be prepared to provide the segment with finished surfaces free from irregularities.
C.
Design and construct molds to produce segments that will conform to the dimensions and
tolerances required. Segments of common dimensions and cast in different molds shall be
interchangeable.
D.
All chamfer and radius strips, bolt pockets, bolt holes, and other inserts and details shown on
the shop drawings shall be provided.
E.
Molds shall be provided with individual identifications to ensure that all segments cast are
marked with this identity and are fully traceable.
F.
Mold circumferential joint surfaces shall form a flat plane perpendicular to the surface of the
segment, radial joint surfaces are skewed and vary perpendicularly to the tangent of the segment
along the joint.
02340-10
G.
Loose mold components that affect the integrity of the mold shall be clearly identified as being
part of the main mold.
H.
All inserts used to form the bolt pockets, bolt holes, and grout holes shall be made of steel or
approved material with a coefficient of thermal expansion similar to that of concrete.
2.09
FINISHES
A.
On formed surfaces, the maximum local irregularity acceptable shall be rounded protrusions of
0.02-inch in height above the general concrete surface. Larger irregularities may be accepted if
they are abraded giving no clear transition to the surrounding surface.
B.
If the extrados of the segments is not formed, it shall have a steel trowel finish and shall comply
with the following:
2.10
A.
2.11
A.
B.
1.
The maximum local irregularity shall be rounded protrusions of 0.125-inch in height

above the general concrete surface.
2.
The maximum surface irregularity over an area of 24 by 24 inches shall be 0.375-inch

from maximum height to maximum depth.
3.
Compliance with the above finish limitations shall not eliminate the need to meet
tolerances specified.
PACKERS
Packers shall be 0.125-inch thick APA marine grade plywood, free of knots, having a secant
modulus not less than 5,000 psi and not more than 15,000 psi, when measured on a 3-inch by 3inch specimen loaded from zero to 1.45 ksi, or approved equal.
TESTING
Perform tests demonstrating joint connector, bolt and lifting insert capacities as follows:
1.
Minimum 12,000 pounds pullout capacity on the circumferential joint connector

assemblies.
2.
Minimum 12,000 pounds pullout capacity on the radial joint bolt assemblies.
3.
Minimum pullout capacity on the threaded lifting/grouting insert of three times the
maximum segment weight.
Perform tests demonstrating watertightness of the gaskets as follows:

1.
A metal test rig shall be used to carry out tests to prove the watertightness of the
gaskets. The gaskets shall be installed in the manner to be used in the tunnel. Where
gaps between segment faces are stated in the test procedure below, these shall be
construed as the gaps required for testing components of the least favorable
dimensions within the allowable tolerances, i.e. gaskets of the smallest permitted
dimensions in grooves of the largest permitted dimensions. The gaps used in the tests
shall be larger by an amount, calculated from the tolerances quoted and the actual size
02340-11
of the materials and groove under test, so as to simulate tests on components of the
least favorable dimensions.
2.
C.
The gasketed joints shall resist a test pressure without leakage under the conditions
commensurate with the specified working pressures. The test pressure shall be related
to the relaxation and other properties of the gasket and shall not be less than twice the
working pressure. The gasketed joints shall resist a test pressure without leakage
under the conditions stated below:
a.
Straight gaskets with a gap of 0.5-inch between the segment faces and the
gaskets displaced relative to each other in a direction normal to their length by a
distance of 0.5-inch.
b.
Cross joint representing the meeting of radial and circumferential tunnel joints
under each possible combination of gaps of 0.04-inch and 0.5-inch between the
segment faces for the four legs of the cross joint and relative displacement
normal to the lengths of the gaskets of zero and 0.5-inch.
3.
In each test the water pressure shall be increased in increments of 15 psi and held at
each value for 15 minutes. The final pressure shall be held for 72 hours during which
no leakage shall occur.
4.
The gaskets shall be shaped such as to render them inherently resistant to mechanical
damage during transport, handling, and erection.
5.
Finished gaskets shall be free from surface imperfections, porosity, voids, inclusions
or flow marks, and other defects that would impair satisfactory performance. Joints in
the gaskets shall be made with such accuracy so as not to impair satisfactory
performance of the gaskets.
6.
Bonding agent to attach gasket to concrete segments shall be compatible with gasket
and concrete and shall provide sufficient bond to hold the gasket secure during
transportation, erection and bolting.
7.
The gasket manufacturer shall specify the type of packaging to be used for its gaskets
and the conditions under which they will be stored. The gaskets shall be stored in
accordance with the manufacturers recommendations.
8.
Before manufacturing gaskets in quantity, the manufacturer shall make trial units and
fit them to actual segments so that the correct amount of stretch can be ascertained to
ensure a secure, snug fit to the segments.
Ring Build Test Assemblies:

1.
As the initial test, erect a set of three full rings of tunnel linings, without gaskets and
packers, vertically on a flat level base to demonstrate the accuracy of segments within
the allowable tolerances.
2.
The lowest ring shall be retained as a master ring for the duration of the Contract. The
segments forming this ring may be selectively hand picked and the segments for the
other trial rings shall be selected by the RE.
02340-12
3.
The test bed shall be under cover, equipped with a crane, and be kept clean and dry.
4.
Furnish all necessary tools and equipment to measure the dimensions required at no
additional cost to the Corporation.
PART 3 EXECUTION
3.01
CASTING PREPARATION
A.
Concrete spacers shall be fixed so that the reinforcement is held firmly in the correct position
within the formwork with all the cover as specified and shown on the Contract Drawings. The
spacers shall be rigidly fixed to the reinforcement to prevent displacement. If the spacers are
wired on, the ends of the wires shall be turned into the unit.
B.
Spacers shall not be used in the circumferential or radial joint regions. The joint regions are the
areas up to a distance of 4 inches from the joint surface.
C.
Concrete spacers shall be made from the same concrete mix design as the segments, and
compacted and cured to the same standards as the segments. Plastic spacers shall not be used.
D.
All spacers shall be saturated with clean water prior to use. Spacers shall not be allowed to dry
out after being fixed to reinforcement cages before the concrete is cast.
3.02
SEGMENT CASTING
A.
The segments shall be produced under plant-controlled conditions with production areas
protected against rain, dust, and direct sunlight.
B.
Each segment shall have cast into the inside surface:
C.
D.
1.
Type of segment.
2.
Mold number.
3.
Dimples on the intrados surface of segments shall be provided to identify locations of

no reinforcing steel where holes may be drilled into the lining for temporary or
permanent attachment of tunnel services or concrete dowels.
4.
Alignment marks.
Each segment shall also be identified on both the inside surface and a circumferential joint edge
using a stencil with an appropriate durable ink. The following information shall be provided:
1.
Segment type with match marks.
2.
Date cast.
3.
Serial number.
Placing concrete in cold weather shall conform to ACI 306.
02340-13
3.03
CONSOLIDATING
A.
The segment concrete consolidation shall be in accordance with ACI 309.
B.
Work concrete into complete contact with forms and embedded items. Consolidate concrete
adjacent to side forms and along the entire length of forms to ensure a smooth surface finish
after stripping of formwork.
3.04
CURING AND STRIPPING
A.
Segments shall not be removed from their molds until a minimum compressive strength of
2000 psi is attained. The minimum compressive strength required for de-molding shall be
increased if a higher strength is necessary to handle the segments without causing damage or
stress.
B.
Segments shall be steam cured. Steam curing at atmospheric pressure shall be in accordance
with ACI 517, Accelerated Curing, with a maximum temperature of 120 degrees F.
C.
Protect the segments from thermal shock. Utilize thermal blankets to minimize thermal shock.
Do not allow rate of change of temperature to exceed 27 degrees F per hour. Do not allow a
concrete temperature difference of more than 18 degrees F between any two points of the
segment at any time during the curing process. Trials of full sized segments shall be conducted
with suitable instrumentation to demonstrate conformance with the above temperature gradients.
D.
As part of the production process, segments shall be moist cured for a period of five days after
manufacture before being placed in the stockyard to attain the specified 28-day strength. This
moist curing shall be achieved by placing the segments in a special area where water shall be
sprayed continuously or atomized to ensure a 100% relative humidity environment for the
segments.
E.
Membrane curing compounds shall not be used.
3.05
STORAGE AND PROTECTION
A.
When handling and storing segments, supports shall be used to avoid damage or subjecting
segments to undue strains.
B.
Prevent damage to segment surfaces during handling and storage. Wire ropes, chains, or hooks
shall be kept from direct contact with the segment surfaces, joint assemblies, and gaskets.
C.
Plant and field inventories of segments that have gaskets installed shall not be stored out-ofdoors for more than 120 calendar days, unless the gaskets are protected from sunlight.
Alternatively, gaskets may be installed just prior to shipment of the segments.
D.
During cold weather, water shall be prevented from filling the pockets, inserts and recesses of
the segments and freezing.
3.06
A.
GASKET INSTALLATION
Install gasket in accordance with manufacturers recommendations and reviewed shop drawings
prior to shipping. Field installation of the gaskets is not permitted.
02340-14
3.07
DELIVERY TO SITE
A.
Provide the RE with one complete copy of all delivery notes. These shall show the number of
segments, the date of manufacture, the identification markings of each segment and individual
inspection certificates.
B.
Segments shall have attained the specified design strength prior to loading.
C.
Prior to loading segments for delivery to site, inspect the segments, remove defective or
damaged segments, and repair minor damage, in accordance with procedures approved by the
RE.
D.
Segments shall be shipped with spacers to avoid direct contact, in units of complete rings, all
properly identified.
3.08
REPAIR OF DEFECTS
A.
Segments with major damage which impairs structural integrity or performance shall not be
used.
B.
The following procedures cover patching and repair of concrete segments with non-structural
damage that will be used for correction of defects in the concrete.
1.
Segments which show excessive crazing, damage or defects shall be recorded and
investigated to determine the cause. Such segments shall, after completion of the
investigation, be rejected or accepted following repair.
2.
Cosmetic repairs of edge damage, scuff damage, and blow holes shall be performed
where damage or a defect exceeds that listed in the following table. Generally, blow
holes and air voids shall not be filled in, except in the area of the gasket groove, and
for blow holes in excess of 0.625-inch diameter and 0.188-inch deep.
3.
Circumferential and radial edges shall be stone rubbed to remove sharp edges.
4.
Repair of damage shall be performed as shown in the following table:

Table 02340.1 Repair of Defects
Class of
Damage/Defect
Class A1
Non-Structural
Patching
Class B
Non-Structural
Patching
Description
Blow holes and air
voids
Blow holes and air

voids
Location
All locations
except of gasket
groove, intrados
and caulking
groove
Gasket groove
02340-15
Extent
Diameter > 0.5inch or depth >
0.188-inch
Remedy
Repair Procedure
2A
> 0.125-inch
diameter
Repair Procedure
1
Class of
Damage/Defect
Class C
Non-Structural
Cosmetic
Description
Chipping and
spalling
Location
Gasket groove
edges
Class D
Non-Structural
Cosmetic
Chipping and
spalling
Allocations except
as noted in C
Class E1
Surface
Irregularities
Class E2
Surface
Irregularities
Class F1
Localized Surface
Cracking and
Crazing
Class F2
Localized Surface
Cracking and
Crazing
Class F3
Localized Surface
Cracking and
Crazing
Class G1
Structural Cracks
Local protrusions
Non-formed
surfaces
Local protrusions
Formed surfaces
> 0.03-inch high
Stone rubbed,
check mold
Minor nonstructural local

defects
Gasket groove and

extrados edge on
joint faces
Cracks < 0.008inch wide
No repair
Gasket groove and

extrados edge on
joint faces
Cracks > 0.008inch wide
Review for
approval of repair
procedure
Extrados and all

locations not noted
in F1 or F2
Cracks < 0.01-inch

wide
No repair
Radial joint
bearing areas only
Any crack
Circumferential
joint bearing area
only
Cracks < 0.002inch wide
Review for
approval of repair
procedure
No repair
Class G2
Structural Cracks
Class G3
Structural Cracks
Cracks > 0.002inch and < 0.008inch wide that do

not cross the
gasket groove
Multiple cracks >
0.008-inch wide
emanating from a
single source and
producing a wedge
pattern on the
bearing face
Cracks > 0.008inch wide
Class G5
Structural Cracks
Class G6
Structural Cracks
Extent
Area:
Length > 1-inch x
Depth > 0.188inch
Area:
> 1.5-inch x 1.5inch or depth >
0.625-inch
> 0.125-inch high
CSA Standard
CAN 3-A23.4M78 Definition
30.3.2
02340-16
Remedy
Use Procedure 2A
or 2B
Use Procedure 2A
or 2B
Stone rubbed or
ground
Use Procedure 3
Reject segment
Review for
approval of repair
procedure
Class of
Damage/Defect
Class H
Broken Segment
Class J1
Honeycombing
Description
Structural crack
Location
Through segment
Damage exposing
reinforcing
At locations within
the circumferential
and radial joint
bearing areas
All locations
except as noted in
J1
All surfaces except
radial joints
Class J2
Honeycombing
Class K
Structural Damage
5.
Extent
Full depth
Remedy
Reject segment
Reject segment
Use Procedure 2B
To be assessed by
examination
Review for
approval of repair
procedure
Repair procedures shall be as follows:

Table 02340.2 Repair Procedures (1)
Repair Procedure 1
Type III Cement (High Early)
Material:
Type II White Portland Cement
Silica Sand
Procedure:
Mix at the rate of one part cement to 2.5 parts sand, with 0.4 water/cement ratio.
Proportion White Portland Cement as required for color matching.
Clean and wire brush off all dirt and dust from areas to be filled. Dampen repair area
with water.
Measure and mix cement and sand with water in accordance with the instructions. Do
not re-temper mixture with water.
Fill the repair area, and sack rub the finished surface

Repair Procedures 2A and 2B
Material 2A to be used in areas less than 1.5-inches long and 0.625-inch deep.
Sikadur 31 Epoxy Mortar or approved alternative.
Material:
Mix in one-to-one ratio by volume adding oven-dried silica sand until a uniform and
consistent mix is achieved. Do not mix a quantity larger than can be used within 30
minutes.
Repair area must be dry. Remove any dust, laitance, grease, oils or loose materials from
Procedure:
the area to be repaired and wire brush.
Place mixed material into the void working the material by trowel or spatula to ensure
bond. Strike off level to existing concrete.
Cure the epoxy mortar at a minimum temperature of 40 degrees F.
Ensure accurate profile by removing any excess mortar by grinding.
Material 2B to be used on area in excess of 1.5-inches long and 0.625-inch deep.
BASF/MBT EMACO S88-CI, or approved alternative.
Material:
Mix at the rate of 55 lb bag EMACO with 0.7 to 1.0 gallons of potable water (10.5
02340-17
percent - 15 percent by weight).

Saw-cut all edges of repair to a depth of 5/8 inch with mechanical disc.
Break back to sound concrete and remove surplus material by low impact method.
Clean and wire brush off all loose particles, dirt and dust from areas to be filled. Soak
burlap or sponge over the repair area to dampen for a period of 2 hours.
Procedure:
Measure and mix the patching compound with water in accordance with the manufacturers instructions. Do not re-temper mixture with water.
Fill the repair area, and finish open edges with a steel trowel and use temporary formwork when necessary, ensuring that repair material is thoroughly compacted.
Place a damp rag over the patch area and keep moist for a period of seven days until
patch material is sufficiently cured.

REPAIR PROCEDURE 3 - CRACK SEALING
Sikadur Injection Gel or approved alternative.
Material:
Mix in a ratio of 1:1 in accordance with the manufacturers recommendation. Do not
prepare more resin than can be used within 20 minutes.
1.
Concrete must be clean and sound. Remove dust, laitance, grease, form oil,
and foreign particles with a damp to dry cloth or sponge. Do not contaminate inside of
crack.
2a.
Mix injection gel from coaxial cartridges by gunning equal beads on to a
pallet and mixing thoroughly to a uniform color using a putty knife or spatula.
2b.
Using a putty knife or spatula, force material into the crack to seal it.
3.
Wipe excess resin from the surface, adjacent to the crack, using a dry cloth.
4.
Allow to cure for four hours before removing any remaining excess material
with a rubbing stone.
Procedure:
6.
Load testing may be specified by the RE, particularly for any repairs of concrete near
the lifting insert.
7.
In all cases, acceptance or rejection of a repaired segment shall be at the REs

discretion.
END OF SECTION
02340-18
SECTION 02400
TUNNEL CLEANING
PART 1 GENERAL
1.01
SCOPE OF WORK
A.
The Work specified in this Section includes, but is not limited to, the general requirements for
final cleaning of tunnel, shafts and pipelines including disinfection operations.
B.
The disinfection treatments shall be carried out at the shafts and within the pipelines throughout
the tunnel alignment.
C.
The Contractor shall ensure that the facilities are prepared for conveyance of drinking water
immediately after construction is complete.
1.02
RELATED SECTIONS
A.
B.
C.
D.
E.
Steel Water Main Piping in Tunnel and Shafts is included in Section 02617.
F.
G.
H.
Backfill Concrete in Shafts and Tunnels is included in Section 03301.
I.
Concrete for Pre-cast Concrete Tunnel Lining is included in Section 03360.
J.
K.
L.
M.
Tunnel and Shaft Temporary Ventilation and Utilities is included in Section 13130.
1.03
REFERENCE STANDARDS
A.
ANSI/AWWA C652-02 Disinfection of Water-Storage Facilities
B.
ANSI/AWWA B300 Hypochlorite

02400 - 1
1.04
DEFINITIONS
A.
Cleaning: The removal of all visible dust, dirt, oils and other foreign matter and materials from
all interior surfaces along the tunnel, shafts and pipelines within the contract limits.
B.
High-Pressure Washing: Application of water spray with a minimum pressure of 50 psi.
C.
Disinfection: Application of approved chemical disinfectant product under a minimum pressure

of 50 psi over all interior surfaces of the shafts and pipelines within the contract limits.
1.05
A.
B.
C.
SUBMITTALS
Pollution Control Plan for keeping the tunnel in a clean condition during construction shall be
submitted to the RE 30 days before commencing tunnel excavation. The Pollution Control Plan
shall include the following information:
1.
Spill contingency plan.
2.
Fuelling procedures.
3.
Hazardous materials handling plan.
4.
Sanitation plan.
5.
Garbage disposal plan.
Underground Cleaning and Disinfection Work Plan: Submit a detailed work plan for all
cleaning and disinfection operations 30 days prior to commencing work, including as a
minimum the following information:
1.
Name and qualifications of person(s) responsible for tunnel cleaning and disinfection,
30 days prior to commencing cleaning and disinfection work.
2.
Methods, procedures, types of equipment and sequences for cleaning and disinfection.
3.
Ventilation and illumination.
4.
Procedures for handling and control of groundwater inflows, including plans and
equipment for a back up power supply and calibration data for flow meters.
5.
A detailed description of all equipment to be used.
6.
Drawings illustrating the above as necessary.
Disposal Plan: Plan describing disposal of solid and liquid waste materials generated during the
Work shall be submitted 10 days prior to commencing cleaning and disinfection work. The plan
should include the following information:
1.
Anticipated daily volume generated.
2.
Description and layout of handling equipment.
3.
Temporary stockpile locations (if any), layouts and details.
4.
Loading and hauling operations, including traffic management plan for haul road,
noise and dust measures.
5.
Disposal at disposal site.
6.
Drawings illustrating the above as necessary.

02400 - 2
1.06
A.
1.07
DELIVERABLES
Reports and Records: General Shift Report: Prepare a shift report for each shift worked at each
shaft and tunnel, and provide the RE with one copy of the report on the following work day. The
following cleaning and disinfection work information shall be included in the report:
1.
Time and location of work places by station at start and end of shift.
2.
Methods employed.
3.
Crew sizes and employee classifications for all workers on site.
4.
Daily reports of test for dust, toxic and hazardous gases and other atmospheric
impurities in the working environment during cleaning and disinfection work.
A.
All work shall be performed in accordance with current applicable government and local
authority regulations and codes. In the event of a conflict, comply with the most stringent
requirements.
B.
Operators of all high pressure cleaning and disinfection equipment shall have been adequately
instructed in the safe operation of the equipment and safe performance of the work.
C.
The RE will review tunnel cleaning and disinfection work plans for approval. The RE shall
verify that the cleaning and disinfection works are executed as approved.
D.
The RE will perform surveys and inspections to verify that the Contractors work meets the
requirements of this Section, however, this does not relieve the Contractor of its obligations to
ensure the quality of the work
PART 2 PRODUCTS
2.01
A.
2.02
A.
TUNNEL CLEANING WATER

Clean portable water to be used with no foreign admixtures or chemical products.
DISINFECTANTS
All disinfectant work shall be performed using the following approved products: Sodium
hypochlorite conforming to ANSI/AWWA B300
PART 3 EXECUTION
3.01
A.
This work shall be carried out after the completion of all excavation and shaft and tunnel lining
work.
B.
The Contractor shall maintain its plant and equipment so as to minimize leakage of fluids to the
extent possible, and shall use drip trays and absorbents to control and dispose of any leaking
fluids.
02400 - 3
C.
D.
3.02
As necessary preliminaries, the Contractor shall, during shaft and tunnel construction and to the
REs satisfaction:
1.
Keep the tunnel and shafts free of waste or spilled materials and garbage.
2.
Install adequate sanitary facilities, enforce their use, keep them in a clean, sanitary
condition, and remove their contents in a sanitary manner to approved disposal site(s).
3.
Use only biodegradable hydraulic and lubricating oils.
The Contractor shall carry out cleaning and disinfection work in accordance with the approved
working hours established for the project. The Contractor shall notify the RE at least 48 hours in
advance of a proposed change in working hours.
CLEANING
A.
Following completion of excavation and support of the shafts and tunnel, all remaining foreign
material shall be removed from within the shafts and tunnel, and a thorough cleaning operation
using a high-pressure wash shall be carried out to remove all visible dust, dirt, and foreign
material to the approval of the RE
B.
Following completion of the installation of steel pipe lining, transition zones and sand traps and
the installation of the surface pipelines, all remaining foreign material shall be removed from the
Work Site and disposed of by type according to the Specifications. The entire interior of the
tunnel, shafts and pipelines within the contract limits shall be thoroughly cleaned using a highpressure wash to remove all visible dust, dirt, and foreign material to the approval of the RE.
C.
The Contractor shall remove the wash water after use from the tunnel, shafts and surface
pipelines within the contract limits and dispose of it as approved by the RE.
3.03
DISINFECTING
A.
Following high-pressure washing subsequent to the installation of steel pipe lining, the entire
interior of the shafts and pipelines within the contract limits shall be disinfected to the approval
of the RE.
B.
Disinfection shall be by means of a high-pressure spray with a 200-mg/L chlorine solution at a

rate not less than 1 quart (0.95 liter) per 10 square feet of surface to be disinfected.
C.
The Contractor shall remove the disinfection solution in the shafts and pipelines after use.
D.
The Contractor shall disinfect the shafts and pipelines in a sequence approved by the RE and
shall not re-enter any part of the work once it has been disinfected.
END OF SECTION
02400 - 4
SECTION 02416
COMPRESSED AIR WORKING
PART 1 GENERAL
1.01
SCOPE OF WORK
A.
Requirements for the compressed air system on the TBM. The operation of the TBM
compressed air systems shall be in accordance with the TBM manufacturers operation manuals
and is not covered in this Section.
B.
Requirements for furnishing all labor, materials, tools, equipment and services necessary for
design and installation of TBM low pressure compressed air systems, for its use and maintenance
during tunneling and subsequent removal in accordance with the Contract Documents.
1.02
RELATED SECTIONS
A.
B.
C.
1.03
A.
REFERENCE STANDARDS
OSHA

Health Regulations for Construction 803 Compressed Air.
1.04
1.05
SUBMITTALS
A.
At least 60 days prior to commencement of tunnel excavation, submit the following for review by
the RE:
1.
TBM Manufacturers operation manuals for air locks and compressed air systems.
2.
Full details of the proposed equipment for power and compressed air supply and
ventilation to be used in the compressed air operations, including emergency backups.
3.
Full details of the proposed system of signaling, communications, and controls to be used
in the compressed air operations.
4.
Full details of the medical care facilities and supervision for compressed air working.
Include number of medical staff required for supervision and control and their relevant
experience.
5.
Full details of fire fighting provisions to be installed for use in compressed air.
02416-1
1.06
6.
Resumes of personnel proposed to enter compressed air workings, including their date of
birth and prior compressed air experience.
7.
Documentation as required by OSHA and applicable regulations and codes of Federal,

State, and local agencies having jurisdiction.
8.
Compressed Air Method Statement detailing methods, procedures, equipment, and

operations for working under compressed air. Include method for determining required
compressed air pressure. Include procedures for sealing the face to limit air loss, and
procedures to restore safe and stable working conditions if air consumption increases
steadily or rapidly.
9.
Location of the medical lock and alternative medical lock.
DELIVERABLES
A.
Provide records of all personnel working in compressed air, with the exception of personal
medical records, to the RE every day. Provide copies of records for each person of the working
pressure, compressed air working time, decompression time, temperature, humidity, and weather
conditions, daily during compressed air work.
B.
Provide continuous records of pressures in the working chamber and all locks throughout the
total period of using compressed air in the Works.
C.
Prepare, maintain, and provide records in accordance with OSHA and all current applicable
regulations and codes of Federal, State, and local agencies having jurisdiction.
D.
Provide records of compressed air consumption.
1.07
A.
Compressed air working shall be in accordance with OSHA, and all current applicable
regulations and codes of Federal, State, and local agencies having jurisdiction.
PART 2 PRODUCTS
2.01
A.
EQUIPMENT
Compressed air equipment shall be in accordance with the reviewed method statement.
PART 3 EXECUTION
3.01
A.
CONSTRUCTION AND OPERATION

The TBM or tunnel shall be equipped with separate air locks for personnel and equipment in
accordance with Section 02315 or Section 02316. No cables or hoses shall be placed through the
open airlock door(s) at any time.
02416-2
B.
Provide and install facilities in the tunnel and maintain the system so that compressed air
working can be undertaken without delay, in accordance with submitted method statement, and
so that pressurization of the TBM plenum chamber is maintained.
C.
Operate the installation in accordance with reviewed method statement.
D.
Notify the RE prior to commencing work in compressed air. If Contractor has to apply
compressed air in an emergency, then the RE shall be notified immediately.
E.
During construction of the Works the use of compressed air working shall be kept to a minimum.
The working pressure and quantity of air used are to be kept to a minimum. Working pressures
shall be no greater than can be safely contained by the ground cover. Sand, gravel or fill with
high permeability may be present. Take precautions to minimize the escape of air through the
ground. Monitor volumes of compressed air consumed and investigate the ground surface for
bubbling or other indications of air loss. If air is escaping, seal the area of escape within the
compressed air tunnel with impermeable material.
F.
Any sudden change in working conditions shall be responded to in accordance with the reviewed
method statement, and shall be immediately reported to the RE.
G.
Changes in pressure of the working chamber outside the allowable working range shall be
responded to in accordance with the reviewed method statement, and shall be immediately
reported to the RE.
H.
Record all pressures in the working chamber and all locks continuously throughout the total
period of using compressed air in the Works. The RE shall be given access to this information at
all times.
I.
Each person employed in compressed air Work, and any other person required to enter
compressed air, shall be provided with a laminated identification card displaying a passport type
photograph stating their name, employer, occupation and reference number. This card shall be
handed to the lock attendant before entering the lock. No person shall be allowed to enter the
lock without handing in his identification card. The lock attendant shall display all cards on a
suitable noticeboard for inspection at any time. A similar card with identification of persons as
compressed air personnel and the location of the medical lock and alternative medical lock shall
be carried by all persons at all times.
J.
Record volume of air consumed. If volume of air consumed increases rapidly or steadily,
immediately implement procedures to prevent loss of air or blowout.
3.02
HEALTH AND SAFETY
A.
See Section 13000.
B.
Perform continuous air quality and gas monitoring during compressed air working, and as
required and in accordance with OSHA, and other Federal, State, and local regulations.
C.
When bagged cement is used, no more than one shifts supply may be stored in the working
chamber and all empty bags must be removed without delay. Only essential timber shall be
stored in the working chamber and hydraulic oil or other flammable materials shall not be stored
in the compressed air Work area.
02416-3
END OF SECTION
02416-4
SECTION 02432
JET GROUTING
PART 1 GENERAL
1.01
A.
1.02
SCOPE OF WORK
The Work specified in this Section includes the design, construction, and testing of stabilized
soil-cement columns by the jet grouting method for temporary applications including:
1.
Stability of shaft excavations including walls and bases.
2.
Stability of ground and control of groundwater and inflows during tunnel boring
machine (TBM) breakout from the launching shaft and break-in to the receiving shaft.
RELATED SECTIONS
A.
B.
C.
D.
E.
F.
G.
H.
1.03
REFERENCE STANDARDS
A.
API 13A
Specification for Drilling-Fluid Materials.
B.
API 13B
Recommended Practice for Field Testing Water-based Drilling Fluids.
C.
ASTM C39
Standard Test Method for Compressive Strength of Cylindrical Concrete

Specimens.
D.
ASTM C94
Standard Specification for Ready-Mixed Concrete.
E.
ASTM C109
Standard Test Method for Compressive Strength of Hydraulic Cement

Mortars (Using 2 in. or 50 mm Cube Specimens).
F.
ASTM C150
Specification for Portland Cement.
02432 - 1
G.
ASTM C494
Specification for Chemical Admixtures for Concrete.
H.
ASTM C618
Standard Specification for Coal Fly Ash and Raw or Calcined Natural
Pozzolan for Use in Concrete.
I.
ASTM C918
Standard Test Method for Measuring Early-Age Compressive Strength and

Projecting Later-Age Strength.
J.
ASTM C939
Standard Test Method for Flow of Grout for Preplaced-Aggregate Concrete

(Flow Cone Method).
K.
ASTM D1633
Standard Test Method for Compressive Strength of Molded Soil-Cement

Cylinders
L.
ASTM D2434
Standard Test Method for Permeability of Granular Soils (Constant Head)
M.
ASTM D2850
Standard Test Method for Unconsolidated-Undrained Triaxial Compression

Test on Cohesive Soils.
N.
ASTM D4044
Standard Test Method for (Field Procedure) for Instantaneous Change in

Head (Slug) Tests for Determining Hydraulic Properties of Aquifers.
O.
ASTM D4050
Standard Test Method for (Field Procedure) for Withdrawal and Injection
Well Tests for Determining Hydraulic Properties of Aquifer Systems.
P.
ASTM D7012
Standard Test Method for Compressive Strength and Elastic Moduli of Intact
Rock Core Specimens under Varying States of Stress and Temperatures.
Q.
ASTM D4832
Standard Test Method for Preparation and Testing of Controlled Low

Strength Material (CLSM) Test Cylinders.
R.
ASTM E329
Standard Specification for Agencies Engaged in Construction Inspection

and/or Testing.
S.
USBR
Test E-18 Field Permeability Test in Boreholes, in USBR Earth Manual.
1.04
DEFINITIONS
A.
Soil-Cement: The mixture created by mixing in-situ soils with a stabilizing cement grout mix.
B.
Jet Grouting: The process of creating stabilized soil-cement columns in place utilizing a grout
mix delivered at high pressure through a special drill bit that has high velocity horizontal jets.
This process produces soil-cement columns by pumping neat cement grout slurry through
horizontal jets which cut and mix in-situ with the surrounding soil materials as the drill bit is
rotated and slowly withdrawn at a constant speed to achieve a continuous geometry and quality
of soil-cement column.
C.
Column: A jet grouted soil-cement element is typically referred to as a column.
D.
Primary Column: Jet grout columns constructed in soil.
02432 - 2
E.
Secondary Column: Jet grout column constructed between and overlapping with the primary
columns.
F.
Column Spacing: The theoretical designed offset between the centers of adjacent jet grout
columns in a given direction.
G.
Column Overlap: The distance by which one column periphery is designed to overlap an
adjacent column periphery such that a homogenous block of treated ground is created.
H.
Drilling Deviation: The deviation of the drill hole from a theoretical straight line, either vertical
or inclined.
I.
Spoil Return: The return through the drill hole to the drill collar of excess jet grouting materials,
soil, groundwater, or a combination thereof.
J.
Single Fluid System: A jet grouting system where a high-pressure jet of cementitious grout is
used to erode and mix the grout with the ground.
K.
Double Fluid System: A jet grouting system where a high-pressure jet of cementitious grout
surrounded by a shroud of air is used to erode and mix the grout with the ground. The air shroud
increases the efficiency of the erosion process.
L.
Triple Fluid System: A jet grouting system where a high-pressure jet of water shrouded by air is
used to erode the ground with separate injection of grout below the erosion jet.
M.
Closure Column: An additional column installed to maintain column overlap in the event of
excessive drilling deviation.
1.05
A.
SUBMITTALS
The Contractor shall submit to the REs approval the following, at least 30 days prior to the
work commencement:
1.
Shop drawings, including test section, where jet grouting is to be performed, with
description of the size of the grouted zone and details of the soil-cement column
layout required to achieve the zone indicated.
2.
Design calculations with clearly identified design parameters and assumptions for the
jet grouted soil-cement columns based on anticipated subsurface conditions indicating
the arrangement, spacing, inclination, and diameter of boreholes, grout mix to be used,
diameter and overlap of columns, and depth of the grouted mass.
3.
Equipment and methods for drilling, including:
4.
a.
Drilling equipment.
b.
Drilling deviation control and monitoring equipment.
c.
Drill alignment measuring equipment.
d.
Drill depth control and monitoring equipment.
Equipment, methods, and details of jet grouting operation, including:
02432 - 3
a.
Details and arrangement of batching and grout mixing plant.
b.
Details of jet grouting system including whether single, double or triple fluid
system will be used.
c.
High-pressure grout pumps and high-pressure air compressors.
d.
Jet grout column production monitoring.
e.
Site layout and clearances from adjacent facilities.
f.
Sequence and details of grout column placement
g.
Minimum set time and strength before jet grouting adjacent columns.
h.
Methods for estimating column diameter in wet columns in-situ.
i.
Provisions for closure columns should drilling deviation exceed tolerances.
5.
Health and safety plan for operation of high-pressure pumps that includes protection
of high-pressure hoses.
6.
Materials:
a.
Portland cement.
b.
Bentonite.
c.
Cement additives.
7.
Details for identifying, protecting, and maintaining existing utilities in working

service.
8.
Test program layout and procedures to establish jet grouting parameters, including
sampling and testing to determine quality and properties of grout and soil-cement
mixture. Append as soon as practicable, information, mix designs, or procedures that
have been updated or revised through the implementation of additional test sections.
9.
Environmental control plan detailing methods of controlling, containing, handling,

treating, and disposing of excess or spilled materials and spoil return generated during
the jet grouting operation.
10.
Extent of and means and methods for effecting repairs to streets, sidewalks, and other
facilities damaged or disturbed during jet grouting operations.
B.
Mix Designs: The Contractor shall submit the proportions of materials for each mix design.
C.
Quality Control Plan:

1.
Qualifications as specified herein.
2.
Certifications:
a.
Certificates of compliance for materials specified in Part 2 herein.
b.
Required permits for performing work in close proximity to the public right-ofway.
c.
Required permits for disposing of waste materials.

02432 - 4
3.
4.
D.
1.06
A.
Quality Control Plans:

a.
Sampling, handling, and laboratory testing procedures and proposed sampling

locations for determining compliance with design criteria, with reference to the
relevant ASTM, ACI or other standards. Include name of laboratory and contact
information.
b.
Procedure for conducting permeability tests in accordance with a USBR

standard or other nationally accepted procedure. Permeability testing shall not
be conducted until the testing procedure has been approved by the RE.
c.
Methods for controlling and verifying the vertical limits of the jet grouting
operation, column diameter and the amount of grout column overlap.
d.
Criteria, equipment, and procedures for abandoning or remedying grout

columns occasioned by equipment failure, inadequacy of grout mix or delivery
systems, or other cause.
e.
Plan for monitoring and controlling jet grout induced deflection, settlement, and
heave.
f.
Contingency plan to minimize the damage to existing facilities and utilities due
to jet grouting operations.
Notifications
a.
Provide location of jet grouting test section no less than three days in advance
of performing jet grouting at test section.
b.
Inform the RE at least two days in advance of performing jet grouting

operations.
Test Program: The Contractor shall submit layout and procedures for a test program specified
in this Section to demonstrate that proposed jet grouting methods and equipment will produce
acceptable results. The Contractor shall provide details of sampling and testing program to
determine quality and properties of the columns installed. Subject to the results of the test
program, modifications to the jet grout procedures may be agreed to with the RE to achieve
acceptable results.
DELIVERABLES
Daily Records within one day of performing the work, checked for correctness and signed by
the Grouting Manager, and including:
1.
Number and classification of labor and equipment used.
2.
Grout hole geometry comprising location, design column diameter, diameter, spacing,
inclination, depth and casing details.
3.
Grout column information comprising start and finish times, upper and lower
elevation limits, ground surface elevation, grout mix data, grout take, rates of rotation
and withdrawal of monitor, jet pressures, flow rates, and other observations such as
grout leakage and ground heave, spoil return, and any unusual behavior of any
equipment during the jet grouting process.
02432 - 5
4.
Date, time, plan location, sample designation and elevation, and other details of soilcement sampling and other quality control and field testing, and results thereof.
5.
Print-outs of column digital data logger.
6.
Color photographs of cored columns.
7.
Nature, causes, duration, and impacts of interruptions and delays to the jet grouting
operation.
B.
As-built drawings indicating the locations of jet grout columns.
C.
Electronic versions of all print-outs provided and all data files.
D.
Detailed records of verification of jet grouted ground treatment zone outside of shaft break-out
and break-in locations prior to assembly of the TBM in accordance with the specifications.
1.07
A.
The Contractor shall be responsible for all quality control testing of jet-grouted columns.
B.
Jet grout injection, rotation, and extraction rates shall be sufficient to produce grout columns
meeting the diameter, depth, overlap, and material property requirements shown on the shop
drawings and specified herein.
C.
Drill bits shall be capable of advancing through ground conditions described in the GBR.
D.
Schedule the jet grouting work so that columns have achieved specified minimum 28 day
strengths prior to excavation.
E.
Qualifications:
1.
Independent Laboratory: An established laboratory that can certify compliance with

the requirements of ASTM E329, with a demonstrable track record of undertaking the
relevant testing. Details of the Laboratorys testing and quality assurance methods
shall be submitted together with details of testing undertaken for works of a similar
nature.
2.
Shift Supervisors: At least five years of recent experience in responsible charge of jet
grouting operations.
3.
Design Engineer: Experienced in the design and application of jet grouting systems,
and a licensed Professional Engineer registered in the State of New York to stamp all
design drawings and calculations.
4.
Grouting Subcontractor: No less than five projects completed within the last ten
years comprising the planning and execution of a jet grouting program of the scope
and type required for this project.
5.
Grouting Manager: Full-time, on-site individual with duties limited to responsible

charge for all grouting operations, and who has at least ten years of experience in the
02432 - 6
design and field application of grouting technology similar to that required for this
project.
F.
Grout Mix:
1.
G.
Grout and Soil-Cement Samples:

1.
2.
H.
Grout mix uniformity shall be verified by unit weight (density) measurements of the
mixed grout by mud balance, marsh viscosity, and bleed from samples taken from the
grout return line. Testing shall be performed in accordance with API Standard 13B
test method. Testing frequency shall be as specified herein. Complete and accurate
records shall be kept to verify that grout mix is as reviewed.
During execution of the production columns, the following shall be measured on

liquid samples of grout:
a.
Unit Weight or Specific Gravity (minimum one test per column).
b.
Marsh Viscosity (daily).
c.
Bleeding at 1 and 2 hours (daily).
Every fourth column, the following samples shall be taken:

a.
One set of four samples of the cement grout used for the construction of one of
the columns shall be prepared in accordance with ASTM C 109.
b.
One set of four samples of wet soil-cement from construction of one of the
columns shall be prepared in accordance with ASTM C 109.
c.
Each of these samples shall be stored in a damp environment at constant

temperature in accordance with applicable ASTM procedures.
d.
After the samples have cured sufficiently, they shall be taken to the independent
laboratory for testing.
e.
Two grout samples and two soil-cement samples shall be tested for compressive
strength at 7 days in accordance with ASTM C 39 or C 109 and ASTM C 1633,
respectively. The remaining samples shall be tested for compressive strength at
28 days following the same ASTM testing procedures.
Core Samples:
1.
When jet grouting is complete at any excavation and has reached sufficient strength,
vertical core samples shall be taken from the treated zone, at locations selected by the
Contractor and agreed by the RE.
2.
The coring or sampling operations shall be scheduled according to the jet grouting and
construction activities schedule and performed with suitable equipment and a qualified
driller.
3.
Triple tube core barrels with thin walls shall be employed to obtain a continuous core
sample of the jet grout columns. The nominal size of the core barrel shall be 3-inch
I.D. or greater. Drilling shall be performed using rotary wash or air rotary methods by
02432 - 7
an experienced driller familiar with the triple tube coring process, and coring and
sampling of jet grouted columns.
I.
J.
K.
4.
All cores and samples shall be taken to an independent laboratory where they shall be
stored in a moist environment at constant temperature. Extreme care shall be exercised
in handling the cores at the site, in transport, and at the laboratory such that the cores
do not become disturbed or otherwise damaged prior to testing.
5.
The cores of jet-grouted soil shall be examined for continuity of the treatment and
subjected to unconfined compressive strength tests at ages corresponding to design
assumptions. All testing results shall be recorded on a quality control sheet.
6.
If samples tested do not meet specified strength requirements then additional

replacement jet grout columns shall be installed, or other provisions shall be
implemented, as approved by RE, to compensate for the lower strength columns.
7.
All cores or sampling holes shall be backfilled with cement grout at the completion of
coring or sampling.
Permeability Tests:
1.
Two permeability tests shall be performed on each jet grouted zone, including the test
location.
2.
Permeability shall be determined using constant head testing. Core holes may be
utilized for tests however the Contractor will be required to demonstrate that the test
section is adequately sealed.
Verification of jet grouted ground treatment zone: In addition to the samples and test outlined
above, the efficacy of the jet grouted ground treatment zone at the tunnel break-out and break-in
locations shall be verified in accordance with the following criteria prior to installation of the
TBM in the launch shaft:
1.
A minimum of three open check holes shall be drilled as indicated on the Contract
Drawings.
2.
Leakage of water from any one check hole shall be less than 1 gallon in 5 minutes.
3.
Conduct secondary and tertiary grouting by injecting cement grout or sodium silicate
grout until leakage criteria in a new check hole located by the RE is satisfied.
4.
Prevent transport of soil particles into the shaft excavation via water or gravity.
5.
Use suitable drill-through blow-out preventers when drilling check holes.
6.
On completion of verification, ensure all check holes are fully grouted.
Test Program:
1.
The Contractor shall conduct a test program to evaluate the proposed grouting
methods and the ability of the proposed grout mix to produce grout columns meeting
02432 - 8
the depth, diameter, overlap, and material property requirements shown on the Shop
Drawings and specified herein.
1.08
A.
B.
2.
The Contractor shall select one representative location as a test section for the test
program and this location shall be approved by the RE prior to starting the test
program.
3.
The test program shall be designed to verify the following items:

a.
The range of column diameters and column strengths which can be achieved.
b.
The column overlap and continuity between columns which can be achieved.
c.
Maximum pressures that can be used before ground surface heave occurs.
4.
The test section shall consist of a minimum of five jet grout columns (3 primary and 2
secondary) installed as specified for the production jet grouting work.
5.
Execute the test program in accordance with the approved submittals. The Contractor
shall expose two columns from each test section for physical inspection. Measure the
column diameter and compare with the design diameter. Alternatively, columns can
be sampled by drilling near the center and perimeter of columns, if exposing columns
in areas of representative soil conditions is not feasible.
6.
After the jet grout columns have set up sufficiently, obtain a continuous core sample
from one of the primary columns. Inspect the core and check for segregation. Select
three samples from the core column and perform compression tests in accordance with
ASTM D1633 or D2850, as appropriate.
7.
Subject to the results of the test program, the RE may require modifications in the jet
grout column production to achieve satisfactory results.
DESIGN CRITERIA
Soil-Cement Columns:
1.
Where used at shaft break-in and break-out locations, the Contractor shall verify the
adequacy of the design criteria as related to the behavior of anticipated soils and
groundwater conditions.
2.
The Unconfined Compressive Strength of jet grout columns at 28 days shall be

between 300 and 600 psi, and at least 100 psi at 7 days. The Contractor shall design
and install the jet grouted columns so as to ensure that the TBM is able to excavate
through the treated ground without difficulty.
3.
Column overlap: No less than the larger of 1/8 of the column diameter or 6 inches.
4.
Maximum in-situ permeability: 1.010-5 cm/sec measured in accordance with this

specification.
5.
Allowable drill deviation: 1.0 percent of depth.
Acceptance Strength Criteria:
02432 - 9
1.
The average strength of the soil-cement column mass shall be determined by sampling
the production jet grouting, as specified in this section under Quality Control.
2.
Production jet grouting shall be considered acceptable when no less than 67 percent of
test results meet or exceed the minimum design strength and the remaining 33 percent
of test results meet or exceed 80 percent of the minimum design strength.
PART 2 PRODUCTS
2.01
MATERIALS
A.
General: All materials shall be delivered, transported, handled, and stored in accordance with
the manufacturers recommendations. No materials shall be used that have exceeded the
manufacturers recommended shelf life. An adequate supply of materials for jet grouting shall
be present on site at all times.
B.
Grout: Grout shall be a mixture of Portland cement, water, and bentonite or other non-toxic,
biodegradable admixtures if required. The grout shall be mixed in a grout plant that combines
dry cement and water in predetermined proportions. Grout mixes shall have a consistency that
is fluid and pumpable. Grout mixes shall be proportioned to provide the required strength and
mixing consistency. The grout mix utilized shall have a maximum water/cement ratio of 1:1 by
weight.
C.
Cement: Portland cement, ASTM C 150, Type I or II.
D.
Bentonite: Premium grade Wyoming Sodium Montmorillonite, or equal, manufactured in

accordance with API Standard 13A. Grout mix shall not contain more than 2 percent bentonite,
by dry weight of cement.
E.
Water: Fresh and potable water shall be used.
F.
Admixtures: Admixtures may be used as necessary to improve pumpability, to control set time,
and to prevent segregation and bleeding. Admixtures shall be non-toxic and biodegradable and
conform to ASTM C 494.
2.02
EQUIPMENT
A.
Drilling Equipment: All jet grouting equipment used for drilling boreholes; lowering, raising
and rotating grout tubes; mixing grout; and injecting grout shall have proven performance for
use in performing jet grouting work.
B.
Mixers: Grout mixers, holding tanks, and associated equipment shall be of a type and capacity
for producing uniform grout mixtures at all times, and in the quantities required for the timely
prosecution of the work.
C.
Jet Pumps: Pumps shall be high-pressure pumps capable of delivering the grout at the flow
rates and pressures required.
02432 - 10
D.
Recording Equipment: Provide automatic recording equipment with a meter to determine the
volume of grout injected. The meter shall be calibrated in gallons to the nearest quarter-gallon
(0.25 gallon).
E.
Measurement of water to be used in grout mixes shall be carried out using approved meters
graduated to read to an accuracy of 0.5 gallons.
F.
Spare parts and/or equipment shall be available on site to maintain the jet grouting equipment in
satisfactorily operating condition at all times during execution of the grouting work.
PART 3 EXECUTION
3.01
GENERAL
A.
The columns shall consist of soil mixed with cement grout, by the jet grouting method using a
single, double or triple fluid system.
B.
The columns shall provide stability for shaft and tunnel excavations.
C.
The work includes: mobilizing equipment for jet grouting; determining suitable grouting
procedures and grout mixes; installing test and production jet grout columns; control, clean up,
and disposal of waste materials resulting from jet grouting; and sampling and testing.
D.
All ground improvement work shall be performed in accordance with all local, state, and federal
safety regulations and permits required for the project.
E.
The general procedure for constructing each individual jet grouted column shall be as follows:
3.02
A.
1.
The jet grout column shall be constructed into soils as shown on the shop drawings.
2.
The grout shall be pumped through the nozzles. The rods shall be rotated and
withdrawn in prescribed increments creating the jet-grouted column.
3.
Excess grout and soil from jet grouting operations shall be contained in mud tanks or
by other reviewed methods to facilitate rapid cleanup at the end of each shift.
4.
Equipment for mixing, holding, and pumping grout shall be in a secure location and
shall be operated to prevent spillage of material. No water, waste, grout, or soil shall
be allowed to discharge into any body of water.
5.
At the completion of daily jet grouting operations, thoroughly clean site and dispose
of all debris, water, waste grout, and spilled material.
ENVIRONMENTAL AND SAFETY REQUIREMENTS

Provide, install and maintain environmental controls to contain and dispose of surface water
run-off, grout and drilling fluid overflows, and spoil return, including:
1.
Containment walls and dikes with membrane barriers.
2.
Sumps and cleanouts.
02432 - 11
3.
Silt traps.
4.
Liquid storage tanks.
B.
The Contractor shall protect all existing utilities in place. This includes avoiding disturbance to
bedding and pipe zone backfill or equivalent due to jet grouting activities.
C.
For any jet grout column within 5 feet of the outside of a utility conduit or bedding outside the
conduit, a casing or duct shall be installed from the ground surface past the utility or bedding
and sealed into the underlying soil to a minimum depth of 12 feet. The casing shall be placed
prior to jet grouting and removed upon completion of grouting the column.
D.
Maintain site in a clean and orderly state to the satisfaction of the RE.
E.
Perform work in a manner that minimizes safety hazards and exposure of personnel and
equipment to hazardous and potentially hazardous conditions.
F.
Provide safe work areas and temporary platforms and stands at all times.
G.
In case of emergency or if a work stoppage is likely to endanger or effect adjacent structures or

a highway, continuously maintain a full work force 24 hours per day including weekends and
holidays until the work is stabilized and the stability of adjacent structures is maintained.
3.03
COLUMN CONSTRUCTION
A.
If the performance requirements for the jet grout columns specified herein are not achieved,
additional jet grout columns shall be installed, as directed by the RE, at no additional cost to the
Corporation.
B.
The completed columns shall be a homogeneous mixture of grout and in situ soils. Mixing is to
be controlled by shaft rotational speed, drilling speed, and grout injection rate.
3.04
COLUMN LOCATIONS
A.
The jet-grouted column locations shall be surveyed and checked by the Contractor before
commencement of drilling. Column layout shall be based on the minimum column diameter and
column overlap shown on the approved submittal including provisions for a minimum overlap
of 6 inches in all directions and control of ground water inflow. Provide additional overlap if
required for adequate support of shaft and trench excavations. The location of each column
shall be noted and recorded on the daily shift report.
B.
All drill holes shall be set out to within 2 inches of the design position and elevation.
3.05
COLUMN INCLINATIONS
A.
The drilling/grouting rods shall be of sufficient stiffness to ensure that the deviation of jetgrouted columns from the theoretical axis is maintained at 1:100 (horizontal to vertical) or
better.
B.
Vertical columns shall be installed unless utilities or other obstructions require the columns to
be inclined to avoid conflicts. The inclination of each column shall be noted and recorded on
the daily shift report.
02432 - 12
C.
3.06
Initial drill inclination shall be set up within 1.0 percent of the design value and azimuth to be
set up within 1.0 degree of design value.
COLUMN DEPTH AND HEIGHT
A.
Column depth shall be measured with respect to ground surface by observing the length of the
rods inserted. Markings shall be located on the drill mast in one-foot increments to assist the
drill operator in determining the exact depth.
B.
Column length shall also be measured by observing the length of the rods withdrawn while
grouting.
C.
The depth to the bottom and length of each column shall be noted and recorded on the daily
shift report.
3.07
GROUT MIXING
A.
A mixing plant shall be used for the preparation of the grout. The mixing plant shall consist of
high-speed grout mixer, grout agitator, grout pumps and control unit, as required.
B.
Grout shall be produced such that jet grouting will not be interrupted due to insufficient grout
being available. The grout batching plant shall be capable of producing a uniform grout mixture
at 125 percent of the maximum required rate.
C.
Mix cement, water, and any admixtures in the proportions indicated in the reviewed submittals.
If bentonite is used, add bentonite to water and mix thoroughly to fully hydrate prior to adding
cement. Time of mixing shall be as required to fully hydrate the cement but not less than 5
minutes. Any grout not injected within 90 minutes shall be wasted.
D.
Weigh batchers shall be checked daily and calibrated at weekly intervals.
E.
A series of agitating tanks shall be provided to allow acceptance or rejection of grout to be

carried out. The feed into the tanks shall be equipped with adequately sized screens to remove
any hardened grout or foreign material larger than 0.04 inches from entering the tanks from
mixers or grout return lines. The capacity of the holding tanks shall be not less than two times
that of the grout mixer or otherwise sufficient to sustain continuous operations. Tanks shall be
fitted with a graduated dip-stick capable of measuring the volume of grout in the tank to within
0.05 cubic feet.
3.08
DRILLING FOR JET GROUTING
A.
Provide suitable drilling equipment capable of drilling to the depths and inclinations required.
B.
Each drill rig shall be fitted with instrumentation to monitor drilling inclination and bearing to
the required tolerance.
C.
The drill rig shall be checked at set-up and every 25 linear feet of hole length for positional
accuracy, bearing and drilling inclination. Any deviation outside of the specification shall be
noted and the hole re-drilled in accordance with the Quality Control Plan.
3.09
JET GROUTING
02432 - 13
A.
Use equipment that can be controlled to the desired design rate of withdrawal, rotation, grout
flow and pressure, airflow and pressure. As a minimum maintain all designated parameters with
a tolerance of 5.0 percent.
B.
Use equipment that records the parameters set out in Article 3.09A with real time display to
allow the jet grout operators to control the column construction.
C.
Maintain equipment in fully functional condition and provide operational procedure for
checking jet grout nozzle(s) for efficiency and diameter.
D.
In addition to information recorded on solid-state memory, the equipment shall be fitted with a
chart recorder to provide a hardcopy record of the drilling operation in the event of
instrumentation equipment failure.
E.
Hard copy records shall be produced at appropriate scales with parameters recorded both
against time and depth.
F.
The Contractor shall provide to the RE software to allow the rig instrumentation data to be
downloaded and processed on a computer.
G.
The drill rig shall have direct communication with the high-pressure pump through a wireless
link to allow flow to be recorded in real time.
H.
Prior to the start of jet grouting operations, the Contractor shall determine the relationship
between air pressure and airflow through the jet grouting rods and monitor. This will be carried
out by passing compressed air through the system at varying pressures and noting the
corresponding flow. The system should include the maximum number of rods that can be fitted
to the mast together with the monitor. If the Contractor changes rod or monitor type then the
measurements shall be repeated to determine the new relationship prior to using the new
equipment within the trials.
I.
The rig operator shall monitor the spoil return at all times to ensure that the return is free
flowing and preventing increase in bottom hole pressure. If spoil return is interrupted for more
than 20 seconds, the rig operator shall take action to regain the spoil return immediately. Before
the trials commence, the Contractor shall detail within his method statement all actions required
to regain the spoil return. This will take the form as a minimum, reaming the hole or moving
the rods up and down while maintaining reduced pressure and flow.
J.
If the double system is employed then the rig operator shall also monitor the air-flow. Should
this begin to reduce and potentially signal an increase in bottom hole pressure then the
relationship between the air-flow and spoil return quantity shall be noted. If the spoil return is
reducing then action will be taken to ream the hole.
K.
Where the jetting of a column is interrupted for any reason including the addition or removal of
drill rods, then the jet grout stem shall be reintroduced into the column by a minimum distance
of 12 inches or distance to be proposed by the Contractor and approved by the RE.
L.
Jetting shall be commenced from the bottom of the hole and withdrawn towards the top of the
hole.
02432 - 14
M.
3.10
The Contractor shall have available at all times sufficient standby equipment to ensure that jetgrouting operations can be continuous and without significant interruptions due to breakdowns
of equipment.
GROUT INJECTION RATE AND PRESSURE
A.
The appropriate grout injection rate and pressure shall be determined during the test program
and is subject to the approval of the RE. This injection rate and pressure shall be maintained
during construction of the production columns.
B.
The grout injection rate shall be monitored by counting the strokes of the piston pump in a fixed
period of time if piston displacement calibration is available or by using a flow meter.
C.
The grout injection pressure shall be monitored with calibrated pressure gauges mounted on the
injection lines. Prior to the start of each column, the pressure shall be checked to verify that
there is no blockage in the jet grout rods.
D.
The grout injection rate, volumes injected, and injection pressure for each column shall be noted
and recorded on the daily shift reports.
3.11
AIR/WATER PRESSURE
A.
The necessary air and/or water pressure shall be determined during the test program and
maintained during construction of the production columns. The air pressure shall be checked on
the pressure gauges mounted on the compressor and drill rig.
B.
The air pressure shall be noted and recorded for each column on the daily shift reports.
3.12
ROTATION AND WITHDRAWAL RATE
A.
The appropriate rate of rotation and withdrawal of the jet grout monitor shall be determined
during the test program and maintained during construction of the production columns.
B.
The rate of rotation shall be controlled by adjusting the rotary head speed. The rate shall be
checked by counting the number of rotations of the drilling/grouting rods in a fixed period of
time.
C.
The rate of withdrawal shall be controlled by an electronic sensor mounted to the mast.
D.
The rate of rotation and withdrawal of the jet rods shall be noted and recorded for each column
on the daily shift reports.
3.13
A.
QUALITY CONTROL OF JET GROUTING

The Contractor shall produce a graphical record of the jet grouting operation that shall include
the following:
1.
Graph of rotation speed, rate of withdrawal, grout pressure, grout flow, air pressure
and air flow plotted against depth.
2.
Graph of drill hole deviation in two orthogonal directions and showing the design
inclination and actual drilled alignment, where measured.
02432 - 15
B.
3.14
A.
3.15
A.
3.
Plan showing as-built and design position of the jet grout columns at the top and
bottom of the jet grouted block.
4.
Plan showing any proposed setting out of required closure columns.
All column surveying, location, positional data, grouting parameters, and performance testing
shall be maintained on a computer database for ease of assessment of jet grouting overall
performance. The software and format for the database shall be proposed by the Contractor and
approved by the RE.
PREVENTION OF GROUND HEAVE OR SUBSIDENCE
Perform construction in a manner that prevents subsidence or heave of the ground surface in the
vicinity of the works. Compliance with the following minimum requirements shall not relieve
the Contractor of the responsibility to prevent subsidence or heave:
1.
In order to prevent ground heave and the potential for discharging grout into water
ways during jet grouting, the drilling shall be carried out with an oversize drill bit with
respect to the drilling/grouting rods. Appropriate drilling procedures shall be
determined during the test program and utilized during construction of the production
columns.
2.
The annulus between the rods and the borehole shall be kept clear at all times during
grouting.
CLEANUP
The Contractor shall complete cleanup of the work area after jet grouting operations as soon as
possible, and remove all grout spillage and residue from the work area prior to shaft excavation.
END OF SECTION
02432 - 16
SECTION 02495
INSTRUMENTATION AND MONITORING
PART 1 GENERAL
1.01
SCOPE OF WORK
A.
The Work specified in this Section includes but not limited to drilling of monitoring boreholes,
furnishing, and installing geotechnical instrumentation to monitor ground and structural
movements, groundwater response, and monitoring noise and vibration as required. The Work
shall include the establishment of baseline readings, taking of regular readings, interpreting and
presenting the monitoring data, and alerting and taking actions as required.
B.
Locations for the installation of the geotechnical instrumentation are shown on the Contract
Drawings. The Contractor shall install the indicated instrumentation at these locations unless
directed otherwise by the RE.
C.
Noise/vibration limits shall meet the requirements of all applicable federal, state and local
codes, laws, regulations and ordinances.
1.02
RELATED SECTIONS
A.
B.
Shaft Support - Slurry Walls is included in Section 02310.
C.
D.
E.
F.
1.03
REFERENCE STANDARDS
A.
ASTM A53
Standard Specification for Pipe, Steel, Black and Hot-Dipped Zinc-Coated

Welded and Seamless.
B.
ASTM C778
Standard Specification for Standard Sand.
C.
Federal Geographic Data Committee, Document FGDC-STD-007.
1.04
A.
DEFINITIONS
Surface Settlement Point (SSP/I and SSP/II): Monitoring points installed at the ground surface
that are monitored by optical survey methods to determine whether vertical displacements occur
during construction and used for precise survey leveling as required by the RE.
02495 - 1
B.
Optical Survey Prism (OSP): Instrument installed on the face or ground surface of a structure
or object to monitor horizontal and vertical movements during construction by precision optical
survey methods.
C.
Inclinometer in Concrete (INC/I): Instrument installed in a preformed hole in a slurry wall panel
to monitor lateral movements of the slurry wall panel.
D.
Inclinometer in Soil (INC/II): Instrument installed in a drilled hole in soil to monitor lateral
movements of the ground.
E.
Multiple Point Borehole Extensometers (MPBX): Instruments installed in a drilled borehole to

monitor ground deformations during construction. A multiple point borehole extensometer
consists of two or more anchors at selected positions within the borehole, with rods extending to
a readout head at the ground surface. Deformation is determined by measurements of movement
of each anchor relative to the readout head, and by optical surveying of the readout head itself.
Multiple point borehole extensometers shall utilize rod extensometers in plastic sleeves with
hydraulic or packer anchors encapsulated in cement grout backfill as shown on the Contract
Drawings.
F.
Open Standpipe Piezometer (PZO): Piezometers shall consist of a slotted PVC well screen and a
PVC riser pipe. The slotted well screen is installed in a sand filter at the base of the borehole.
The top of the sensing zone is sealed with bentonite and the annulus around the riser pipe is
filled with grout. Water levels in the riser pipe are monitored with a water level indicator.
G.
Orange Trigger Review Level: Value of instrumentation readings at which the RE and
Contractor jointly assess necessity of altering methods, rate or sequence of construction.
H.
Red Trigger Alert Level: Value of instrumentation readings at which the RE orders the
Contractor to cease construction operations immediately, make site and affected ground and
properties secure, and take necessary and agreed upon measures to mitigate unacceptable
movements and to assure the safety of the work and the public.
I.
Baseline Reading: Value of instrumentation readings taken prior to construction to provide a

baseline bench mark against which all subsequent readings are compared.
J.
Response Level: Review and Alert values as defined above and specified herein for specific
instruments. Response levels encompass the cumulative movement, deformation, stress, and
strain from the baseline readings.
1.05
A.
SUBMITTALS
Submittals shall be made in accordance with the requirements of the General Conditions of the
Contract Documents. In addition the following documentation shall be submitted to the RE at
least 30 days prior to the work they refer to commences:
1.
Qualifications: Submit personnel qualifications as defined in this Specification

Section.
2.
Shop Drawings: Submit the Shop Drawings or items listed below, as prepared by
qualified specialists submitted above.
02495 - 2
3.
Instrument Installation Schedule: Submit the proposed schedule for installing

instruments. The RE shall be informed a minimum of 48 hours before installation
procedures commence.
4.
Methods and equipment to be used for drilling and instrumentation grouting, including
manufacturer and model number of drill rigs, and method to be used for cleaning
inside of casing or augers.
5.
Methods related to the installation and protection of surface settlement points, optical
survey prisms, borehole instruments, and any other instruments.
6.
Method for overcoming buoyancy of instrumentation components during grouting.
7.
Method of sealing joints in pipes and inclinometer casing to prevent ingress of grout.
8.
Materials and mix portions for grout for installation of instruments such as for
inclinometers.
9.
Method for conducting post-installation acceptance test.
10.
Methods for surveying and monitoring instruments, including procedures to ensure

good repeatability of readings, and forms for reporting instrumentation data.
11.
Product Data and Samples: Submit all applicable manufacturers literature and
drawings describing operation and maintenance procedures for each type of
instrument including any probes, readout units and accessories associated with the
instrument.
B.
Response Plan: At least 30 days prior to the commencement of any excavation, submit to the
RE for review a generalized plan for action to be implemented in the event of a review or alert
level being reached, as defined herein.
C.
Noise and Vibration:

1.
No later than 60 days after Notice-to-Proceed, Noise Control and Vibration Control
Plans shall be submitted to the RE for approval. The plans shall describe the procedure
for establishing ambient baseline noise and vibration levels prior to the
commencement of construction and shall provide details on the noise/vibration
reduction measures required to meet the noise/vibration level limitations and minimize
nuisance noise/vibration conditions. Noise/vibration generating equipment shall not be
operated prior to acceptance of the plans by the RE. Updated Noise Control and
Vibration Control Plans shall be resubmitted every six months thereafter, or whenever
the construction activities or the construction Work hours have changed.
2.
No later than 60 days after Notice-to-Proceed, Noise Monitoring and Vibration

Monitoring Plans shall be submitted to the RE for approval. The plans shall describe
the noise/vibration monitoring and reporting procedure to be used prior to and during
construction. Noise/vibration generating equipment shall not be operated prior to
acceptance of the plans. The Plans shall include details of receptor locations,
noise/vibration level measurement devices, methods and procedures, data reporting
02495 - 3
methods, and response procedures to be taken if limits are exceeded or if complaints

are received from the public.
3.
1.06
A.
B.
1.07
A.
Submit noise and vibration measurement reports every week and update the Noise
Control Plan and Vibration Control Plan every 6 months during construction.
DELIVERABLES
Within ten working days of installing each instrument, provide the following:
1.
A certificate issued by the instruments manufacturer stating that the manufacturer has
inspected and tested each instrument before it leaves the factory to see that the
instrument is working correctly and has no defects or missing parts. Include
calibration curve with tabulated data points.
2.
As-Built drawings showing the exact installed location including coordinates and
elevations, the instrument identification number, the instrument type, the installation
date and time, the station, or open excavation or shaft excavation depth on the
installation date and the rod anchor or tip elevation and instrument length, when and
where applicable. Include details of installed instruments, accessories and protective
measures including all dimensions and materials used.
Reports and Records: Provide reports of monitoring data to the RE in accordance with the
requirements herein.
Personnel Qualifications for Instrument Installation and Monitoring:
1.
The Contractor shall employ qualified technicians with a minimum of 2 years

experience in the installation and monitoring of geotechnical instrumentation similar
to that specified herein or required in order to comply with this Specification. Written
documentation of qualifications shall be submitted to the RE before installation of
instrumentation devices begins.
2.
The Contractor shall employ a New York State Professional Engineer, with a
minimum of 5 years experience in the installation of instrumentation specified herein,
to supervise and direct technicians and be responsible for instrument installation as
required by the Contract Drawings and Specifications. This person is to be physically
present at the installation site(s) to directly supervise the installations.
3.
Surveyor Qualifications: All surveying for monitoring ground movements shall be

performed by a land surveyor licensed in the State of New York with previous
experience surveying for the detection of structural or ground deformations.
B.
Each instrument specified herein shall be the product of an acceptable manufacturer currently
engaged in manufacturing geotechnical instrumentation hardware of the specified types.
C.
The Contractor shall engage the services of an authorized manufacturers representative who
shall visit the site and provide training as necessary for the Contractors personnel to properly
02495 - 4
install and monitor these devices. The authorized representative shall inspect and approve at
least the first two installations for each type of instrumentation.
D.
All instrumentation materials, after receipt at the site and prior to installation, shall be stored in
an indoor, clean, dry and secure storage space. Instruments shall not be exposed to temperatures
outside the manufacturer's stated working temperature range.
E.
The RE shall be notified prior to the installation of instrumentation.
1.08
TOLERANCES
A.
Tolerances specified herein may be modified by the RE at any time, depending on location,
construction progress, scheduling and efficiency of temporary Works, construction rates of
movement, and other factors affecting earth or structures that are subject to monitoring.
B.
Noise/vibration tolerances shall meet the requirements of all applicable federal, state and local
codes, laws, regulations and ordinances.
C.
Install surface settlement points within 5 feet of the horizontal location shown on the Contract
Drawings in agreement with the RE.
D.
Install inclinometers and multiple point borehole extensometers within 2 degrees of vertical for
the entire length.
E.
Notify the RE if actual field conditions prohibit installation at the location and elevations
specified on the Contract Drawings.
F.
Perform surveying to Third Order, Class 1 minimum accuracy of 1:10,000 as defined by the
Federal Geographic Data Committee.
G.
Three-dimensional coordinates (Northing, Easting, and elevation) of each instrument

installation to 0.005 foot.
PART 2 PRODUCTS
2.01
A.
MATERIALS
Inclinometers:
1.
Provide inclinometer casing, probe, cable, readout unit and accessories as

manufactured by Slope Indicator Company or approved equivalent.
2.
Inclinometer casing shall be 2.75 inch outside diameter ABS or acceptable equivalent
with broached internal keyways and twist tolerance better than 1-degree per 10-foot
length. Couplings shall be of the non-telescoping type. Provide proper joint sealing
associated with the selected type of casing such as solvent cement and tape or O-ring
seals.
3.
Probe shall be a Slope Indicator Company Model 5032500 or approved equal. Probe
shall be biaxial, consisting of two force balance accelerometers mounted at 90
degrees, with a 2-foot wheelbase. Probe shall be supplied in a carrying case.
02495 - 5
4.
Cable shall be a minimum of 180-feet long, sheathed with neoprene and have
vulcanized rubber markers, and an internal wire rope core. Minimum cable outside
diameter shall be 0.4 inch.
5.
Readout unit shall be a Slope Indicator Company Digitilt DataMate or approved

equivalent. The time interval between recordings 2-feet apart in the casing shall be
such that the reading stabilizes to within plus or minus 1 unit of display within eight
seconds. Readout unit shall include a battery charger. Furnish sufficient number of
readout units to ensure constant availability of functioning units on site in case of loss
or failure of prime units.
6.
Provide accessories including end caps, tools and materials for attaching coupling and
taking readings.
7.
Provide inclinometer software such as Slope Indicator Company DigiPro for

Windows or approved equivalent.
8.
Factory calibrations of inclinometers shall include comprehensive calibrations of the

force balance accelerometers before assembly in the probe. A final calibration shall
include measurements made at 10-degree vertical intervals from minus 30 to plus 30
degrees with respect to vertical, and a comprehensive repeatability check over a
smaller zone near vertical.
9.
Inclinometers in Soil (INC/II):

a.
Inclinometer casings in soil shall be installed at the locations and depths shown
on the Contract Drawings or as directed otherwise by the RE. After installation,
the casing groove spiral shall not exceed one degree per 10 feet of length, the
orientation of the grooves at the top of the casing shall be within 5 degrees of
the planned orientation, and no part of the casing shall deviate from vertical by
more than 1 percent of the depth to that part. The bottom of the casing shall be
a minimum of 15 feet within a stratum suitable for providing base fixity.
b.
Three samples shall be taken of the material assumed to provide base fixity, one
at the bottom of the borehole, others at 5 and 15 feet above the bottom of the
borehole, and submitted to the RE within 24 hours. If the material is bedrock, a
core sample shall be taken throughout the bottom 15 feet.
c.
Casing groove orientation shall be maintained throughout installation. Fill the

casing with non-toxic antifreeze with a propylene glycol base.
d.
After completion of installation, a post-installation acceptance test shall be

performed to verify that there is no grout in the inclinometer casing, that groove
orientation and verticality are correct, and that the inclinometer probe tracks
correctly in all four orientations.
e.
After completion of installation, the as-built location in horizontal position shall

be determined to an accuracy of plus or minus 0.01-foot, and the elevation of
the top of the inclinometer casing to an accuracy of plus or minus 0.01-foot.
The point selected to determine horizontal position shall be shown on the
drawings and shall be indicated on the installation record sheet.
f.
The inclinometer grooves shall be positioned perpendicular and parallel to the

anticipated direction of maximum ground movement.
02495 - 6
10.
B.
C.
Inclinometers in Concrete (INC/I):

a.
Installation of inclinometer casings shall be as specified in Article 10 above.
b.
Drill below slurry wall panel, with borehole size adequate for inclinometer
casing installation, to a minimum of 15 feet below the bottom of the slurry wall
panel.
c.
Grout for use in inclinometers installed in slurry walls shall include sand and
water and shall have a similar strength to the slurry wall concrete.
d.
Provide sleeve pipe to be installed in the slurry wall before concreting. Sleeve
pipe shall be 6-inch diameter Schedule 80 PVC pipe, or extra strong 6-inch
diameter steel pipe, threaded and coupled, ASTM A 53, Grade B. A plug, of a
material other than steel so that it can later be drilled through shall be provided
at the bottom of each sleeve pipe to prevent concrete from entering the pipe
during placement.
11.
Surface protection shall have a diameter adequate to follow attachment of cable

support assembly, or shall allow for an inclinometer casing extension while readings
are being taken. The length of the inclinometer casing extension shall not vary by
more than 0.05 inch. Provide threaded pipe cap with hasp and padlock. Cap end shall
be 3 inches above the inclinometer casing.
12.
Inclinometers shall be visible and protected from damage from site activities. All site
personnel must be made aware of the instruments importance through a toolbox talk
session.
Surface Settlement Points (SSP/I):

1.
Surface settlement points shall be installed in a drilled hole and shall consist of steel
pipe casing of 2.5-inch outside diameter; 1.5-inch inside diameter black steel pipe
conforming to ASTM A53, standard weight; welded or threaded bottom steel tip; and
steel pipe cap for read point. The combined length of the 1.5-inch black steel pipe and
the bottom steel tip shall be 5 feet.
2.
Provide 18 x 18 x 0.31-inch steel plate with a central hole and steel pipe clamp to fit
the 2.5-inch steel pipe casing. Steel plate and pipe clamp assembly shall be capable of
transferring the total weight of the 2.5-inch pipe to the soil underlying the steel plate.
The assembly shall also be capable of maintaining its position on the 1.5-inch steel
pipe over time.
3.
Protect surface settlement points with 6-inch minimum dimension cast iron valve box
installed flush with the ground surface and extending at least 9-inches below grade.
Provide iron cover and lifting rod or pull-up device for lifting top covers.
4.
Sand shall fill the hole from the base of the steel plate. Grout shall fill the space above
the sand to the level of the ground surface. Grout the annular space between the
borehole and pipe casing.
Surface Settlement Point, Type II (SSP/II)
02495 - 7
1.
D.
Instrument shall be a masonry nail of 2 minimum length and diameter driven

vertically into a structure, concrete, or asphalt with metal identification tag suitable for
precise optical survey and leveling.
Multiple point borehole extensometers:

1.
Rod Extensometer: Multiple point borehole rod extensometers shall be Model No. A-3
and/or A-5 as determined by the RE and manufactured by Geokon, Inc., Lebanon, NH
or approved equal. Extensometers shall be with hydraulic or packer anchors as
specified and shall be furnished complete with all heads, rods, connectors, cables,
protective tubes, sensors, accessories and adequate spare parts necessary for
installation and maintenance as recommended by the manufacturer. The extensometer
head shall be of the flangeless type. Extensometers shall be grouted, if deemed
necessary by the RE, in accordance with the manufacturers recommendations.
2.
Furnish sufficient number of readout units to ensure constant availability of

functioning units on site in case of loss or failure of prime units.
E.
Surveying instruments for surface settlement points, optical survey prisms, and multiple point
borehole extensometers: Instruments used for vertical or horizontal deformation monitoring
shall have a minimum accuracy of 0.005 foot.
F.
Standpipe Piezometers: Open Standpipe piezometers shall be installed at the locations and depth
indicated on the Contract Drawings, or as directed by the RE and in accordance with the ground
water control plan developed by the Contractor as required in Section 02145 - Control of
Groundwater and Surface Water.
1.
Piezometers shall consist of 1.25-inch nominal diameter Schedule 40 PVC riser pipe
with a vented cap and a slotted Schedule 40 PVC well screen. The well screen shall
meet the following requirements:
a.
Length: 10 feet
b.
Slot width: 0.010 inch
c.
Number of rows of slots: 3
d.
Spacing between slots: 0.1875 inch
e.
Outside slot length: 1.375 inch
f.
Slots per row per foot: 61
g.
Riser pipe shall have flush joints.
2.
Filter sand shall conform to ASTM C778, Standard Specification for Standard Sand,
20-30 sand.
3.
Granular bentonite shall be Enviroplug Medium, as manufactured by Wyo-Ben, Inc.,

Billings, Montana, or Holeplug, as manufactured by Barold Division, Petroleum
Services, Inc., Houston, Texas, or equivalent.
4.
Water level indicator/probes shall be an electrical indicator cable of appropriate length

with graduations at 0.02 feet or smaller intervals. Provide two (2) such
indicators/probes to enable independent readings by the Contractor and the RE.
02495 - 8
G.
Install Optical Survey Prism (OSP) located on the face of structures at locations shown on the
Contract Drawings or as directed by the RE. It is the Contractors own responsibility to
coordinate the installation including provision of any safety measures required by the relevant
authorities including, but not limited to New York City Transit (NYCT) and New York City
Department of Transportation (NYCDOT).
H.
Grout mixes for instrumentation:
I.
J.
1.
Special Grout (Type A) shall consist of Type II Portland cement, sand and water and
shall have a similar strength to the slurry wall concrete. The grout mix used shall be
sampled and tested and the results sent to the RE.
2.
Special Grout (Type B) shall consist of Type II Portland cement, bentonite and water
and shall have approximately the same shear strength and compressibility as the
surrounding ground. The grout mix used shall be sampled and tested and the results
sent to the RE.
3.
Other proposed grout mixtures may be used subject to the manufacturers

recommendations and approval by the RE.
Noise measurement:
1.
All noise measurements shall be performed with an instrument that is in compliance

with the criteria for a Type 1 (Precision) or Type 2 (General Purpose) Sound Level
Meter as defined in the current revision of ANSI Standard S1.4.
2.
All sound level meters, microphones, and calibrators shall undergo certified laboratory
calibration conformance testing at least once a year. The calibration certificate shall be
submitted to the RE.
3.
The sound level meter shall be on-site and readily accessible at all times.
Vibration measurement:
1.
Vibration measurements shall be performed with velocity seismographs of a type

agreed by the RE and capable of:
a.
Recording vibrations in terms of peak particle velocity and vibrational

amplitude over a frequency of 0 200 Hz in three mutually perpendicular
directions.
b.
Producing a permanent record of vibrations by tracing an ultra-violet light beam

on sensitized paper, or by other methods agreed by the RE.
2.
The accuracy of seismographs shall be checked before commencement of construction

and at regular intervals agreed by the RE no greater than annually.
3.
The velocity seismographs shall be on-site and readily accessible at all times.
PART 3 EXECUTION
3.01
GENERAL
02495 - 9
A.
Instrumentation shall be installed at the locations shown on the Contract Drawings or as

directed by the RE, prior to start of any tunneling, shaft or open excavation construction. The
Contractor shall install such instrumentation taking due regard of the need to establish baseline
conditions. The RE may direct the Contractor to install additional instruments at any time
during construction.
B.
Existing Conditions: Locate conduits and underground utilities in all areas where drilling from
the ground surface will be required to install the instruments. Notification of utility companies
shall be performed in accordance with the General Conditions of Contract. Locations of the
instruments shall be modified, as approved by the RE, to avoid interference with the existing
conduits and utilities. The location of conduits and utilities is the responsibility of the
Contractor prior to any instrument installation. Any subsequent damage to existing utilities
resulting from instrument installations shall be repaired at no additional cost to the Corporation.
C.
Wherever instrumentation locations will conflict with other components of the Work, the
Contractor shall notify the RE prior to installation. Where conditions allow, the RE may agree
to relocate instruments to avoid a conflict, or the Contractor may be directed to install the
instrumentation at the designed location shown on the Contract Drawings and to re-install it at
an adjacent location immediately prior the commencement of the Work that conflicts with the
instrument location, at no additional cost to the Corporation. The Contractor shall verify
compatibility between the location of instruments shown on the Contract Drawings and the
Contractors equipment, means, and methods.
D.
All instruments shall be clearly marked, labeled, and protected to avoid being covered,
obstructed or otherwise damaged by construction operations or the general public. Both
protective housing and box or vault covers shall be marked.
E.
Surveying: Immediately following installation, the location of the top of all instruments shall be
surveyed to provide horizontal and vertical coordinates.
3.02
A.
3.03
INSTALLATION SCHEDULE
Install all instruments a minimum of 60 days in advance of start of shaft or open cut excavation
at shaft sites.
BASELINE READINGS
A.
All baseline readings are to be agreed with and approved by the RE.
B.
Baseline reading for inclinometers consists of ten consistent sets of readings taken, two within
24 hours and eight every week after installation.
C.
Baseline reading for surface settlement markers and points, prisms or crack gauges consists of
two consistent sets of readings within 10 days of installation.
D.
Baseline readings for noise and vibration monitoring will be as specified in the Noise
Monitoring Plan and the Vibration Monitoring Plan, as defined in this Specification Section.
3.04
A.
MONITORING FREQUENCY
For surface settlement points, optical survey prisms, and multiple point borehole extensometers:
02495 - 10
1.
B.
C.
D.
For excavations at each of the shaft sites including bored tunnel, as shown on the
Contract Drawings, monitor as follows:
a.
Monitor daily 3 days in advance of the start of any excavation. Continue daily
monitoring until the end of all excavations and until any movements have, in
the opinion of the RE, stabilized.
b.
Monitor weekly until the final structures are completed and until no movement
occurs for 4 consecutive readings or until directed by the RE to end monitoring.
For open standpipe piezometers:

1.
Monitor daily for two weeks prior to start of shaft construction at any site.
2.
Monitor daily during shaft excavation.
3.
Monitor more frequently as directed by the RE.
4.
Monitor any existing piezometers in addition to Contractor installed piezometers.

1.
Daily during excavation unless directed otherwise by the RE.
2.
Weekly until final structure is completed and excavation is backfilled and until no
movement occurs for 4 consecutive readings or until directed by the RE to end
monitoring.
Inclinometers in Soil (INC/II)

1.
Monitor every 3 days during slurry wall panel excavation.
2.
Monitor daily during shaft excavation and until 1 week after the shaft base slab has
been installed.
3.
Monitor weekly until final structure is completed and until no movement occurs for 4
consecutive readings or until directed by the RE to end monitoring.
E.
The frequency of noise and vibration readings shall be as submitted by the Contractor and
agreed by the RE as defined in this Specification Section.
F.
Monitoring frequency does not indicate monitoring required for Contractors control or safety
of construction. Perform additional monitoring necessary for safety and performance of
construction operations.
G.
Monitoring frequencies may be modified by the RE at any time, depending on location,

construction progress, scheduling and efficiency of temporary Works, construction rates of
movement, and other factors affecting monitoring.
3.05
A.
REVIEW AND ALERT LEVELS

Immediately inform RE when the Orange Trigger Review and Red Trigger Alert levels
indicated below are reached.
02495 - 11
B.
Review and Alert Levels are defined as a change in instrument reading compared with the
established and agreed baseline reading.
1.
2.
3.
4.
5.
C.
D.
Surface Settlement Points (SSP/I and SSP/II):

a.
Orange Trigger Review Level:
+/- 0.75 inch
b.
Red Trigger Alert Level:
+/- 1.50 inch
Optical Survey Prisms (OSP):

a.
+/- 0.50 inch
b.
+/- 1.00 inch

a.
+/- 0.20 inch
b.
+/- 0.40 inch
Inclinometers in Soil (INC/II):

a.
+/- 0.20 inch
b.
+/- 0.40 inch
Multiple Point Borehole Extensometers (MPBX):

a.
+/- 0.75 inch
b.
+/- 1.50 inch
Action contingency if Orange Trigger Review Level is reached.

1.
Meet with RE to discuss response action(s), and develop an Orange Trigger ReviewLevel Response Plan of Action, based on approved generalized response plan.
2.
Implement reviewed and accepted Review-Level Response Plan of Action.
Action contingency if Red Trigger Alert Level is reached:

1.
Stop work immediately and make Work and any affected properties safe and secure.
2.
Work may be stopped by RE.
3.
Meet with RE to discuss response action(s) and develop a Red Trigger Alert-Level
Response Plan of Action, based on approved generalized response plan.
4.
Work may be restarted by RE provided:

a.
Additional instruments are installed and monitored as directed by the RE.
b.
The reviewed and accepted Alert-Level Response Plan of Action is

immediately implemented.
02495 - 12
E.
Red Trigger Alert Levels are not to be exceeded. Activities must be suspended in affected area
with exception of those actions necessary to avoid exceeding Red Trigger Alert Level or to
make the Work and affected properties safe and secure.
F.
No response levels are specified for instruments other than those defined herein or as directed
by the RE. For other instruments not specified herein or on the Contract drawings, the RE will
order the Contractor to take actions as defined under the Action Contingencies for Orange
Trigger Review and Red Trigger Alert Levels when the RE deems it necessary based on the
monitoring data.
3.06
REPORTING FREQUENCY AND FORMAT
A.
Submit three (3) copies of the instrument monitoring data to the RE, on forms approved by the
RE within 24 hours after the observation has been made.
B.
Plot and submit all data versus time in format and frequency approved by the RE.
C.
Submit reduced data and updated data plots of changes in ground movements relative to time
within 2 working days after observations have been made.
D.
Inform RE immediately when Orange Trigger Review Level or Red Trigger Alert Level is
reached for any instrument.
E.
Submit electronic instrumentation monitoring data, including Contractors own monitoring data
for safety and performance, by modem to RE in standard PC based ASCII DOS file format.
Data transferred by RE will be in same format. In addition to parameters being measured, such
as x, y and z co-ordinates for survey data, include date, time, temperature, weather conditions,
instrument name and number, location, name of person(s) taking readings and other pertinent
data required by RE. In addition, submit hardcopy of each round of monitoring data to RE.
Maintain complete record of monitoring data on-site in compatible form to above.
3.07
A.
3.08
SURFACE SETTLEMENT POINTS AND OPTICAL SURVEY PRISMS

Surface settlement points, optical survey prisms, and multiple point borehole extensometers
shall be installed, identified, and marked clearly for identification purposes at locations as
shown on the Contract Drawings or as directed otherwise by the RE.
INCLINOMETERS AND MULTIPLE POINT BOREHOLE EXTENSOMETERS
A.
Meet with the RE at least 3 days in advance of installing inclinometers or multiple point
borehole extensometers (MPBXs) to verify that all necessary materials are available.
B.
Drill holes in accordance with the locations, orientations, and lengths shown on the Contract
Drawings. The hole diameter shall be compatible with the instruments to be installed, as
approved by the RE.
C.
Inclinometers and MPBXs shall be protected by a locking protective housing.

1.
Install protective housing, with locking cap and padlock, over the readout head such
that all readout plugs are locked and sealed from the elements.
02495 - 13
2.
Protective housings shall be installed within a flush-mounted pre-cast concrete or steel

box, or vault, so as not to obstruct vehicle or foot traffic.
D.
Each reading shall include a three-dimensional coordinate reading of the instrument reference
head.
E.
Anchor positions for multiple point borehole extensometers are shown on the Contract
Drawings.
F.
The Contractor shall supply plots of inclinometer measurements, corrected for drift, to indicate
any movement against time in standard SINCO format and in addition shall supply the base data
to enable independent verification by the RE.
3.09
OPEN STANDPIPE PIEZOMETERS
A.
Prior to the start of Work the Contractor shall locate and assess the condition of all existing
monitoring wells installed during the design phase of work at the Staten Island and Brooklyn
Shaft sites. Existing monitoring well locations are shown on the GT-series Drawings. The
Contractor may elect to repair and utilize functioning wells as an open standpipe piezometer,
provided it meets the post-installation acceptance test stated herein. Existing wells incorporated
into the Work shall be protected, maintained and repaired in accordance with the requirements
of Section 3.10. Non functioning existing wells and existing wells not selected for use in the
Work shall be abandoned according to the requirements of Section 3.12.
B.
Piezometers shall be installed at the locations and depths as indicated on the Contract Drawings,
directed by the RE and as required by the Contractors ground water control plan. Bentonite
drilling mud shall not be used in piezometer installation.
C.
A standard split spoon sample shall be taken at the top and bottom of the piezometer sensing
zone and submitted to the RE within 24 hours.
D.
Sand and bentonite pellets shall be placed slowly to avoid bridging and resulting voids in the
backfill depth. Backfill shall be checked regularly during installation using a cable mounted
sounding device. The backfill shall not be tamped and care shall be taken so that the settling
sand/bentonite does not consolidate around the sounding device locking it in place.
E.
After completion of installation, a post-installation acceptance test shall be performed by

conducting a falling head permeability test to verify seal integrity.
3.10
INSTRUMENT PROTECTION, MAINTENANCE, AND REPAIR
A.
The Contractor shall protect all instruments and appurtenant fixtures, leads, connections, and
other components of instrumentation systems from damage due to construction operations,
weather, traffic, and vandalism.
B.
Maintain the instruments by draining water and flushing debris from under protective covers
and keeping covers locked and sealed at all times.
C.
If an instrument is damaged or inoperative, including an existing instrument installed by others,

the Contractor's instrumentation personnel shall repair or replace the damaged or inoperative
instrument within 72 hours at no additional cost to the Corporation. The Contractor shall notify
02495 - 14
the RE at least 24 hours prior to repairing or replacing a damaged or inoperative instrument. The
RE is the sole judge of whether repair or replacement is required. The RE may impose a work
stoppage in the vicinity of the damaged or inoperative instrument until it is again operational, at
no additional cost to the Corporation.
D.
3.11
A.
3.12
A.
B.
C.
Freezing of water in piezometers and inclinometers shall be prevented.

DISCLOSURE OF DATA
The Contractor shall not disclose any instrumentation data to third parties and shall not publish
data without prior approval and written consent of the RE.
DISPOSITION OF INSTRUMENTS
Surface settlement points:
1.
All instruments on public property shall remain in place at the completion of the
Contract unless directed otherwise by the RE.
2.
Remove all instruments on private property during the cleanup and restoration Work,
unless directed otherwise by the RE.
Optical Survey Prisms:

1.
All optical survey prisms shall be removed on completion of the Contract.
2.
Prisms, prism supports, and associated accessories shall remain the property of the
Corporation following completion of the Contract unless directed otherwise by the
RE.
3.
Structures that have had an optical survey prism installed shall be repaired to the
satisfaction of the RE.

1.
D.
E.
Grout all inclinometers after completion of the Work, unless directed otherwise by the
RE. Notify the RE at least 24 hours prior to grouting and provide all grouting records
to the RE.
Inclinometers in Soil (INC/II) and Multiple Point Borehole Extensometers (MPBXs):

1.
Grout all inclinometers and MPBXs after completion of the Work, unless directed
otherwise by the RE. Notify RE at least 24 hours prior to grouting and provide
grouting records to RE.
2.
Remove riser pipe to a minimum depth of three feet beneath paved areas and two feet
beneath unpaved areas.
3.
Restore ground surface to match adjacent ground surface.
Open Standpipe Piezometers:
02495 - 15
1.
Grout all existing and Contractor installed piezometers after completion of the Work,
unless directed otherwise by the RE. Notify RE at least 24 hours prior to grouting and
provide grouting records to RE.
2.
Remove piezometer riser pipe to a minimum depth of three feet beneath paved areas
and two feet beneath unpaved areas.
3.
Restore ground surface to match adjacent ground surface.

END OF SECTION
02495 - 16
SECTION 02617
STEEL WATER MAIN PIPING AND VALVES IN TUNNEL AND SHAFTS
PART 1 GENERAL
1.01
A.
1.02
SCOPE OF WORK
This Section specifies the furnishing and installation of steel water main piping and valves in
the tunnel and shafts. This Section is intended to supplement requirements for steel water main
piping and valves located in Volume 5 Land Piping of the Contract Documents; and the New
York City Department of Environmental Protection Bureau of Water and Sewer Operations
Standard Water Main Specifications, which are a part of Volume 5. This Section specifies
requirements which are unique to the pipe and valves within the tunnel and shafts. Except as
otherwise specified herein, steel pipe and valves installed in the tunnels and shafts shall conform
to the requirements of Volume 5 of the Contract Documents and the NYCDEP Standard Water
Main Specifications.
RELATED SECTIONS
A.
B.
C.
D.
E.
Backfill Concrete in Shafts and Tunnel is included in Section 03301.
F.
G.
H.
1.03
REFERENCE STANDARDS
A.
ASTM E1417
Standard Practice for Liquid Penetrant Testing
B.
AWS D1.1
1.04
1.05
SUBMITTALS
A.
Shop drawing submittals, layout drawings, and quality control documentation shall be as
required for steel pipe and fittings under Volume 5 Land Piping.
02617 - 1
B.
Submit Installation Procedures indicating proposed methods and sequencing of pipe and valve
installation including handling, temporary support, welding, weld inspection, backfill, cleaning,
pressure testing, and disinfection.
C.
In addition to any other specified submittal requirements, the Contractor shall submit detailed
fabrication drawings with design calculations for all steel pipe fittings, outlets, blind flanges,
and other specials for which there is no standard NYCDEP detail. Standard NYCDEP details
are those shown on the Reference Drawing sub-series of the Civil series of the Contract
Drawings. The Contractor shall have these drawings and calculations prepared under the
supervision of, and signed and stamped by, a Licensed Professional Engineer, currently
registered in the State of New York. Design shall be in accordance with the requirements of
AWWA Standard C-208 and AWWA Manual M-11.
1.06
PART 2 PRODUCTS
2.01
A.
B.
MATERIALS
Steel pipe and fittings shall conform to the NYCDEP Standard Water Main Specifications,
except as follows:
1.
Exterior surfaces of pipe to be installed in the tunnel and shafts, which will be
backfilled with concrete, shall be bare steel with no coatings.
2.
Except as otherwise shown on the drawings, all pipe ends shall be bell and spigot style
for field lap welding.
3.
Tapped holes for air pressure testing of lap joints are not required.
4.
Pipe shall be suitable for a working pressure of 180 psi and a hydrostatic field test
pressure of 250 psi. Pipe wall thickness shall be as specified in the NYCDEP Standard
Water Mains Specifications, or as required for these pressures, whichever is greater.
5.
No cathodic protection is required.
Riser pipes (vertical pipe) within the shafts shall be 96 inch internal diameter. All other carrier
pipe within shafts and the tunnel shall be 72 inch internal diameter.
PART 3 EXECUTION
3.01
GENERAL SEQUENCE OF INSTALLATION
A.
Complete tunnel cleaning, as specified in Section 02400 Tunnel Cleaning.
B.
Install pipe in tunnel. Pipe shall be supplied from Staten Island shaft site only. As each pipe is
placed into final position, weld the joint to the preceding pipe before the next pipe is placed into
final position.
02617 - 2
C.
Place tunnel backfill concrete in stages not to exceed 500 feet as the pipe installation progresses.
Tunnel backfill concrete shall be supplied from Staten Island shaft site only.
D.
Perform weld testing where and when directed by the RE.
E.
After acceptance of welding by the RE, apply cement mortar lining to all bare steel inside the
pipe at the joints.
F.
Upon completion of placement and backfill of all pipe in the tunnel, clean the pipe interior.
G.
After cleaning, construct temporary bulkhead on each end of the pipeline, and perform
hydrostatic pressure test.
H.
After successful hydrostatic pressure test, remove temporary bulkheads and begin installation of
vertical riser pipe.
I.
Install pipe in shafts. As each pipe is placed into final position, weld the joint to the preceding
pipe before the next pipe is placed into final position. Keep open (top) end of riser pipe covered
at all times except when positioning the next pipe, to prevent entry of debris, dust, dirt,
rainwater, etc. into the pipe.
J.
Place shaft backfill concrete in stages not to exceed 50 vertical feet as the pipe installation
progresses.
K.
Perform weld testing where and when directed by the RE, prior to placement of backfill
concrete.
L.
Construct temporary bulkhead on top of each riser and perform hydrostatic pressure test on the
entire pipeline (tunnel and both risers). Leave bulkhead in place until installation of the upper
level horizontal piping commences.
3.02
PIPE SUPPORTS
A.
Horizontal pipe in the tunnel is to be supported through the use of casing spacers or saddles as
shown on the Drawings. Spacers are to be non-metallic, or plastic coated steel. Wood, masonry
blocking, or other absorbent materials shall not be used. The spacers shall maintain electrical
isolation between the steel pipe and the tunnel liner. The spacers shall be sized and located in a
manner that will not obstruct complete encasement of the pipe in concrete backfill.
B.
Methods of temporary support of the vertical riser pipe during installation, welding, and
backfilling shall be selected by the Contractor. No temporary support which connects the pipe
to the shaft structure shall be permanently left in place unless it is non-metallic and/or provides
electrical isolation between the pipe and the structure.
3.03
A.
FIELD WELDING
Field welding of pipe joints shall be in accordance with the NYCDEP Standard Water Main
Specifications, except as follows:
1.
Lap joints within the tunnel shall be welded from the interior of the pipe only.
Exterior welds are not required.
02617 - 3
2.
3.04
Lap joints on the vertical riser pipe within the shafts shall be welded from the exterior
of the pipe only. Interior welds are not required.
FIELD WELD INSPECTION AND TESTING
A.
Contractor shall allow access to the RE to perform visual inspection of each weld as it is
completed.
B.
Non-Destructive Testing: Contractor shall perform magnetic particle and/or dye penetrant
testing on welds where and when directed by the RE. Such testing may be directed for one or
more passes of a circumferential weld, and for a portion or the entirety of the circumference.
Testing shall be performed by a qualified weld inspection and testing firm under subcontract to
the Contractor.
3.05
A.
3.06
1.
Qualifications: The firm performing the testing shall have a minimum of 10 years
experience in structural weld testing and inspection; and shall have completed at least
2 projects in the past 5 years specifically involving weld testing on steel pipelines
carrying pressurized gas or liquids. Personnel performing the testing shall possess
current American Society for Non Destructive Testing, NDT Level III Certification
and shall have prior experience testing welds on steel pipelines.
2.
Magnetic particle testing: Procedures and acceptance criteria shall be in accordance

with ANSI/AWS D1.1.1, Section 6.14.5.
3.
Dye penetrant testing: Procedures and acceptance criteria shall be in accordance with
ASTM E1417. Following each test, all residual test material shall be thoroughly
cleaned up.
4.
Reports: Records of each test shall be submitted to the RE within 24 hours of the
completion of each test.
BACKFILL
Backfill of the tunnel and shafts shall be as specified in Section 03301. Procedures for
placement of backfill shall ensure complete encasement of the full length and circumference of
all steel pipe, with full contact and no voids between the pipe and the concrete.
PIPELINE PROTECTION AND CLEANING
A.
Recognizing that the pipeline will be used to convey potable water, take all practical
precautions to keep interior of pipe clean and dry throughout storage, handling, and installation.
B.
Upon completion of pipe installation in the tunnel, conduct cleaning and high-pressure washing
of the pipeline interior using methods similar to those specified in Section 02400, Tunnel
Cleaning.
3.07
A.
PRESSURE TESTING
Perform hydrostatic pressure testing in accordance with the NYCDEP Standard Water Main
Specifications and the following:
02617 - 4
3.08
A.
1.
Test pressure shall be 250 psi.
2.
Test completed tunnel pipeline prior to construction of riser pipes.
3.
Test entire pipeline including tunnel and both risers after completion of riser pipes.
DISINFECTION
Disinfect the pipeline and valves in accordance with the NYCDEP Standard Water Main
Specifications.
END OF SECTION
02617 - 5
SECTION 03100
CONCRETE FORMWORK
PART 1 GENERAL
1.01
SCOPE OF WORK
A.
The Work specified in the Section includes the design, engineering and construction of required
formwork.
B.
The requirements of this Section do not apply to formwork required for the production of
precast concrete tunnel lining which is covered in Section 02340 Precast Concrete Tunnel
Lining.
1.02
RELATED SECTIONS
A.
B.
C.
D.
E.
Cast-In-Place Concrete is included in Section 03350.
F.
G.
1.03
REFERENCE STANDARDS
A.
ACI 347
Guide to Formwork for Concrete
B.
NSF Standard 61 Drinking Water System Components Health Effects
1.04
1.05
SUBMITTALS
A.
The Contractor shall submit shop drawings for fabrication and erection of formwork for specific
finished concrete surfaces. Shop drawings shall show the general construction of forms
including jointing, special formed joints or reveals, location and pattern of form tie placement,
and other items which affect the exposed concrete visually.
B.
Shop drawing review shall be for the general architectural applications and features only. The
design of formwork for structural stability and sufficiency shall be the Contractor's
responsibility. The submission of shop drawings shall be in accordance with the Contract
Specifications.
03100 - 1
1.06
1.07
A.
All forms are to be tight, adequately constructed, and securely held in place. All forms are to
withstand, without deformation, the load of the fresh concrete and the effects of the vibrating
process, as well as prevent the leakage of mortar. The alignment of forms is to be carefully
undertaken to ensure that the forms are secured to the lines and elevations required. Forms are to
be clean and are to be recleaned and repaired for each use. Form surfaces against which concrete
is to be placed are to be coated with a nonstaining material to prevent the adhesion of the
concrete.
B.
Forms for successive floors or levels shall be carried down on shores set directly over each other
and shall terminate so as not to overload any previously placed floor or level.
C.
Proper safe shoring, reshoring, and time of stripping of forms, plus number, adequacy, size and
location of these shores, reshores and forms shall be in accordance with good construction
practice and shall be so designed and constructed that all local Codes are adhered to. It shall be
the sole responsibility of the Contractor to provide a safe Structure at all times, and to provide
safety to human life and property.
D.
All corners, edges and arises are to be constructed with a 0.75-in. chamfer, whether or not shown
on the Contract Drawings. Larger bevels and bull-noses shall be constructed as shown. The
Contractor is to review the Contract Drawings to determine what other special concrete
configurations may be required.
E.
Form design, tolerances of finished lines, and camber to compensate for deflections due to the
weight of the fresh concrete shall conform to ACI 347, or as otherwise required.
F.
The Contractor shall provide all chamfers, bevels, V scores, construction and expansion joints,
waterstops, recesses, notches, reveals, keyways, reglets, inserts, anchors, depressions, ledges,
knock-out panels, and temporary cleanout openings of suitably shaped materials in order to
produce the cast-in-place concrete work as indicated on the Contract Drawings.
G.
The Contractor shall build into the formwork all plates including sliding plates, floor drains,
sleeves, frames, anchors, anchor bolts, shelf angles, flashing, reglets, hangers, recesses,
necessary ties, anchors and inserts required to anchor any brick, masonry, precast concrete or
other special items.
H.
All forms shall be arranged with joints either vertical or horizontal and having a uniform
spacing. All panel faces shall be as large as possible to reduce the number of form joints. Form
ties shall be uniformly spaced. Joints and form ties shall be arranged in a geometric pattern
acceptable to the RE.
PART 2 PRODUCTS
2.01
A.
FORMWORK
Formwork is to be made from metal forms, Exterior grade waterproof plywood panels, or
plastic-coated plywood. All exposed concrete, regardless of specified finish, is to be constructed
03100 - 2
using plastic coated plywood panels. Where the use of form lumber is permitted by the RE, it is
to be dressed on four (4) sides and only selected boards are to be used for form surfaces in
contact with concrete.
2.02
A.
2.03
A.
FORM FASTENERS
Only approved form ties and form hangers are to be used. They are to be provided with a
waterstop washer not less than 0.75-inch in diameter and be of such a type, that after forms are
stripped, the ties can be broken back a minimum of 1.5-inch from the surface of the concrete or,
after bolts are removed, the portion of the tie remaining in the concrete would be no closer than
1.5-inch to the face of the concrete. Ties are to be fitted with lugs, cones, washers, or other
devices within the form which will leave a hole not larger than 0.875-inch in diameter or deeper
than 0.75-inch. That portion of the tie which is removed from the concrete is to be coated to
assure a break back of 1.5-inch with a material which will not impair the concrete strength or
prevent bonding between the concrete and the hole mortar patch. The spacing of form ties and
form hangers is to conform to the Manufacturer's recommendations and the previously specified
criterion for a uniform geometric pattern of form ties.
FORM RELEASE AGENTS
Form release agent shall have NSF Standard 61 approval. The form release agent shall be BioGuard as manufactured by Atlas Construction, Farm Fresh as manufactured by Unitex, or
approved equal.
PART 3 EXECUTION
3.01
A.
Forms are to conform to required shapes, lines, surface scorings, and dimensions of the
members, as shown on the Contract Drawings. All joints are to be horizontal or vertical, and
uniformly spaced. All panel faces are to be as large as possible to reduce the number of form
joints.
B.
Shoring is to be designed to support the weight of concrete and the loads incurred during
placing, with due regard to the height of shores. Shoring is to be laterally braced at all splice
points. Forms and shores are to be braced or tied so that there is no displacement of formwork
during casting and hardening of concrete.
C.
The Contractor is to provide cross bracing for shoring to resist lateral wind forces, and especially
against braking, turning and acceleration forces due to any mechanical equipment used in
placing the concrete. The Contractor is to be fully responsible for the design of forms and their
shores.
D.
Where shoring is supported on the ground, temporary footings of timber, steel or concrete are to
be provided which will support the wet concrete without settlement. These footings are to be
founded on firm soil, sufficiently below the ground surface so that they will not settle when the
ground is wet, or when frozen ground is thawing.
E.
Finished concrete surfaces are not to vary from the theoretical horizontal or vertical planes as
specified elsewhere in these Specifications. Where it is necessary to maintain the specified
03100 - 3
tolerances, the formwork is to be cambered so as to compensate for anticipated deflections in the

formwork due to the weight and pressure of the fresh concrete and due to construction loads.
F.
Positive adjustment of shores and struts is to be provided by means of wedges or jacks, and all
settlement is to be taken up during the concrete placing operation. Adjusting devices are to be
securely braced against lateral deflections.
G.
In columns, walls and similar members of small dimensions, the height of the forms for each
vertical lift is not to exceed 8-feet, unless suitable openings are provided at not more than 8-feet
vertical intervals to permit the proper placing of concrete.
H.
Earthcuts shall not be used as forms for vertical surfaces, unless otherwise specified and shown
on the Contract Drawings as an acceptable alternate detail.
I.
The Contractor is to construct and erect formwork for all exposed interior or exterior concrete
surfaces in such a manner that, upon completion, a uniform and truly symmetrical pattern of
horizontal and vertical joints will be evident. All form ties are to be uniformly spaced in both
horizontal and vertical directions. The Contractor is specifically alerted to the intention of this
Section of the Specifications with regard to appearance. It is the intention of this Section of the
Specifications to do the minimum amount of concrete finishing work and rely upon form liners,
where used, and the uniform geometric pattern of the forms and form ties to create the desired
esthetic effect.
J.
The Contractor is to meet with the RE prior to constructing forms to plan the form arrangement
or form pattern.
3.02
A.
3.03
A.
3.04
CURVED SURFACES
Forms for any curved surfaces shall be of circular segments constructed to a true radius
complying with the dimensions shown on the Contract Drawings, except that the use of flat
forms arranged to form a series of chords shall be permitted provided standard width forms, such
as those accepted by the RE, are used. Chord dimensions shall not exceed 2-feet and rise
dimensions shall not exceed 0.25-inch. Form panels and fillers shall be placed so as to present a
uniform pattern on both exposed interior and exterior walls.
ACCESSORIES
All insert items are required to be placed in formwork, for the accommodation of other
formwork, are to be as specified in other Sections or Divisions of the Specifications. The
Contractor shall place and/or build into the formwork all of these insert items, as required.
PRE-PLACEMENT INSPECTION
A.
Before placing concrete, the Contractor shall complete and inspect the formwork installation,
including forms, form ties, form oil, attached items, etc., reinforcing steel, and items to be
embedded or cast in. The Contractor shall notify other crafts involved in ample time to permit
the installation of their work and cooperate with other trades in setting such work, as required.
B.
The Contractor shall thoroughly wet all wood forms immediately before placing concrete, as
required.
03100 - 4
C.
3.05
The Contractor shall coordinate the installation of all joint materials and moisture barriers with
the placement of forms and reinforcement.
FORM REMOVAL
A.
All forms are to be removed, cleaned, repaired and stored for subsequent use. If an inspection by
the RE indicates that the form materials are not satisfactory for reuse, they are to be removed
from the Project Site.
B.
No forms are to be removed until the concrete work has gained sufficient strength to support its
own weight and normal construction loadings without permanent damage. The Contractor is to
provide and place all temporary posts, shores, braces or other devices which might be required
for the temporary support of the concrete work. No temporary bracing is to be removed until the
concrete work achieves its design strength.
C.
The Contractor is to assume full responsibility for the premature removal of concrete forms. Any
concrete which is damaged or does not achieve its design strength as a result of early form
removal is to be removed and replaced at no cost to the Corporation.
D.
In general, form removal shall adhere to the following schedule:
Atmospheric Temperature
Element
Above 50F
Below 50F
a. Bottom Forms of Slabs, Beams and Girders
7 Days
12 Days
b. Walls and Columns
2 Days
6 Days
c. Sides of Beams and Girders(*)
2 Days
6 Days
(*) Where such forms also support formwork for the bottom of beams, girders and slabs, the longer
removal time is to govern.
E.
The intent of the above schedule is to serve as a guide; however, forms shall remain in place for
greater periods than indicated above if, in the opinion of the RE, the removal of such forms
would be detrimental to the stability or safety of the structure.
F.
Forms may be removed earlier than indicated above upon receipt of satisfactory evidence by the
RE that the concrete supported thereon has attained sufficient strength to maintain the stability
and safety of the structure. Laboratory test reports of job-cured test specimens shall be
considered satisfactory evidence. All test specimens taken for the purpose of establishing
justification for early form removal shall be made and tested at the expense of the Contractor.
G.
Forms shall be removed from the bottoms of slabs, beams, and girders in sections and said slabs,
beams and girders shall be immediately reposted with shores sufficient in number and strength
to safely sustain all live and dead loads until all members have attained their design strength.
03100 - 5
H.
Any hairline cracks, which occur due to premature form removal, are to be repaired by the
Contractor, to the satisfaction of the RE.
I.
Form ties are to be broken back immediately after removing the forms. All holes left by such ties
are to be filled immediately with mortar consisting of one part Portland cement and two parts
sand, of the same type, manufacture and quality as used in the concrete.
J.
If taper ties or she-bolts are used, the Contractor shall submit, for the REs review, method of
filling the entire tie hole after removal of forms.
K.
Care is to be taken in removing forms, walers, shorings, supports, and form ties to avoid spalling
or marring of the concrete work.
3.06
A.
RE-USE OF FORMS
Lumber, once used in forms, shall have nails withdrawn, and surfaces to be in contact with
concrete shall be thoroughly cleaned before being used again. Plastic coated plywood forms,
either patented or Job Site fabricated, shall not be used more than 10 times. Other plywood
forms of Exterior grade surface shall not be used more than 3 times. The reuse of forms shall
be permitted only if the forms, in the opinion of the RE, are suitable for the intended purpose.
Split, frayed, delaminated or otherwise damaged form facing materials shall not be acceptable.
Patched forms for exposed concrete surfaces shall not be used unless such forms are inspected
by the RE. The Contractor shall apply new form coating compound materials to form surfaces as
specified for new formwork. When forms are extended for successive concrete placement, the
Contractor shall thoroughly clean surfaces, remove fins and laitance, and tighten forms to close
all joints. He shall align and secure joints to avoid offsets
END OF SECTION
03100 - 6
SECTION 03200
CONCRETE REINFORCEMENT
PART 1 GENERAL
1.01
SCOPE OF WORK
A.
The Work specified in this Section covers the furnishing, bending and placement of all reinforcing
steel, welded wire reinforcement, supports and fastenings used in the concrete work. This Section
also includes furnishing placement shop drawings covering the layout and bending of all
reinforcing. These placement drawings are to be furnished to the RE for review, in accordance with
the Contract Specifications, prior to cutting, bending, or placing any reinforcement. No work shall
be started until the shop drawings have been reviewed by the RE.
B.
The requirements of this Section do not apply to reinforcement required for the production of
precast concrete tunnel lining which is covered in Section 03370 Reinforcement for Precast
Concrete Tunnel Lining.
1.02
RELATED SECTIONS
A.
Section 02310 Shaft Support Slurry Walls
B.
Section 03100 Concrete Formwork
C.
Section 03250 Concrete Accessories
D.
Section 03350 Cast-In-Place Concrete
E.
Section 13000 Tunnel and Shaft Safety
F.
Section 13060 Shaft Construction
1.03
REFERENCE STANDARDS
A.
ACI 318
B.
ASTM A185 Standard Specification for Steel Welded Wire Reinforcement, Plain, for Concrete.
C.
ASTM A615 Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete
Reinforcement.
D.
AWS D1.4
E.
CRSI Manual of Standard Practice.
F.
CRSI Placing Reinforcing Bars.
1.04
Building Code Requirements for Structural Concrete and Commentary.
Structural Welding Code Reinforcing Steel.
03200 - 1
1.05
SUBMITTALS
A.
The Contractor is to allow proper time for the review of shop drawings. The Contractor is to allow
sufficient time for inspection of reinforcing steel, once placed, before ordering and placing of
concrete. Whenever possible, the RE may attempt to reduce the amount of time required for the
completion of these functions.
B.
The Contractor is to submit rebar shop drawings showing all plans, sections, details, elevations, bar
schedules and diagrams of all bars, arrangements and assemblies as required for the fabrication and
placement in the concrete formwork. Details are to be included for all special reinforcements at
openings, and for all support accessories, which shall be adequate in strength to hold applied live
and dead loads without excessive or permanent displacement of the reinforcement.
1.06
PART 2 PRODUCTS
2.01
REINFORCING STEEL AND ACCESSORIES
A.
Reinforcing bars are to be deformed, intermediate grade, 60,000 psi minimum yield strength, new
billet steel, manufactured in the United States and conforming to the requirements of ASTM
A615-96a Grade 60. Reinforcing bars used for stirrups and column ties shall conform to ASTM
A615-96a, Grade 40.
B.
Reinforcing tie wires are to be No. 16 U.S. steel wire gage, black soft annealed wire, conforming to
Federal Specifications FS-QQ-W-461G.
C.
Welded wire reinforcement is to conform to the requirements of ASTM A185-97. All welded wire
reinforcement is to have a 70,000 psi minimum yield strength. Testing as indicated in ASTM
A185-97 is to be undertaken and the results are to be given for the REs review.
2.02
REINFORCING SPLICE SYSTEMS
A.
Where shown on the Contract Drawings or accepted by the RE, the Contractor is to furnish and
install a dowel bar substitution and reinforcing splice system as manufactured by Richmond Screw
Anchor Co., Inc., Dywidag Systems International, or Williams Form Engineering Co, or approved
equal.
B.
The Contractor shall submit the Manufacturers literature, product samples, and certified test
reports of the system he proposes to use to the RE for review.
C.
Test reports are to include yield and ultimate tensile strength capacities. The capacity of the system
is to be a minimum of 125% of the specified yield strength of the reinforcement being spliced.
Tensile failure of the system is to occur in the nominal bar diameter of the reinforcing bar being
joined to the splicing system.
PART 3 EXECUTION
3.01
GENERAL
03200 - 2
A.
3.02
All reinforcing is to be kept clean, free of dirt, oil or other substances which might in any way
impair the bond between the reinforcing and concrete. The Contractor is to advise the RE as to the
readiness to have the reinforcing inspected after it has been installed. No concrete is to be placed
unless the reinforcing, which is in place, has been inspected by the RE.
REINFORCEMENT TESTS
A.
The Contractor is to fulfill all requirements relative to testing of reinforcing steel as may be
specified in this Section of the Specifications.
B.
Where reinforcing material is properly identified, mill reports may be accepted. The Contractor
shall submit two (2) copies of the Steel Producer's certificates of the mill tests.
C.
When the Manufacturer's name or the heat identification number of the Manufacturer's chemical
analysis is unknown, a Testing Laboratory is to undertake a testing program. At least one tensile
and one bending test is to be made on each five (5) tons, or fraction thereof, for each size of
reinforcement in each lot. The Testing Laboratory used by the Contractor is to be acceptable to the
RE. The Contractor is to pay for all such tests and submit at least two (2) copies of each test made
to the RE.
D.
Reinforcing steel that fails to meet the requirements of the testing program is to be rejected and
removed from the Project Site. The Contractor is to submit new steel for testing and continue to do
so until the steel passes the tests. No steel is to be used for reinforcing until satisfactory test reports
are received by the RE.
E.
In the event that the RE requires additional testing of reinforcing materials which have been
delivered to the Project Site, the Contractor is to make such materials available in the sizes, lengths,
and quantities necessary for testing, at no additional cost.
3.03
FABRICATION
A.
All reinforcement is to be fabricated to conform to required shapes and dimensions, with fabrication
tolerances complying with CRSI Manual of Standard Practice. In case of fabricating errors, the
Contractor shall not re-bend or straighten reinforcement in a manner that may injure or weaken the
material. All reinforcing steel is to be pre-cut and pre-bent off site in an approved fabricating shop
by an acceptable subcontractor for reinforcing steel fabrication.
B.
All reinforcing is to be correctly rolled to the proper section and shall be free from all defects.
Reinforcing shall have raised symbols to identify the Manufacturer, bar size and grade of steel.
C.
Reinforcement with any of the following defects is not to be permitted in the work:
D.
3.04
1.
Bar lengths, depths, and bends exceeding specified fabrication tolerances.
2.
Bends or kinks not indicated on Contract Drawings or final shop drawings.
3.
Bars with reduced cross-section due to excessive rusting, surface defects, or other causes.
All bends or hooks, unless otherwise required, are to be cold formed around pins. All hooks are to
conform to the typical details on the Contract Drawings and ACI 318.
DELIVERY, HANDLING, AND STORAGE
03200 - 3
A.
All concrete reinforcement is to be delivered to the Project Site bundled, tagged, and marked. Metal
tags are to be used to indicate bar size, lengths, and other information corresponding to markings
shown on the placement diagrams.
B.
All concrete reinforcing materials are to be stored at the Project Site, to prevent damage and
accumulation of dirt or excessive rust.
3.05
INSTALLATION
A.
The Contractor is to comply with the previously specified Codes and Standards and CRSI
recommended practice described in Placing Reinforcing Bars, latest edition, for details and
methods of reinforcement placement and supports, and as herein specified.
B.
All reinforcement shall be cleaned prior to installation to remove loose rust and mill scale, earth,
ice, and other materials which reduce or destroy the bond with the concrete.
C.
Bar supports shall be provided for reinforcement in foundation elements, slabs on ground, and all
framed beams and slabs. Reinforcement shall be positioned, supported, and secured against
displacement by formwork, construction, or concrete placement operations. Reinforcement shall be
located and supported by metal chairs, runners, bolsters, spacers, and hangers.
D.
Reinforcing steel shall be supported in a manner that shall maintain the clear distances between bars
and the face of concrete as indicated on the Contract Drawings or mentioned in the Specifications.
Supports are to include slab and beam bolsters, low and high chairs, spacers and other devices
suitable for the proper spacing, supporting and fastening of reinforcing bars or welded wire
reinforcement in place. Consideration is to be given for all loads applied to the reinforcing.
Supports for slabs on grade are to include sand plates, laterally welded braces for high chair legs
and specially designed steel framed supports for heavy reinforcing.
E.
In no case shall the use of masonry, stone, or wood be permitted for bar supports. Plastic protected
or non-staining legs are to be provided in the case of bar supports being in contact with the
formwork of concrete surfaces exposed to view after completion.
F.
Minimum wire sizes and spacing for support accessories are to be as follows:
G.
1.
Continuous high chairs or individual high chairs are to have legs of not less than #4 wire.
Continuous high chair legs are to be spaced not more than 8-inches on center. Continuous
longitudinal wires are to be not less than #1 wire. The connection of the legs to the
continuous wire is to be strong enough to prevent bending of the legs out of the vertical
plane or the breaking off of the legs from the continuous longitudinal wire.
2.
Slab and beam bolsters are to be not less than #4 wire. Slab bolster legs are to be spaced
not more than 5-inches on center. Beam bolster legs are to be spaced not more than 2inches on center.
3.
The Contractor is to vary the support bar diameters and spacing to suit each specific
support requirement and detail them to suit the condition of loading.
The Contractor shall not place reinforcing bars more than 2-inches beyond the last leg of any
continuous bar support. The Contractor shall not use supports as bases for runways for concrete
conveying equipment and similar construction loads.
03200 - 4
H.
All reinforcement shall be secured against displacement by tying with No. 16 gauge, black soft
annealed wire at all intersections, and shall be so supported so as to keep all reinforcement away
from the exposed surfaces. Whenever the members are reinforced with two curtains of
reinforcement, bar spacers securely tied to both curtains shall be provided.
I.
The Contractor shall set all wire ties so that twisted ends are directed away from exposed concrete
surfaces.
J.
Tack welding of reinforcement shall not be permitted.
K.
Reinforcement shall be contact lap spliced where practical, with the location of and minimum lap
lengths as called for on the Contract Drawings. Where no lap length is noted on plan or section, the
minimum lap shall be as per the typical details for tension lap splices and in accordance with ACI
318. All adjacent splices shall be progressively staggered at 5-0 on center.
L.
All laps or splices shall be tied with No. 16 gauge black annealed wire and seized tight at both ends.
Reinforcement shall not be spliced at points of maximum stress and, where possible, shall have
splice locations staggered.
M.
The Contractor shall install welded wire reinforcement in as long lengths as practicable. He shall
lap adjoining pieces at least one full mesh and lace splices with No. 16 gauge wire. He shall not
make end laps midway between supporting beams, or directly over beams of continuous members.
The Contractor shall offset end laps in adjacent widths to prevent continuous laps. If fabric is
ordered in rolls, transverse wires are to be on the inside of the rolls. All such fabric is to be unrolled
in the direction of the span.
N.
Where welding is shown on the Contract Drawings or specified, the Contractor shall comply with
the requirements of AWS D1.4 for field welding. Prior to field welding, the Contractor shall
determine the weldability of reinforcing bars by a laboratory analysis of steel. Only steel
conforming to the chemical requirements specified in AWS D1.4 shall be used.
O.
After the reinforcement has been placed, the Contractor shall notify the RE as for the readiness to
have the reinforcing inspected. Concrete shall not be placed until the reinforcement placement is
complete and has been inspected by the RE.
END OF SECTION
03200 - 5
SECTION 03250
CONCRETE ACCESSORIES
PART 1 GENERAL
1.01
SCOPE OF WORK
A.
This Work specified in this Section covers the furnishing and installation of all accessories for
concrete construction, exclusive of reinforcing steel. These accessories include, but are not
necessarily limited to: construction joints, waterstops, special anchors, dovetail anchors, embedded
items to support, brace or carry equipment or the work of others, expansion anchors, anchor bolts,
elastomeric bearing pads, electrical conduit, and other items to be placed in the concrete work.
B.
The requirements of this Section do not apply to accessories required for the production of precast
concrete tunnel lining which is covered in Section 03360 Concrete for Pre-cast Concrete Tunnel
Lining.
C.
Concrete accessories may in some instances be specified in other Sections of these Specifications
but their inclusion in the concrete work is covered under this Section.
D.
The Contractor is to install expansion joints and construction joints as specified in this Section and
shown on the Contract Drawings.
E.
Insert or embedded items are to include supports, anchorages, base plates, pipe sleeves, electrical
conduit, and other such items which may not necessarily be related to concrete construction, but are
required in order to accommodate the work of others. All such items are to be securely installed to
prevent movement when the concrete is placed. Concrete shall not be placed until all insert items
have been placed and the RE has observed their location.
F.
The Contractor is to arrange to furnish and install all insert items, of whatever material necessary
within the formwork, prior to the placing of concrete.
1.02
RELATED SECTIONS
A.
B.
C.
D.
E.
F.
G.
1.03
REFERENCE STANDARDS
03250-1
A.
1.04
A.
1.05
A.
1.06
ASTM A307
Standard Specification for Carbon Steel Bolts and Studs, 60 000 PSI Tensile
Strength
DEFINITIONS
Waterstop Rx: Waterstop Rx is a formulated joint sealant comprised of Volclay bentonite/butyl
rubber and supplied in coil form.
SUBMITTALS
The Contractor is to furnish for the REs review any samples which might be required to determine
the type of materials to be placed in the work. Any shop drawings required to detail such Work are
to be submitted at that time.
PART 2 PRODUCTS
2.01
WATERSTOPS
A.
The Contractor is to furnish and install waterstops in the locations indicated on the Contract
Drawings or as may be directed by the RE at the time of construction.
B.
Dumbbell waterstops shall be of extruded polyvinyl chloride which is dimensionally stable, dense,
homogeneous, and non-porous. The waterstops shall be capable of effectively sealing construction
joints in concrete against the infiltration or leakage of water.
C.
Polyvinyl-chloride waterstops are to be as manufactured by Greenstreak, Progress Unlimited Inc, or

equal. Waterstops shall be 9 wide dumbbell and dumbbell center bulb type meeting U.S. Army
Corps of Engineers CRD C-572-74 Specifications, unless otherwise noted on Contract Drawings.
D.
Dumbbell waterstops are to be of the following style or equal:

1.
2.
Greenstreak:
a.
Construction Joints
751
b.
Expansion Joints
753
c.
Split 751
Progress:
a.
Construction Joints
b.
Expansion Joints
c.
Split E
E.
Split-type waterstops may be used where acceptable to the RE provided the two divided sections
are joined together by stapling.
F.
Bentonite waterstops are to be Volclay Waterstop Rx as manufactured by American Colloid

Company, or equal.
03250-2
G.
2.02
A.
2.03
Bentonite waterstops are to be used where acceptable to the RE, or as shown on the Contract
Drawings.
EMBEDDED ELECTRICAL CONDUIT
All conduit encased in concrete shall be iron or steel (uncoated or galvanized). Conduit wall
thickness shall conform to standard schedule 40-steel pipe.
OTHER EMBEDDED AND INSERT ITEMS
A.
Dovetail anchors for securing masonry work are to be furnished and installed where indicated on
the Contract Drawings.
B.
Anchorages for mechanical and/or process equipment requiring a high degree of accuracy in their
locations, are to be made by using heavy duty concrete anchors as manufactured by Deco-Decatur
Engineering Company; Jakebolt, Unisorb Corporation; or approved equal. Anchor bolts are to be as
indicated and/or detailed on the Contract Drawings.
C.
Expansion anchors are to be self-drilling anchors, as manufactured by ITW Ramset/Redhead;

Carpenter and Patterson; or equal. Bolts for expansion anchors are to be Type 316 stainless steel.
D.
Anchor bolts cast in concrete for attachment of aluminum and stainless steel work are to be Type
316 stainless steel hooked bolts, with stainless steel nuts and washers. Anchor bolts, for attachment
of structural steel work, shall conform to ASTM A307, unless otherwise indicated on the Contract
Drawings.
E.
Anchor bolts for attachment of structural steel and equipment bases are to be as shown on the
Contract Drawings.
F.
Epoxy anchors shall be stainless steel type 316 threaded rod stud. Epoxy shall be a two component,
low deflection ceramic filled epoxy. The epoxy material shall be C-6 Epoxy as manufactured by
ITW Ramset/Red Head and supplied as a part of the Epcon System, or equal. The adhesive shall
contain no solvents or styrene.
PART 3 EXECUTION
3.01
WATERSTOPS
A.
The Contractor is to ensure steel reinforcing bars do not interfere with proper position of
waterstops. The joints shall be cleaned of dirt and construction debris prior to second placement of
concrete.
B.
Waterstops shall be installed in all construction and expansion joints in walls and slabs. The
waterstop shall extend the entire length of the joint and shall be positioned across the center of the
joint.
C.
Field jointing of the dumbbell waterstops shall be made by welded butt splices. At intersections,
dumbbell waterstops shall be spliced to preformed type joints which have been fabricated at the
Manufacturer's plant. Splices are to be located a sufficient distance away from corners and
elsewhere to permit adequate working room and are to be formed by means of electric tools
03250-3
designed specifically for this purpose, or by other acceptable methods. Splices shall be neatly made
and the resulting joint is to have continuity and be in true alignment with the unspliced portions of
the embedded waterstops. The splices shall have a tensile strength of not less than 80% of the
tensile strength of the unspliced material. The procedure for making splices in the field, and the
description of the equipment required for properly making such splices, is to be presented for
review at the time of the submission of the certified copies of the test reports and the samples of the
waterstops. All field splices are to be made in the presence of the RE, and the initial splices are to
be made under the supervision of a qualified representative of the Manufacturer of the waterstops.
D.
All splices shall be electrically tested, by an instrument recommended by the waterstop

Manufacturer and supplied by the Contractor for unwelded protons, pinholes, openings, or any
other imperfections in the weld which would affect its watertightness. The Contractor shall test
every welded joint in the presence of the RE and any joint not passing the testing, as determined by
the RE, shall be immediately replaced with a new joint and retested. Concrete shall not be placed
against welded waterstops until they have been tested and accepted.
E.
Dumbbell waterstops shall be placed as shown on the Contract Drawings or as ordered, forming a
continuous watertight diaphragm in each joint, and be so secured and supported as to prevent
displacement during the progress of the work and until the concrete has set. Waterstops are to be
held rigidly in place. In no case are the waterstops to be bent over the joint. To insure their proper
embedment in concrete, the waterstops shall be secured in position by means of anchoring rings, 16gauge tie wire, or other acceptable methods. The placing of concrete in forms is not to be done until
the secured waterstops have been inspected.
F.
The bentonite waterstop material shall be confined within a joint, with a minimum 3 concrete
cover to the exterior of the joint surface. An exposed length of the waterstop material should not be
submerged for extended periods of time. If the waterstop material exhibits considerable swelling
prior to confinement in the joint, it must be replaced with new material. Field joining shall be made
by butt splice.
G.
The Contractor shall ensure that the bentonite waterstop material will not be displaced during or
prior to concrete placement. The Contractor shall use cut nails and/or Waterstop Rx Adhesive,
as manufactured by American Colloid Company, to hold the material in place.
3.02
EMBEDDED ELECTRICAL CONDUIT
A.
The Contractor, and/or the electrical trade Sub-Contractor, shall review with the RE the proposed
location and method of installation of conduits in concrete construction and shall not proceed with
installation of same until arrangement of conduits and openings has been agreed upon.
B.
No conduits shall be so located and installed that may impair the structural integrity of the concrete
members.
C.
All conduit cross-overs shall be so located so they do not vertically displace any main reinforcing
bars or otherwise impair the structural integrity of the framing system.
D.
No conduit with an outside diameter larger than one-third of the concrete slab thickness shall be
permitted to be installed in the slab system.
E.
All conduits shall be spaced a minimum of three conduit diameters center to center. Larger spacing
of conduit is preferred.
03250-4
F.
3.03
A.
3.04
A.
Continuous rows of conduit shall not be placed parallel to the bearing edges of concrete slabs
within a distance equal to the slab thickness from the face of the bearing edge.
OTHER EMBEDDED AND INSERT ITEMS
Anchor bolts are to be set in pipe sleeves, where directed by the RE. All anchor bolts are to be set in
templates and adequately braced to prevent misalignment during the placement of concrete. All
bolts are to be of such a length that at least two (2) threads are exposed after tightening.
EPOXY ANCHOR SYSTEM
Where shown on the Contract Drawings or typical details, attachment or anchorage of equipment
and/or structural steel shall be made by using stud anchors epoxied in place. Installation of these
anchors shall be in accordance with the Manufacturer's written instructions using the proper setting
equipment and allowing for sufficient curing time.
END OF SECTION
03250-5
SECTION 03301
BACKFILL CONCRETE IN SHAFTS AND TUNNEL
PART 1 GENERAL
1.01
SCOPE OF WORK
A.
The Work specified in this Section includes, but is not limited to the requirements of structural
and non-structural backfill concrete for surrounding the carrier pipes that constitute the water
siphon or other permanent works in the tunnel and in the two shafts, as shown on the Contract
Drawings.
B.
The Contractor shall be responsible for furnishing, erecting and removing all formwork
associated with the backfill concrete.
C.
The Contractor shall be responsible for furnishing, installing, and securing all concrete
reinforcement, waterstops, wall fittings, embedded items, and other appurtenances as specified
or shown on the Contract Drawings.
D.
The Contractor shall be responsible for furnishing all equipment, labor, tools and appurtenances
necessary to successfully place and cure the backfill concrete and for sampling and testing.
E.
Additional backfill concrete mixtures proposed by the Contractor are subject to the REs
approval.
1.02
RELATED SECTIONS
A.
B.
C.
D.
E.
F.
1.03
REFERENCE STANDARDS
A.
ASTM C31
B.
ASTM C39
Method for Compressive Strength of Cylindrical Concrete Specimens
C.
ASTM C33
Standard Specification for Concrete Aggregates.
D.
ASTM C150
Standard for Portland Cement
03301-1
E.
ASTM D5971
Standard Practice for Sampling Freshly Mixed Controlled Low Strength

Material
F.
ASTM D6103
Standard Test Method for Flow Consistency of Controlled Low Strength

Material
1.04
A.
1.05
A.
DEFINITIONS
Flowable Fill: a low-strength self-leveling and self-compacting lean cementitious material
which is used as backfill concrete in tunnel and shafts. The material is also known as
unshrinkable fill or controlled low strength material (CLSM).
SUBMITTALS
The following requirement shall be submitted to the RE for approval prior to the actual use of
backfill concrete materials in any part of the work under this Contract, and whenever the
Contractor proposes any other materials, or changes to the mix or sources of materials:
1.
Procedures comprising narratives and working drawings for each type of backfilling
operation complying with specified requirements including, but not limited to:
a.
Plant and equipment for each type of backfilling application:

1)
Proposed mixers, proportioning and batching equipment, holding tanks,

pumps, drilling equipment, piping and manifolds, valves, packers, water
test equipment gauges for measuring volume and pressure, and
calibration gauges.
2)
Means to reliably control backfill pressures at the maximum pressure

specified for the particular backfilling type.
3)
Methods of storage and transportation including cross-sections and

profiles showing the arrangement of transportation, handling, and placing
equipment including passing clearances.
4)
Procedures for batching and mixing of materials for test and production.
b.
Methods for controlling critical mix parameters, such as mixture density and
water content.
c.
Details of pumping pressures and rates, placement sequences and volumes, lift
thickness, including the theoretical quantity for each placement.
d.
Methods for diverting and manifolding construction water and groundwater and
protecting backfilling materials and operations.
e.
Work plan including quality control procedures describing the sequence of

operations for each type of backfilling and details of how backfilling shall be
carried out concurrently with other activities including the assignment of labor,
equipment and supplies required to perform this work.
f.
Concrete forms showing details including construction, operation, form joints,

construction joints, method of connections, access openings etc.
g.
Backfill concrete sequence, criteria and threshold values for modifying mix,
location of operations and methods.
03301-2
h.
For each type of backfill mixtures described in this Section, provide the
following:
1)
Mix design data, including all mix ingredients, proportions, properties,

admixtures and test results to meet minimum design criteria.
2)
Manufacturers product data sheets indicating mixing and handling

requirements, Material Safety Data Sheets (MSDS), personal safety
equipment, first aid measures, and methods for proper storage and
disposal of waste materials, include container details.
3)
The Contractor shall submit history details of prior use of the mixture in
a minimum of five similar works including statistical data.
4)
Certificates of compliance of all mix components with specified

standards.
5)
Recommended Superplasticizer/dispersant or high-range water reducer.
6)
Written affidavits from respective suppliers of backfill materials stating

that the proposed product to be used in the mix is compatible with all
other components in the proposed mix.
7)
Certification that all admixtures are low corrosive.
8)
Certificate of compliance stating the chloride content of accelerators.
9)
Proposed material specifications, handling and placement procedures,

and any additional information requested by the RE.
B.
Submit test results to certify that mix design properties meet specified requirements according
to ASTM C39 at 7 and 28 days after placement.
C.
Submit Quality Control Plan for backfill materials, including sampling and testing frequency.
1.06
A.
DELIVERABLES
As a minimum the following information shall be included on the record sheet upon completion
of backfilling, and shall be submitted as part of the daily shift report, by the Contractor to RE:
1.
Date and time of backfilling operation.
2.
Name of workers.
3.
Station of backfilling activity.
4.
Station of tunnel Work at time of backfilling.
5.
Placement Record: Submit records of the location and volume of backfill concrete
placed.
B.
Delivery Tickets: Submit duplicate delivery tickets for backfill materials delivered to Project
site.
C.
Batching Records: Submit batching records of all batches of backfill materials used in the
works.
03301-3
1.07
A.
B.
Design and Testing of Concrete:
1.
The design, sampling and testing of the concrete mix design for use in the shafts and
tunnel shall be as specified in this Section.
2.
Not less than 7 Compression cylinders shall be prepared for each pour totaling 50
cubic yards placed and in any event for each days concrete production if less than 50
cubic yards. Sufficient cylinders shall be prepared to provide representative
compressive strength results at 7, 28 and 56 days both in the field and laboratory
respectively. Refer to Section 03350 Cast-in-Place Concrete for sample preparation
details.
3.
The Contractor shall supply all specialist services for design, preparation and testing
of backfill concrete and shall arrange for laboratory testing of the compression
cylinders and cores, as required, by an independent testing laboratory in accordance
with ASTM C31, C39 and D5971. The tests shall be performed at no cost to the
Corporation.
Defective Concrete
1.
Defective concrete shall be repaired, by cutting out and removing the unsatisfactory
material and replacing with new concrete. The new concrete shall be secured with
keys, dovetails, or anchors to the satisfaction of the RE. Concrete for patching shall
be drier than the original mixture and shall be thoroughly tamped into place. An
epoxy bonding compound, Para-Bond No. 1200 or equal shall be used to bond
patching concrete to the existing concrete.
PART 2 PRODUCTS
2.01
A.
B.
MATERIALS
Type A Backfill Concrete, (Structural)
1.
Where required the structural Backfill Concrete shall have a 28-day compressive
cylinder test of 3,000 psi minimum, unless otherwise indicated.
2.
Maximum slump shall not exceed 4-inches unless water reducing admixtures and/or
super-plastersizers are added as subject to the REs approval and manufacturers
guidelines.
3.
Water cement ratio shall not exceed 0.45. Where concrete with micro-silica
admixtures are used as determined by the RE, the maximum water cement ratio shall
be 0.43.
4.
Minimum cement content of concrete in all underground structures: 300 lbs of cement
per cubic yard of concrete.
Type B Backfill Concrete, (Non-Structural)
03301-4
1.
Where required the Non-Structural Backfill Concrete (Flowable Fill) shall have a 28day and 56 day compressive cylinder test of 200 psi and 290 psi respectively, unless
otherwise indicated.
2.
The design mix should produce a flowable, self-leveling material at the time of
placement. Normal flowable material shall have a slump of between 6 to 8 inches as
tested in accordance with ASTM D6103.
3.
Concrete density shall not be less than 130 pcf or as required otherwise by the RE.
C.
Cement shall be Type II Portland cement ASTM C150.
D.
Fine Aggregates and Sand shall be in accordance with ASTM C33.
E.
Water: Potable, clean and free of impurities that may affect the strength or gel development of
the backfill concrete. The water shall not be detrimental to concrete.
F.
The design mix shall be proportioned to achieve the required strength and slump requirements
and allow transport by pumping methods without segregating or excessive bleeding.
G.
The flowable fill and its constituent components shall not have any detrimental effect on the
environment in which the flowable fill is to be placed.
2.02
EQUIPMENT
A.
Concrete shall be transported with minimum handling and promptly placed by methods that
shall prevent loss of materials or segregation, and avoid the displacement of the inner main pipe
and any embedded item. The concrete shall be deposited in the tunnel and shafts as near the
final position as possible.
B.
Concrete shall be placed in shafts and tunnel by mechanical equipment and methods.
C.
Concrete placed by mechanical equipment shall be pumped by methods capable of forcing it

into crevices and filling all void spaces. The concrete shall be placed under pressure by means
of pneumatic or positive displacement pumps.
D.
The equipment for placement of concrete and the method of its operation shall be such that the
concrete is not placed at a high velocity and that segregation of the concrete does not occur.
E.
Equipment for placement of concrete shall be operated by experienced operators only.
F.
All formwork shall be built mortar tight of sound material, sufficiently strong and rigid to
maintain their position and shape under all loads and operations incidental to the placing and
curing of the concrete. The forms shall be true to the required shape, size, alignment, and grade,
adequately braced, and so maintained until the concrete has sufficiently hardened to permit their
removal as specified.
G.
Steel formwork shall be of such thickness and so constructed that they will remain true to shape
and shall be substantially watertight. All bolts or rivet heads occurring in the inside face of the
forms shall be countersunk so that a plane smooth surface of the required contour is obtained.
03301-5
Metal formwork that does not present a smooth surface, line up properly, or are distorted,
dented, or bent, shall not be used.
H.
Clamps, pins, or other connecting devices shall be designed to hold the forms rigidly together,
and allow later removal without damage to the concrete. Form ties and spreaders shall be of
sufficient size and strength to hold the formwork securely in place during the pouring of
concrete. The type and use of the ties and spreaders shall be subject to review by the RE.
PART 3 EXECUTION
3.01
A.
3.02
GENERAL
Backfill concrete in the tunnel shall be supplied from the Staten Island shaft site only.
PREPARATION
A.
Before placing concrete, care shall be taken to determine that the inner main pipe and all
embedded items are firmly fastened in place and braced. Embedded items shall be free from
scale, loose, rust, dried mortar, oil or other coating which might impair bond.
B.
Before placing concrete, the space within the limits of the pour shall be completely cleared of
all deleterious substances, adjacent concrete surfaces prepared as hereinafter specified, and the
preparations and proposed methods for pouring reviewed by the RE.
3.03
CONTROL OF WATER
A.
Water shall not be allowed to flow over newly placed concrete. Concrete shall not be poured
through or under water as tremie concrete.
B.
Seepage or water inflows into the tunnel and shafts shall be stemmed, channeled, piped or
controlled in a manner agreed by the RE before placing the concrete backfill.
3.04
FORMWORK
A.
Formwork tolerances and requirements shall conform to Section 03100 Concrete Formwork
Surface Structure or as specified herein.
B.
Care shall be taken to keep the forms free from rust, grease, or other foreign material such as
may tend to discolor the concrete.
C.
Before being erected for re-use, forms shall be thoroughly cleaned of all mortar or other
adhering materials.
D.
The inside of the forms shall be coated with a light, clear, paraffin-base oil layer which shall not
discolor or otherwise injuriously affect the concrete surface.
E.
Forms and their supports shall not be disturbed or removed until the concrete has attained
strength sufficient to insure structural stability and to carry both the dead load and any
construction loads that may be imposed on it. The concrete shall be hard enough so that the
surfaces shall not be injured in any way when reasonable care is used in removing forms.
03301-6
3.05
CONSTRUCTION JOINTS
A.
Vertical sloping type joints are permitted with a maximum angle of 20 degrees from vertical.
B.
Prior to placement of concrete, the sloping joint shall be thoroughly cleaned and dampened and
covered with a layer of bonding compound or cement grout. The bonding grout shall be
prepared using a mix of approximately one part cement to one part fine sand passing a No. 30
mesh sieve, mixed to the consistency of thick cream and applied to the surface of the sloping
joint.
C.
Cleaning of construction joints shall consist of the removal of all laitance, loose or defective
concrete, coatings, and sand, curing compound and other foreign material. Formed construction
joints shall be wet sandblasted or washed with air-water jets.
3.06
REINFORCEMENT
A.
Steel reinforcement shall be of the sizes and be accurately placed, spaced, and located as noted
on the Contract Drawings. Bars shall not be spliced except where shown on the Concrete
Drawings or permitted by the RE.
B.
Bars shall be securely wired and held in position by metal chairs and spacers at 18-inch centers
around the circumference of the lining and 36-inch centers longitudinally. When the use of
chairs is impractical, approved concrete supports may be used. The method used must be such
that reinforcing cannot be disturbed or removed from the required position during placing of
concrete.
C.
Reinforcing steel shall be free of mud, mill scale, rust, paint, oil, or other deleterious coating.
Reinforcement shall be inspected and approved by the RE before any concrete is placed.
3.07
PLACEMENT OF CONCRETE
A.
The method of placement shall be such to ensure complete filling, in the locations shown on the
Contract Drawings between the inner main pipe and the internal surface of the pre-cast tunnel
lining and shaft wall concrete.
B.
The method of placing, of vibrating the concrete for proper placing, and of venting the void or
forms to allow the escape of trapped air, shall be such as to ensure a dense concrete without
cavities of unfilled space.
C.
Forms shall not be removed for a minimum of 8 hours after placement of structural concrete and
until the concrete gains a minimum of 1,000 psi strength.
3.08
A.
CONSOLIDATION OF CONCRETE
Concrete during and immediately after placing shall be vibrated, or otherwise suitably worked
to produce a dense, compacted, homogeneous concrete, completely filling the void between the
inner main pipe and excavation and be free of voids, pockets, or seams of segregated materials.
03301-7
3.09
A.
3.10
A.
TOLERANCES
After the primary supports have been completely installed the Contractor shall install the
concrete backfill shown on the Contract Drawings. Slopes shall be maintained in the designed
direction without any ponding of water at any location along the entire tunnel length.
FINISHING AND CURING OF CONCRETE SURFACES
Surface finishing of backfill concrete shall not be required providing the concrete surface has no
defects requiring the special treatment specified above.
END OF SECTION
03301-8
SECTION 03350
CAST-IN-PLACE CONCRETE
PART 1 GENERAL
1.01
SCOPE OF WORK
A.
The Work specified in this Section includes the furnishing and installation of cast-in-place
concrete in shafts and tunnel as shown and indicated on the Contract Drawings and as specified
in this Section.
B.
Concrete for Precast Concrete Tunnel Lining is covered in Section 03360 Concrete for Precast
Concrete Tunnel Lining.
C.
Backfill Concrete is covered in Section 03301 Backfill Concrete in Shafts and Tunnel.
1.02
RELATED WORK
A.
B.
C.
D.
E.
F.
G.
1.03
REFERENCE STANDARDS
A.
ACI 301
Specification for Structural Concrete for Buildings, (includes ASTM

Standards referred to herein).
B.
ACI 304
Recommended Practice for Measuring, Mixing, Transporting and Placing

Concrete.
C.
ACI 305
Recommended Practice for Hot Weather Concreting.
D.
ACI 306
Recommended Practice for Cold Weather Concreting.
E.
ACI 308
Standard Practice for Curing Concrete.
F.
ACI 309
Recommended Practice for Consolidation of Concrete.
G.
ACI 318
03350 - 1
H.
ACI 347
Recommended Practice for Concrete Formwork.
I.
ASTM C31
Standard Method of Making and Curing Concrete Test Specimens in the

Filed.
J.
ASTM C33
Standard Specification for Concrete Aggregates.
K.
ASTM C39

Specimens.
L.
ASTM C40
Standard Test Method for Organic Impurities in Fine Aggregates for

Concrete.
M.
ASTM C42
Standard Methods of Obtaining and Testing Drilled Cores and Sawed Beams
of Concrete.
N.
ASTM C94
Standard Specification for Ready-Mixed Concrete.
O.
ASTM C138
Standard Test Method for Unit Weight, Yield and Air Content (Gravimetric)
of Concrete.
P.
ASTM C143
Standard Test Method for Slump of Portland Cement Concrete.
Q.
ASTM C150
Standard for Portland Cement.
R.
ASTM C157
Standard Test Method for Length Change of Hardened Cement Mortar and
Concrete.
S.
ASTM C171, (1986) Standard Specification for Sheet Materials for Curing Compounds.
T.
ASTM C172
Standard Method of Sampling Freshly Mixed Concrete.
U.
ASTM C173
Standard Method for Air Content of Freshly Mixed Concrete by the

Volumetric Method.
V.
ASTM C192
Standard Method of Making and Curing Concrete Test Specimens in the

Laboratory.
W.
ASTM C231
Standard Test Method for Air Content of Freshly Mixed Concrete by the
Pressure Method.
X.
ASTM C260
Standard Specification for Air-Entraining Admixtures for Concrete.
Y.
ASTM C494
Standard Specification for Chemical Admixtures for Concrete.
Z.
ASTM C827
Standard Test Method for Early Volume Change of Cementitious Mixtures.
AA. Federal Specification CCC-C-467C: Cloth, Burlap Jute or Kenaf.

BB.
AASHTO M 182 Burlap Cloth Made from Jute or Kenaf and Cotton Mats.
03350 - 2
1.04
1.05
SUBMITTALS
A.
B.
1.06
Submit the following to the RE for approval at least 30 days before concrete is to be placed:
1.
List of concrete materials and concrete mix designs proposed for use submitted for the
various required concrete strength, w\c ratios, and aggregate sizes. Include the results
of all tests performed to qualify the materials and to establish the mix designs.
2.
Manufacturer and/or suppliers details including names, distance in miles from the
Concrete Plant to the Job Site and other required details specified by the RE.
3.
Copies of manufacturer's specifications with application and installation instructions

for proprietary materials and items, including admixtures and bonding agents.
4.
Submit Laboratory Test reports including sieve analyses for each aggregate size,
required cylinder test results and strength curves from the design mix proportions of
the proposed mixes. For the purpose of establishing a design mix containing a setretarding admixture, the temperature may be assumed at 65 degrees F.
5.
Submit certified reports of tests indicating that the aggregates comply with the
Specifications requirements specified below. If samples are ordered for testing by the
RE, they are to be submitted at least one 30 days before the aggregates are to be used.
Additional samples may be ordered for testing by the RE at any time.
Do not begin concrete production until the mixes have been reviewed and accepted by the RE.
DELIVERABLES
A.
Laboratory Test Reports: Submit copies of laboratory test reports for concrete cylinders,
materials and mix design tests. Production of concrete to comply with specified requirements is
the responsibility of the Contractor. Submit the testing lab's average strength curve from the
design mix proportions of the approved materials.
B.
Submit notarized certification of conformance to referenced standards to the RE and a copy of

the batch plant's most recent scale calibration.
C.
Delivery Tickets: Furnish to RE copies of all delivery tickets for each load of concrete delivered
to the site. Provide items of information as specified in ASTM C94, Section 14.
1.07
CONCRETE TESTING SERVICE

1.
By Contractor's Testing Laboratory:

a.
Contractor shall employ, at its own expense, a testing laboratory, approved by

the RE and experienced in design and testing of concrete materials and mixes to
perform material evaluation tests and to design concrete mixes.
b.
Testing agency shall meet the requirements of ASTM E329.
03350 - 3
2.
c.
Submit a written description of the proposed concrete testing laboratory giving

qualifications of personnel, laboratory facilities and equipment, and other
information, which may be requested by the RE.
d.
Submit certification that the testing laboratory meets the requirements of ASTM
E329.
e.
Materials and installed Work may require testing and retesting, as directed by
the RE, at any time during the progress of the Work. Allow free access to
material stockpiles and facilities at all times. Tests not specifically indicated to
be done at the Corporations expense, including the retesting of rejected
materials and installed Work, shall be done at the Contractor's expense.
By Independent Testing Laboratory.

a.
B.
Test for Concrete Materials:

1.
1.08
A.
B.
Testing for concrete field quality control as specified herein shall be performed
by an independent testing laboratory approved by the RE. The Contractor shall
be responsible for notifying the independent testing laboratory to schedule the
testing as specified.
Submit written reports to the RE, for each material selected and tested, prior to the
start of Work. Provide the Project identification name and number, date of report,
name of Contractor, name of concrete testing service, source of concrete aggregates,
material manufacturer and brand name for manufactured materials, values specified in
the referenced specification for each materials, and test results. Indicate acceptability
of materials for intended use.
PRODUCT DELIVERY, STORAGE AND HANDLING

All materials used for concrete shall be:
1.
Kept clean and free from all foreign matter during transportation and handling and
kept separate until measured and placed in the mixer. Bins or platforms having hard
clean surfaces shall be provided for storage. Suitable means shall be taken during
hauling, piling and handling to insure that segregation of the coarse and fine aggregate
particles does not occur and the grading is not affected.
2.
Stored and transported in a manner to prevent ingress of water and emission of dust.
3.
Packaged, marked and stored in accordance with OSHA requirements. Material safety
data sheets shall be provided for all materials and employees shall be briefed on any
health and safety hazards and be provided with the appropriate Personal Protective
Equipment.
An adequate supply of materials used for concrete shall be maintained on site.
PART 2 PRODUCTS
03350 - 4
2.01
A.
B.
CONCRETE MATERIALS
Cement:
1.
Portland cement, ASTM C 150, Type II, domestic manufacture.
2.
All cement is to be delivered in approved containers and stored as directed and

specified. Bagged cement is to be plainly marked with name of Manufacturer, the date
of manufacture, the type of cement, and the net weight. All cement is to be the product
of one Manufacturer. Bulk deliveries are to be provided with delivery tickets
containing data as to name of Manufacturer, date of manufacture, type of cement, and
weight.
3.
Do not use cement which has deteriorated because of improper storage, handling or
for any other reason.
Aggregates: ASTM C33 and as herein specified.

1.
Do not use aggregates containing soluble salts or other substances such as iron
sulfides, pyrite, marcasite, ochre, or other materials that can cause stains on exposed
concrete surfaces. Acceptability of the aggregate is to be based upon satisfactory
evidence, furnished by the Contractor, that the aggregate is free from such materials.
Such evidence is to include service records of concrete of comparable properties under
similar conditions of exposure or certified records of tests by an approved Testing
Laboratory. Tests are to conform to ASTM C227-03. Supply the aggregate for
exposed construction only from one source. Slag materials are not allowed.
2.
Fine Aggregate: Clean, sharp, natural sand free from loam, clay, lumps or other
deleterious substances.
3.
a.
Dune sand, bank run sand and manufactured sand are not acceptable.
b.
The fineness modulus shall not vary by more than 0.20 throughout the work.
c.
Fine aggregates from different sources of supply are not to be mixed or stored
in the same stockpile, nor used alternately in the same concrete mix or the same
structure.
Coarse Aggregate: Clean granitic, uncoated, processed aggregate containing no clay,

mud, loam, or foreign matter.
a.
Apply the following maximum percentages by weight:

1)
Soft Particles
2.0
2)
Chert, as a Soft Impurity
1.0
(defined in Table 3, ASTM C33-03)

3)
Total of Soft Particles and Chert
2.0
(as soft impurities)

4)
Flat and Elongated Particles
15.0
(long dimension more than 5 times the short dimension)
03350 - 5
C.
2.02
Water: Clean, free from injurious amounts of oils, acids, alkalis, organic materials or other
substances that may be deleterious to concrete or steel. Take water only from an approved
source.
CONCRETE ADMIXTURES
A.
Provide admixtures produced by established reputable manufacturers, and use in compliance

with the manufacturer's printed instruction. Do not use admixtures, which have not been
incorporated and tested in the accepted mixes, unless otherwise authorized in writing by the RE.
B.
Water-Reducing Admixture: ASTM C 494, Type A.
C.
Water-reducing, retarding admixture shall conform to ASTM 494, Type D.
D.
Crystalline waterproofing admixture shall conform to the following ASTM Specifications:

C1202, C494, and C233 as well as the Army Corp of Engineers Permeability Testing CRD C4892.
E.
Non-Corrosive, Non-Chloride Accelerator: The admixture shall conform to ASTM C 494,

Type C.
F.
Air entraining admixture shall conform to ASTM C 260.
G.
Fly ash shall conform to ASTM C 618, Type F. Fly Ash shall be obtained from an approved
source.
H.
High range water reducer (HRWR) shall conform to ASTM C 494, Type G.
I.
Calcium Chloride: Do not use calcium chloride in concrete.
J.
Silica fume shall conform to ASTM C 1240 and shall be obtained from an approved source of
supply.
K.
Do not use frozen materials containing ice or snow in the mixture.
2.03
A.
PROPORTIONING AND DESIGN OF MIXES

The following proportioning and design of concrete classes are required.
1.
Fly ash is required in Class C concretes. The combined weight of cement and fly ash
shall contain no less than 20 percent nor more than 25 percent of fly ash. The
combined weight of cement and fly ash shall be used as the weight of cement in the
determining of the water-cement (w/c) ratio.
2.
Fly ash and Silica Fume are required in Class F concretes. The combined weight of
the cement, fly ash and silica fume shall contain no less than 15 percent nor more than
30 percent fly ash and no less than 10 percent nor more than 15 percent silica fume.
The combined weight of cement, fly ash and silica fume shall be used as the weight of
cement in determining the water cement (w/c ratio).
3.
Provide crystalline waterproofing admixture for all reinforced concrete walls unless
otherwise noted on the Contract Drawings. The concrete waterproofing shall be of the
03350 - 6
cementitious crystalline type that chemically controls and permanently fixes a nonsoluble crystalline structure throughout the capillary voids of the concrete. The
crystalline waterproofing admixture shall be Kryton Krystol Internal Membrane
(KIM), as manufactured by Kryton, or approved equal. Handle, mix, apply, and dose
as per manufacturers instructions. Concrete mixes containing the Kryton KIM shall
not have a retarder unless trial mix test results were submitted for the REs review.
4.
The water-reducing admixtures are to be furnished by the Grace Corp., Master

Builders, or Sika Corporation, or approved equal. The admixtures are to be used in
strict accordance with the Manufacturer's written recommendations. Admixtures shall
be applied, as follows:
Table 2.03.1 Admixtures per Air Temperature
Air Temperatures
Admixture
Dosage
Plastocrete 161FL
32 F. to 49 F.
Pozzutec 20
16 fl. oz./100 lbs. of cement
Daraset 200
50 F. to 64 F.
Plastocrete 161
Pozzolith 200N
WRDA with Hycol

65 F. to 84 F.
Plastiment
Pozzolith 100XR
Daratard 17
Above 85 F.
Plastiment
Pozzolith 100XR
Daratard 17
5.
Use admixture Rheobuild 1000 as manufactured by MasterBuilders, or approved

equal. The admixture shall not contain added chlorides, thiocyanates, (naphthalene or
melamine) formaldehydes, or lignins. Use the admixture in strict accordance with the
Manufacturer's written instructions. Concrete containing an HRWR admixture shall
not contain a water-reducing set controlling admixture.
6.
Slump tests shall be made prior to adding the HRWR. The HRWR shall be added to
the concrete at the batch plant. Do not add water after the introduction of a HRWR
into the concrete mix. The slump range required after the addition of the HRWR is
indicated in the table below. HRWR shall be capable of maintaining the required
slump in excess of 60 minutes of continuous mixing at 4 to 6 rpm in a truck mixer and
workability up to 90 minutes. Upon 72 hours notice, the HRWR manufacturer shall
03350 - 7
supply jobsite technical service to the Contractor. The manufacturer shall be consulted
for mix proportions and dosage rates. The initial set shall not be in excess of six hours
at temperatures above 50 degrees F. HRWR shall be used with due consideration
given to the air temperature at the time of batching and casting. Keep an inventory of
additional HRWR, from the same Manufacturer as used at the plant, for approved redosage no more than twice or as specified by the RE.
7.
If field experience method is used to select concrete mixes, the proposed mix designs
shall be accompanied by complete standard deviation analysis and at least 20
consecutive strength tests that represent the proposed mix.
8.
All dry materials, fine and coarse aggregate and cement, shall be measured by weight.
Provide suitable automatic weighing equipment so that the fine and coarse aggregates
for each batch shall be weighted separately. Water shall be weighed in a separate
batcher or measured by volume in a calibrated tank or by water meter. Admixtures
shall be measured by volume. Regardless of how the required materials or quantities
are measured, they shall be within the following tolerances; cement, 1%; aggregates,
2%; water, 1%; and admixtures, 3%.
9.
The proposed mix design and supporting data shall be submitted, in triplicate, to the
RE at least 30 days prior to the expected start of concreting operations.
10.
Compression test specimens made to verify the mixes shall be made in accordance
with ASTM C 192. All compression test specimens shall be tested in accordance with
ASTM C 39.
11.
Adjustment to Concrete Mixes During Construction: Mix design adjustments may be

requested by Contractor when characteristics of materials, job conditions, weather, test
results, or other circumstances warrant; at no additional cost to the Corporation and as
accepted by RE. Laboratory test data for revised mix designs and strength results shall
be submitted to the RE for acceptance before using the revised mixes.
12.
Mix design shall be proportioned in accordance with ACI 211.1 making maximum use
of the coarse aggregate. The proportioning shall be based on the requirements of a
well-graded high-density plastic workable mix within the slump range and strengths
required. The mix shall be based on conventional conveying and shall not be altered
for use in pumping. Pumping equipment, if used, shall be of sufficient size and design
to pump the mix designed for conventional conveyance.
13.
Submit samples, in adequate quantities for each mix design and verification, of all
concrete materials to be used on the project to the contractors testing laboratory. Do
not use any concrete in this work without acceptance and verification of design mix by
the contractors testing laboratory and the approval of the RE.
14.
If Laboratory trial batches are used to select concrete mixes, the contractors testing
laboratory shall make strength tests from trial batches in the laboratory using materials
and mix designs proposed for use by the Contractor. The contractors testing laboratory
shall prepare trial batches in accordance with ACI 211.1.
15.
Provide air-entrainment for all concrete mixtures through the addition of an airentraining admixture for concrete conforming to ASTM C260-01. The admixture is to
03350 - 8
be MB-AE90 as manufactured by Master Builders, or approved equal. The

admixture is to be used in strict accordance with the Manufacturer's recommendations
and in such quantity to produce the required air content.
16.
All concrete classes shall have 5 1% air content.
17.
No-Fines Concrete shall consist of non-angular, coarse aggregate in the range 0.75 to
1 inches. Water/Cement ratio shall be 0.38 by weight. Minimum compressive strength
shall be 2000 psi at 28 days. Aggregate/cement ratio shall be 6 by volume. Cement
type shall be Portland cement ASTM C150, Type II.
18.
The following table describes the concrete class requirements:

Table 2.03.1 - Classes Concrete Requirements
2.04
A.
2.05
Class of
Concrete
Compressive
Strength
@ 28 Days
(psi)
Min
Cement
Content
Lbs/CY
Slump
Range
Before
HRWR
Slump
Range
After
HRWR
4,000
611
1 2
6,000
650
1 2
Max
W/C
Ratio
Max Gallons of
Water
Per Cubic
Yard
Size
(inch)
Min.
Lbs/CY
6 9
0.45
33
2.25
1850
6 9
0.45
33
2.25
1850
Coarse Aggregate
BONDING AGENT
The epoxy-bonding agent shall be Armatec 110 as manufactured by Sika. The chemical
bonding agent shall be P.V.A. Bonder (Ready to Use), as manufactured by ANTI Hydro
Company, or approved equal.
CONCRETE CURING AND PROTECTION MATERIAL
A.
Absorptive Cover: Burlap cloth made from jute of kenaf, weighing approximately 10 ounces
per square yard and complying with AASHTO M 182, Class 3.
B.
Moisture-Retaining Cover: One of the following, complying with ASTM C 171.
C.
1.
Waterproof paper consisting of two sheets of Kraft paper cemented together with
bitumous material with embedded cords or strands.
2.
Polyethylene film shall consist of a single sheet manufactured from polyethylene

resins, free from visible defects.
Curing and Sealing Compound: ASTM C-309. The curing compound shall contain a fugitive
dye. Curing compounds shall conform to all applicable VOC regulations and shall have NSF
Standard 61 approval. The curing compound shall be Quantum Cure as manufactured by
Atlas Corporation, Unitex 12-34 as manufactured by Unitex, or approved equal.
03350 - 9
2.06
MATERIAL FOR CONSTRUCTION JOINTS AND EXPANSION JOINTS
A.
Foam filler material shall be Progress Unlimited, Inc., Resilient White Closed Cell CrossLinked Polyethylene/Vinyl Foam Joint Filler, Code No. FF-7 with 90% recovery factor, and
with a density of 2.2 pounds per cubic feet, or approved equal. Fiber filler material shall be
Fibre Joint by W.R. Meadows, or Sonoflex Cane Fiber by Sonneborn-Contech or approved
equal.
B.
Where a joint sealing compound is required, the sealant shall be a two-component Polyurethane
High Performance Gun Grade Sealant equal to Dualthane as manufactured by W.R.
Meadows, Inc.; Sikaflex 2C, NS, as manufactured by Sika Corporation, or approved equal.
C.
Where a one component polyurethane joint sealant is required as noted on the Contract
Drawings, it shall be a one-component modified urethane sealant, Sikaflex 1a, as
manufactured by Sika Corporation, Dyne Seal W-100, as manufactured by Williams Products,
Inc., or approved equal.
2.07
MIXING EQUIPMENT
A.
Mixing plants shall comply with ASTM C 94 and ACI 304R-00, except as otherwise specified.
The plants shall have sufficient capacity to produce concrete of the qualities specified, in
quantities required to meet construction schedule. All plant facilities are subject to inspection
by the Independent Testing Laboratory and acceptance of the RE, at all times.
B.
Mixers shall be of the rotary batch type approved by the RE and so made and operated as to
insure a thorough mix, homogeneous in composition and uniform in color, with all coarse
aggregate completely covered with mortar. Each mixer shall be equipped with a suitable
charging hopper, water storage tank and a water measuring device that is capable of being
locked and will permit the discharge of water only while the mixer is being rotated. All water,
except that used for cleaning purposes, is to be admitted to the mixer through the measuring
device. Each mixer is to be so equipped as to lock the discharge lever automatically until the
batch has been placed in the mixer.
C.
Do not use non-agitating equipment for the transportation of concrete.
D.
Plant equipment and facilities: Conform to National Ready Mix Concrete Association "Plant
and Delivery Equipment Specification".
E.
Mix concrete in revolving type truck mixers, which are in good condition and which produce
thoroughly mixed concrete of the specified consistency and strength.
PART 3 EXECUTION
3.01
CONCRETE MIXING
A.
Remove hardened accumulations of cement and concrete frequently from drum and blades to
assure acceptable mixing action.
B.
Replace mixer blades when they have lost 10 percent of their original height.
03350 - 10
C.
Do not exceed the proper capacity of the mixer.
D.
Mix concrete for a minimum of two minutes after arrival at the job site, or as recommended by
the mixer manufacturer.
E.
Do not allow the drum to sit while in transit.
F.
Mix at proper speed until concrete is discharged.
G.
Maintain equipment in proper operating condition, with drums cleaned before charging each
batch. Schedule rates of delivery in order to prevent delay of placing the concrete after mixing,
or holding dry-mixed materials too long in the mixer before the addition of water and
admixtures. Clean the mixer before use if is not been used for a period of 30 minutes.
3.02
TRANSPORTING CONCRETE
A.
Transport and place concrete between 45 minutes to not more than 60 minutes after water has
been added to the dry ingredients. If retarders are used, which have been reviewed by the RE,
they may increase the time limit to a maximum of 75 minutes. Under very severe conditions, the
RE may further reduce the time limits or require a reduction of the size of the batches. During
these intervals, the concrete shall be agitated continuously. Any batch mix exceeding the above
requirements is to be discarded at the contractors expense.
B.
No materials for a batch of concrete are to be placed in the drum of the mixer until the entire
previous batch has been discharged. When concrete arrives at the Project Site with slump below
that suitable for placing, as indicated above, water may be added only if neither the maximum
permissible water-cement ratio nor the maximum slump is exceeded. The water is to be
incorporated by additional mixing equal to at least one-half of the total mixing time required.
An addition of water above that permitted by the limitation on the water-cement ratio is to be
accompanied by a quantity of cement sufficient to maintain the proper water-cement ratio. The
addition may only be authorized by the RE, and the cost shall be borne by the Contractor.
C.
Each delivery of concrete to the Project Site shall be accompanied by a certificate showing:
weights of materials and brand names as applicable, amount of water, type and quantity of
admixture, and date and time of loading.
D.
Take care to avoid spilling and separation of the mixture during transportation.
E.
Do not place concrete in which the ingredients have been separated.
F.
Do not retemper partially set concrete, and do not add any water at the jobsite.
G.
Use suitable and approved equipment for transporting concrete from mixer to forms.
3.03
A.
INSPECTION
Inspection of Work Before Placing Concrete:
1.
Inspect the area to receive concrete for any deficiencies, which would prevent proper
placing of concrete. Do not proceed with placing concrete until such deficiencies are
corrected.
03350 - 11
3.04
2.
Do not place in the concrete any item that is not required to be in the concrete by the
Contract Drawings and Specifications. Insert all the items shown on the Contract
Drawings or specified and ensure that they are properly positioned and secured.
Openings other than those that are facilitated by sleeves shall be properly formed and
positioned.
3.
Remove hardened, or partially hardened, concrete on forms or reinforcement before

placing concrete.
4.
Do not place concrete on earth until the fill or excavation has been prepared as set
forth in Contract Drawings and Specifications.
PERMISSIBLE TOLERANCES AND VARIATIONS
A.
This Subsection includes all tolerances or the allowable variations from the dimensions or
positions indicated for all concrete work. Formwork is to be constructed so as to ensure that the
concrete surfaces shall conform to the tolerances of the ACI 347-01. The Contractor is to set and
maintain the concrete forms so that after removal of the forms, and prior to patching and
finishing, no portion of the concrete work shall exceed any of the tolerances listed. Variations in
floor levels are to be measured before removal of supporting shores. The Contractor is to be
responsible for variations due to deflection, when the latter results from concrete quality or
curing which is different from that which has been specified. The tolerances specified are not to
be exceeded by any portion of any concrete surface. The specified variation for one element of
the Structure shall not be applicable when it will permit another element of the Structure to
exceed its allowable variation.
B.
Unless shown otherwise on the Contract Drawings, specified elsewhere in the Specifications or
required by the equipment or material Manufacturer for proper operation and/or shown on
approved shop drawings; all tolerances shall conform to the following criteria:
1.
Variation from plumb.

a.
In the lines and surfaces of columns, piers, walls, and arises:

In any 10 feet of height
- 0.25-Inch
Maximum for the entire height

b.
2.
- 1-Inch
For exposed corner columns, control-joint grooves, and other conspicuous lines:
In any 20 foot height
- 0.25-Inch
Maximum for the entire height-
- 0.25-Inch
Variation from the level or from the grades indicated on the Contract Drawings.
a.
In slab soffits, ceilings, beam soffits and in arises measured before removal of
the supporting shores:
In any 10 feet of length
- 0.25-Inch
In any bay or 20 foot length
- 0.375-Inch
Maximum for the entire length

b.
- 0.375-Inch
In exposed lintels, sills, parapets, horizontal grooves, and other conspicuous

lines:
03350 - 12
3.
4.
In any bay or 20 foot length
- 0.25-Inch
- 0.25-Inch
Variation of the linear building lines from the established plan position and the related
position of columns, walls, and partitions to the building lines.
In any bay
- 0.5-Inch
In any 20 feet of length
- 0.5-Inch
- 1-Inch
Variation in the sizes and locations of sleeves, floor openings, and wall openings.
At any location
5.
- 0.25-Inch
Variation in the cross-sectional dimensions of columns and beams and in the thickness
of slabs and walls.
Minus
- 0.25-Inch
Plus
6.
- 0.25-Inch
Foundation Elements.
a.
Variations in the dimensions in plan:

Minus
- 0.25-Inch
Plus
b.
- 2-Inches
Misplacement or eccentricity:
2% of the total width of the foundation element in the direction of
misplacement, but not more than 2 inches.
c.
Thickness:
Decrease in specified thickness
Increase in specified thickness
7.
- No Limit
Variation in steps.
a.
In a flight of stairs (full run):

Rise
- 0.125-Inch
Tread
b.
- 0.25-Inch
In consecutive steps
Rise
- 0.0625-Inch
Tread
C.
- 5%
- 0.125-Inch
Tolerances apply to concrete dimensions only and not to the positioning of reinforcing steel,
dowels, or embedded items.
03350 - 13
D.
Establish and maintain sufficient control points and benchmarks in an undisturbed condition
until final completion and acceptance of the Project. Use control points and benchmarks for
reference purposes to check tolerances.
E.
Regardless of the tolerances listed above, do not extend portion of any structure beyond the
legal boundary of the Project.
3.05
A.
B.
CONCRETE PLACEMENT
Place concrete continuously so that no concrete will be placed on concrete which has hardened
sufficiently to cause the formation of seams or planes of weakness within the section. Deposit
concrete as nearly as practical in its final location to avoid segregation due to rehandling or
flowing. Do not subject concrete to any procedure, which may cause segregation
1.
Screed concrete, which is to receive other construction to the proper level to avoid
excessive skimming or grouting.
2.
Do not use concrete which becomes non-plastic and unworkable, or does not meet the
required quality control limits, or which has been contaminated by foreign materials.
Do not use retempered concrete. Remove rejected concrete from the job site and
dispose of it in an acceptable location.
3.
Do not place concrete until all forms, bracing, reinforcement, and embedded items are
in final and secure position.
4.
Unless otherwise approved, place concrete only when the RE is present.
Concrete Conveying:
1.
Handle concrete from the point of delivery and transfer to the concrete conveying
equipment and to the locations of final deposit as rapidly as practical by methods,
which shall prevent segregation and loss of concrete mix materials.
2.
Provide mechanical equipment for conveying concrete to ensure a continuous flow of

concrete at the delivery end. Provide runways for wheeled concrete conveying
equipment from the concrete delivery point to the locations of final deposit. Keep
interior surfaces of conveying equipment, including chutes, free of hardened concrete,
debris, water, snow, ice and other deleterious materials
3.
Do not use chutes for distributing concrete unless approved in writing by the RE.
4.
Do not place concrete in water unless concrete is required and approved to be placed
by the tremie method.
5.
Pumping of concrete is permitted however do not use aluminum piping to convey the
concrete.
03350 - 14
C.
Placement Under Water (Tremie Concrete):

1.
Placement Standards: Placing of concrete in or under water shall conform with

requirements of ACI 304R. All concrete lo be placed under water shall be placed by
the tremie method or by direct pumping.
2.
Placement Requirements: Deposit concrete in water only when indicated or approved

in writing by the RE, and only under the observation of the RE. Use only tremie
method and direct pumping with equipment that has been approved by the RE.
3.
Concrete shall be deposited continuously through tremie pipes until it is brought to the
required height. While depositing the concrete, the top surface shall be kept as near
level as possible and the formation of seams avoided.
4.
The tremie pipe shall have an internal diameter of not less than six (6) inches for
concrete with 0.75 inch maximum size aggregate and not less than eight (8) inches for
concrete with a 1.25 inch maximum size aggregate. The tremie pipe shall have no
internal projections and external projections shall be minimized. The receiving hopper
for the tremie pipe shall have a capacity at least equal to that of the tremie pipe.
5.
At all times the end of the tremie pipe shall be kept clear of the reinforcement, any
embedded steel section and box out and the side of the foundation, to prevent
segregation of the concrete.
6.
A suitable plug of buoyant material shall be inserted in the tremie pipe prior to the
concrete being placed. The plug shall be capable of retaining the concrete within the
tremie pipe and rise to the surface when expelled from the tremie pipe.
7.
Concrete shall be placed continuously to ensure that entrapment of air within the
tremie pipe is minimized and at all times a sufficient quantity of concrete shall be
maintained within the tremie pipe to ensure that the pressure from it exceeds that from
the slurry or support fluid.
8.
At all times the tremie pipe shall be embedded within the concrete by at least one (1)
foot during concrete placement.
9.
The depth to the concrete surface shall be measured and the embedded length recorded
at regular intervals corresponding to the placing of each load of concrete. The depth
measured and the volumes of concrete placed shall be plotted immediately on a graph
and compared to the theoretical relationship between depth and volume.
10.
When concreting large areas by the tremie method, provide a tremie pipe for each 100
square feet of surface area of concrete to be placed and concrete simultaneously
through all tremie pipes.
03350 - 15
D.
E.
F.
Placing Concrete into Forms:

1.
Deposit concrete in forms in horizontal layers not deeper than 18 inches and in a
manner to avoid inclined construction joints. Where placement consists of several
layers, place concrete at such a rate that concrete, which is being integrated with fresh
concrete, is still plastic with adequate vibration.
2.
Do not permit concrete to free fall within the form from a distance exceeding 4 feet.
Use elephant trunks and tremies to prevent free fall and excessive splashing on
forms and reinforcement.
3.
Remove temporary spreaders in forms when concrete placing has reached the
elevation of such spreaders.
4.
Consolidate concrete placed in forms by mechanical vibrating equipment

supplemented by hand-spading, rodding or tamping. Use equipment and procedures
for consolidation of concrete in accordance with the applicable recommended
practices of ACI 309. Vibration of forms and reinforcing shall not be permitted, unless
otherwise accepted by the RE.
5.
Do not use vibrators to transport concrete inside of forms. Insert and withdraw
vibrators vertically at uniformly spaced locations not farther than the visible
effectiveness of the machine. Place vibrators to rapidly penetrate the layer of concrete
and at least 6 inches into the preceding layer. So not insert vibrators into lower layers
of concrete that have begun to set. At each insertion, limit the duration of vibration to
the time necessary to consolidate the concrete and complete embedment of
reinforcement and other embedded items without causing segregation of the mix.
6.
Under special conditions, such as heavily reinforced thin walls, and the RE approval,
deposit concrete through temporary openings in the sides of wall forms with the drop
chutes positioned outside of the forms. Temporary openings are to be provided and
spaced approximately 8' vertically and 8' horizontally.
7.
Force concrete under pipes, sleeves, openings and inserts from one side until visible
from the other side to prevent voids.
Placing Concrete Slabs:

1.
Deposit and consolidate concrete slabs in a continuous operation, within the limits of
expansion joints, until the placing of a panel or section is completed.
2.
Consolidate concrete during placing operations using mechanical vibrating equipment,

so that concrete is thoroughly worked around reinforcement and other embedded items
and into corners.
3.
Bring slab surfaces to the correct level. Smooth the surface, leaving it free of humps or
hollows. Do not sprinkle water on the plastic surface. Do not disturb the slab surfaces
prior to beginning finishing operations.
Tie Holes:
03350 - 16
1.
G.
Tie hole and surface defects should be prepared and cleaned and then filled. Do not
leave voids; be sure to completely fill tie holes. This work shall be done after a
maximum of 48 hours.
Cold and Hot Weather:

1.
Concrete placement is not to be permitted when, in the opinion of the RE, the sun,
heat, wind, rain, sleet, snow or humidity would prevent proper placement and curing.
2.
Obtain REs approval of all methods and materials proposed for heating, cooling and
protecting the concrete. Submit in advance to the RE a detailed plan for taking
appropriate precautions during hot weather operations. The plan should address at
least all of the concerns enumerated below.
3.
Cold Weather Placing:
4.
a.
Protect all concrete Work from physical damage or reduced strength, which
could be caused by frost, freezing actions, or low temperatures, in compliance
with the requirements of ACI 306 and as herein specified.
b.
When the air temperature has fallen to or may be expected to fall below 40 F,
provide adequate means to maintain the temperature, in the area where concrete
is being placed, at between 50 degrees F and 70 degrees F for at least seven
days after placing. Provide temporary housings, automatic heaters or coverings
including tarpaulins, plastic film or insulated blanket. Maintain the heat and
protection, if necessary, to insure that the ambient temperature does not fall
below 30 degrees F in the 24 hours following the seven-day period. Automatic
heaters, if used, shall be properly vented to the atmosphere. Avoid rapid dry-out
of concrete due to overheating, and avoid thermal shock due to sudden cooling
or heating.
c.
When air temperature has fallen to or is expected to fall below 40 degrees F

uniformly heat all water and aggregates before mixing as required to obtain a
concrete mixture temperature of not less than 55 degrees F and not more than
90 degrees F at point of placement. Do not heat the water over 180 degrees F.
Leave coverings in place for the specified curing period.
d.
When it is necessary to remove the protection temporarily during the process of

the work, it is to be done in a manner that causes the least disturbance and
allows the protection to be restored as quickly as practicable.
e.
Do not use frozen materials containing ice or snow. Ascertain that forms,
reinforcing steel, and adjacent concrete surfaces are entirely free of frost, snow
and ice before placing concrete.
f.
Do not use salt and other materials containing anti freeze agents or chemical
accelerators, or set-control admixtures, unless approved in mix designs by the
RE.
Hot Weather Placing:

a.
When hot weather conditions exist that would seriously impair the quality and
strength of concrete, place concrete in compliance with ACI 305 and as herein
specified.
03350 - 17
H.
3.06
A.
b.
Cool ingredients before mixing to maintain concrete temperature at time of

placement below 90 degrees F when the temperature is rising and below 85
degrees F when the temperature is falling. Mixing water may be chilled, or
chopped ice may be used to control the concrete temperature provided the water
equivalent of the ice is calculated by the RE in the total amount of mixing
water.
c.
Cover reinforcing steel with water-soaked burlap if it becomes too hot, so that
the steel temperature shall not exceed the ambient air temperature immediately
before embedment in concrete.
d.
Wet forms thoroughly before placing concrete.
e.
Do not place concrete at a temperature so as to cause difficulty from loss of

slump, flash set, or cold joints.
f.
Do not use set-control admixtures unless approved by the RE in mix designs.
g.
Provide sunshades and windbreakers, when needed, to maintain the required

temperatures and minimize excessive drying. Sunshades and windbreakers are
to be left in place for the specified curing time.
No-Fines Concrete:
1.
No-fines concrete shall be placed at least 24 hours before other placing concrete.
2.
No-fines concrete shall not be vibrated or compacted.
CONSTRUCTION JOINTS AND EXPANSION JOINTS

Furnish, install or otherwise construct all construction joints as indicated or detailed on the
Contract Drawings. The use and location of construction joints is to be subject to the prior
review by the RE. All construction joints are to conform to the details shown on the Contract
Drawings, and they shall be in accordance with the following criteria:
1.
2.
In long walls such as grade walls, partition walls or retaining walls, the maximum
length of a continuous concrete placement is to be 30'. In order to minimize shrinkage
cracks, the walls are to be placed in one of the following manners:
a.
Place alternate wall sections and place the closure sections after the first
sections, on each side of the subsequent placements have been cured.
b.
Place the entire wall length in adjacent sections next to each other, provided
that the preceding Section has been cured.
In slabs on the ground, reinforced with welded wire reinforcement, the Contractor
shall, in order to minimize shrinkage cracks, place the slabs in one of the following
manners:
a.
Place the slab in alternate sections in a checkerboard pattern, with closure

sections placed after alternate sections have cured. Each individual section shall
be approximately square and shall not be more than 400 sq.ft. in area.
b.
Place the slab in strips approximately 15 ft. in width and shall provide
contraction joints by means of saw cutting, hand tooling or by inserting
preformed plastic or metal strips into the slab after it has been placed.
03350 - 18
Maximum spacing shall not exceed the width of the concrete placement. Depth
of joint shall be 0.25 the thickness of the slab. Adjacent sections shall not be
placed until the concrete has cured.
3.
In structural framed areas with beams and girders, or slabs, on grade reinforced with
bars, cut the sections in as long a length as practicable or as shown on the Contract
Drawings. Construction joints shall be located at the midspans of beams and slabs.
The maximum width of placements shall not exceed 50 ft. The adjoining section shall
not be placed until the section placed has been cured.
4.
Place mat foundation areas in as large a volume as practicable.
B.
Joints not indicated on the Contract Drawings are to be so made and located as to least impair
the strength of the Structure. Construction joints in columns, walls, slabs, beams and girders are
to conform to ACI 318.
C.
Submit to the RE for review a plan showing the location of proposed construction joints for
each Structure prior to beginning construction of the various Structures.
D.
Construction joints are to consist of keyed joints, except as shown, and are to be installed as
specified previously. If the Contractor desires to install additional construction joints, at the
Contractors own expense, he is to submit working drawings for approval showing the proposed
locations and a placement schedule. Waterstops are to be installed in the joints where indicated
and in all construction joints, as directed by the RE.
E.
Whenever a stoppage of more than 30 minutes occurs in the placing of concrete, install
construction joints.
F.
All construction joints are to have a row of form ties located at a distance of approximately 6
from the joint, to permit aligning and tightening of the forms for subsequent sections.
G.
Install expansion joints where shown on the Contract Drawings in base slabs and supported
slabs and construct as detailed on the Contract Drawings.
H.
Expansion joints shall be formed by means of a preformed foam or asphalt joint filler consistent
with the type of joint as detailed on the Contract Drawings. Install the joint fillers in strict
accordance with the joint details shown on the Contract Drawings and the Manufacturer's
recommendations.
I.
Formed construction joints in containment structures and where otherwise shown: Prior to
placing concrete next to the joint, the joint surface shall be thoroughly cleaned and dampened
with water. Remove all free water so that the surface of the joint shows signs of drying before
placing the adjacent concrete.
J.
Construction joints in beams, girders and slabs where waterstops are not specified or shown to
be installed: These joints shall be located at points of minimum shear and their locations shall
be approved by the RE before they are bulkheaded. These joints shall be roughened and
thoroughly cleaned of all foreign matter and laitance and dampened with water. Remove all free
water and slush with a coat of neat cements grout before placing the adjacent concrete. Place the
adjacent concrete before the neat cements grout takes its initial set.
03350 - 19
K.
Construction Joints in Beams, Girders and Slabs: Where waterstops are specified or shown to be
installed, these joints shall be treated as specified in Article 3.06I above.
L.
Install sealant material in strict accordance with the Manufacturer's recommendations. A primer
compatible with the sealant used shall be applied to all concrete surfaces. Sealants shall be cured
the length of time required by the sealant manufacturer.
3.07
WATERSTOPS
A.
Waterstops shall be provided where specified and as indicated and noted on the Contract
Drawings and shall be made continuous throughout their length.
B.
Where keyed construction joints are to be installed between new and existing concrete, encase
the existing waterstops in new concrete and prevent movement during the placement of concrete
by firmly tying the waterstops to the reinforcing steel. Install a joint sealing compound where
indicated. The first placement layer of concrete above a horizontal joint having a waterstop is
not to exceed 12 in depth and place with extreme care.
3.08
CONCRETE FINISHING
A.
Before starting the concrete construction of any Structure, submit to the RE, for review, a
finishing schedule indicating the type or types of finishing operations that the various
components of the Structure shall receive based on the Contractor's understanding of the
Contract Documents. Do not begin this work until receiving the RE's concurrence with the
proposed schedule.
B.
Complete finished floor and roof slab surfaces within a tolerance as specified herein. Surfaces
shall be pitched to drains as required. Do not dust surfaces with dry materials other than sand.
C.
Where any process area is to be grouted along the floor surfaces, the base surface is to be left
rough to receive the grout. Grout used shall be as specified by the equipment Manufacturer, or
as directed by the RE, shall be of the thickness shown on the Contract Drawings or
Manufacturer's approved shop drawings, and shall receive a steel trowel finish unless otherwise
finished mechanically.
D.
The RE will make all final decisions with regard to finishes whenever the work to be
undertaken may fall into one or more of the categories described below.
E.
In the event that efflorescence, stains, oil, grease, or any unsightly accumulation of foreign
materials are visible on the exposed surfaces of finished concrete, the RE may require remedial
action to remove these blemishes. Such action may cover all exposed concrete, or when
irregular lapping can be avoided, only such parts that are affected by the stains or other
unsightly appearances shall be cleaned. Cleaning shall proceed as follows:
1.
Remove oil and grease with detergents and scrubbing and thoroughly wash with
water.
2.
Only when directed by the RE, Sack-Rub concrete surfaces as follows:

a.
Mix one-part of Portland cement, adding amounts of white Portland cement

necessary to obtain required color, one-part fine industrial sand, an approved
bonding agent, and sufficient water to give consistency of heavy cream. After
03350 - 20
surfaces are prepared and wetted down, rub the mortar thoroughly over the
entire surface with clean burlap. After short interval, remove dried grout with
dry burlap without removing from pits.
b.
F.
Finish on Formed Surface:

1.
2.
G.
Spots or streaks remaining may be honed dry and lightly so as not to change the
texture of the concrete.
Smooth Form Finish is required for all concrete surfaces exposed to view in the
completed work and inside surfaces of all liquid containment structure walls whether
exposed to view or not in the completed work. Accomplish the required patching and
in addition the following touch-up (rubbing) by employing mechanical or hand
rubbing tools of various types used in the construction industry:
a.
Remove all burrs.
b.
Remove all form marks.
c.
Smooth out lines of indentations.
Rough Form Finish shall be produced by filling all tie holes and honeycomb and in
other respects leaving the surface as formed. All concrete surfaces which will be
covered by earth and which will not be visible in the completed structure (except as
noted above for liquid containment structure walls which shall have a Smooth Form
Finish), may receive a Rough Form Finish.
Steel Troweled Finish Floor Slabs:

1.
Steel troweled finish shall be applied to the surface of all building and liquid
containment structure floor slabs and interior equipment pads.
2.
Concrete shall be placed, consolidated, struck-off and leveled to the proper elevation.
After the surface has stiffened sufficiently to permit the operation and the water sheen
has disappeared, the surface shall be wood floated, by hand or power floated, at least
twice, to a uniform sandy texture. Floors shall be leveled such that depressions
between high spots do not exceed -inch under a 10 foot straightedge except where
drains occur, in which case the floors shall be pitched to the drains as indicated on the
Contract Drawings.
3.
After the concrete has received a wood float finish, it shall be troweled at least twice
to a smooth dense finish. The drying of the surface moisture between floating or
troweled shall not be hastened by the dusting on of dry sand or cement. The first
troweling shall be done by a power trowel and shall produce a smooth surface
relatively free of defects. Additional troweling shall be done by hand after the surface
has hardened sufficiently. The final troweling shall be done when a ringing sound is
produced as the trowel is moved over the surface. The surface shall be thoroughly
consolidated by the hand troweling operations. The finished surface shall be free of
any trowel marks or other imperfections; shall be uniform in texture and appearance,
and shall be in true plane within the tolerance specified. Any deviation from this
condition, which remains after the troweling is completed, shall be corrected by
grinding.
03350 - 21
H.
I.
Wood Float Finish:

1.
A wood float finish shall be applied to all base and top slabs.
2.
Perform a wood float finish until a true, even plane with no coarse aggregate visible,
all while the concrete is still green but sufficiently hardened to bear a man's weight
with out deep imprint. Sufficient pressure shall be used on the floats to bring moisture
to the surface.
Broom Finish:
1.
2.
J.
Broom finish shall be applied to:

a.
All exterior side walks, walkways and platforms.
b.
All steps and landings, both interior and exterior.
The surface shall be given a floated finish as specified above, and then finished with a
flexible bristle broom or burlap belt drawn across the surface. Surface shall be
hardened sufficiently to retain the scoring or ridges. Scores or ridges shall be
transverse to traffic or at right angles to the slope of the slab.
Patching:
1.
As determined by the RE, any concrete, which is out of alignment or level has a
defective surface or has defects, which reduce its structural adequacy, shall be
considered as not conforming to the Contract Drawings and Specifications and shall
be rejected. This refers to all surfaces even though they will be covered with backfill
afterward.
2.
Do not take any remedial action on concrete with any defect without the permission of
the RE.
3.
Unless the RE grants permission to patch the rejected concrete, remove the rejected
concrete and replace it with concrete that conforms to the Contract Drawings and
Specifications. The location of cut lines and the extent of removal shall be determined
by the RE.
4.
If the RE grants permission to patch the rejected concrete, it shall be done in

accordance with the following:
a.
Permission to patch rejected concrete shall not be a waiver of the REs right to
require complete removal of the rejected concrete if the patching does not, in
the REs judgment, restore the concrete to the requirements of the
Specifications and Contract Drawings.
b.
Patching shall be accomplished after the curing is completed.
c.
Defective areas shall be chipped away to a depth of not less than 1-inch, in all
cases to sound concrete, with edges perpendicular to the surface. All surfaces
are to be neatly finished at the edges. Featheredges shall not be permitted.
Remove all loose material and thoroughly clean the chipped surfaces with a
high-pressure air hose delivering air at 100 psi. The area to be patched and an
area at least 6-inches wide surrounding it shall be dampened. A bonding grout
03350 - 22
shall be prepared using a mix of approximately one part cement to one part fine
sand passing a No. 30 mesh sieve, mixed to the consistency of thick cream, and
then well brushed into the surfaces. Sprinkling with dry cement shall not be
permitted.
K.
A.
The patching mixture shall be made of the same materials and of approximately
the same portions as used for the original concrete, except that the coarse
aggregate shall be omitted and the mortar shall consist of not more than one
part cement to two and one-half parts sand by damp, loose volume. While
Portland cement shall be substituted for a part of the gray Portland cement to
produce a color matching the color of the surrounding concrete, as determined
by a trial patch.
e.
The quantity of mixing water shall be no more than necessary for handling and
placing. The patching mortar shall be mixed in advance and allowed to stand
with frequent manipulation with a trowel, without addition of water, until it has
reached the stiffest consistency that will permit placing.
f.
After surface water has evaporated from the area to be patched, the bond coat
shall be well brushed into the surface. When the bond coat begins to lose the
water sheen, the premixed patching mortar shall be applied. The mortar shall be
thoroughly consolidated into place and struck off so as to leave the patch
slightly higher than the surrounding surface. To permit initial shrinkage, it shall
be left undisturbed for at least one hour before being finally finished. The
patched area shall be kept damp for seven days. Finishing tools that produce a
finish matching the surrounding shall be used.
Tie holes left by withdrawal of rods or the holes lefty by removal of ends of wall ties shall be
filled solid with mortar after first being wetted. For holes passing through the wall, a plungertype grout gun shall be used to force the mortar through the wall starting at the back face. A
piece of burlap or canvas shall be held over the hole on the outside and when the hole is filled,
the excess mortar shall be struck off with the cloth flush with the surface. Holes not passing
through the walls shall be filled with a small tool that will permit packing the hole solid with
mortar. Any excess mortar at the surface of the wall shall be struck off flush with a cloth.
Mortar shall consist of one part cement, two and one-half parts sand and no more water than
necessary for handling and packing the Drain Testing:
1.
3.09
d.
After completion of concrete elements, which are equipped with drains, test the
drainage of all such work by (1) temporarily plugging the drains; (2) ponding water to
the highest elevation of sloping concrete; and (3) removing the temporary plugs. The
ponded water shall drain completely from the slab or floor through the drain, leaving
no standing water anywhere within sloped concrete areas. Should the work fail the
test, repair or replace the work, as directed by the RE, and retest until the work
satisfactorily passes the testing. All such testing shall be at the time specified by, and
in the presence of the RE.
PROTECTION
Protect freshly placed concrete from damage or injury due to water, falling objects, persons or
anything that may mar or injure finish surface on concrete. Only light use of slabs shall be
permitted for the first 14 days after placing of the concrete.
03350 - 23
B.
3.10
After curing compound application or required curing period, cover concrete slabs with a
waterproof curing paper. All seams of such paper are to be overlapped at least 4 and sealed
with tape. Provide further protection when erecting equipment, by means of planking of
sufficient size, or such other protection, as is required. Do not remove the paper prior to the final
cleaning, and in any case, not sooner than 28 days after being placed.
CURING
A.
Curing shall conform to ACI 308 except as modified herein.
B.
All Slabs on Grade: After placement and finishing, concrete shall be maintained in a moist
condition for at least 7 successive days during which the temperature of the concrete is 50
degrees F or above. For temperatures of 50 degrees F and below, curing period shall be 14
successive days. Concrete shall be kept moist by any one, or combination, of the following
methods:
C.
1.
Ponding or Immersion: Continually immerse the concrete in water throughout the

curing period. Water shall not be more than 20 degrees F less than the temperature of
the concrete.
2.
Fog Spraying or Sprinkling: Provide uniform and continuous application of water

throughout the curing period.
3.
Pervious Sheeting: Completely cover surface and edges of the concrete with two
thicknesses of wet sheeting. Overlap sheeting 6-inches over adjacent sheeting.
Sheeting shall be at least as long as the width of the surface to be cured. During
application, do not drag the sheeting over the finished concrete nor over sheeting
already placed. Wet sheeting thoroughly and keep continuously wet throughout the
curing period.
4.
Impervious Sheeting: Wet the entire exposed surface of the concrete thoroughly with a
fine spray of water and cover with impervious sheeting throughout the curing period.
Lay sheeting directly on the concrete surface and overlap edges 12-inches minimum.
Provide sheeting lot less than 18inches wider than the concrete surface to be cured.
Secure edges and transverse laps to form closed joints. Repair torn or damaged
sheeting or provide new sheeting. Inspect surface of concrete daily for wetness. The
surface shall be kept continuously wet during the curing period.
All Other Concrete:

1.
3.11
A.
After placement, concrete shall be maintained in a moist condition for the same
periods as specified above for slabs on grade. For concrete in formed surfaces, keep
forms wet with water during the curing period. If forms are removed before the end of
the curing period, continue the moist curing in accordance with Article 3.10B above.
FIELD QUALITY CONTOL TESTING

The Independent testing laboratory shall have access to all places where concrete materials and
concretes are manufactured, stored, proportioned, mixed, placed and tested. Duties shall include,
but not necessarily be limited to the following:
03350 - 24
1.
Make, store, transport, cure and test compression specimens made during the placing
of concrete. Compression test specimens shall be tested in accordance with ASTM C
39. Test reports shall show all pertinent data, such as class of concrete, exact location
of pour, air temperature, date of pour, time of pour, truck number for ready-mixed
concrete, date on which specimen was broken, age of specimen, compressive strength
of specimen, concrete slump test results and air content of concrete from which the
specimen was made. One copy each of all tests shall be sent to the Contractor and two
copies each to the RE.
2.
Each strength test requires four standard test cylinders.
3.
Samples for strength tests of each class of concrete placed each day shall be taken not
less than once a day, nor less than once for each 100 cubic yards of concrete, nor less
than once for each 5,000 square feet of surface area for slabs or walls.
4.
Each class of concrete shall be tested with at least five strength tests.
5.
Each set of four cylinders, two shall be tested at 28 days and shall comprise a strength
test under the definition of these Specifications. One cylinder shall be broken at 7 days
and shall be used as an aid in determining the early strength of the concrete and the 28
day strength, and one cylinder retained in reserve for later testing if required.
6.
Test for unit weight of concrete when the first load of each class of concrete is
delivered and thereafter at the discretion of the testing laboratory.
B.
Periodically inspect the batching plant and file a report with the RE stating whether the
suppliers equipment and methods meet the requirements of these Specifications.
C.
Placing Records: Slump, air content, and temperature tests shall be made each day during
concreting operations at the time of placement, and at the option of the RE as often as it is
necessary for control checks. In addition, these tests shall be made when specified and always
when strength specimens are made. Concrete with a slump greater than specified shall be
rejected. Records shall also include location, quantity and starting and finishing time of
placement for all concrete work. Copy distribution shall be as specified above for test reports.
D.
All work and reports shall comply with Applicable Industry Standards.
3.12
EVALUATION OF COMPRESSION TESTS
A.
Evaluation of compression test results shall be as follows: For each class of concrete,
compression-strength tests for laboratory-cured cylinders shall be considered satisfactory if the
averages of the results of all sets of three consecutive compression-strength tests equal or
exceed the 28 day design compression-strength specified; and, no individual cylinder strength
test falls below the required compression strength by more than 500 psi. Strength tests of
specimens cured under field conditions may be required by the RE to check the adequacy of
curing and protecting of the concrete placed. Specimens shall be molded by the field testing
laboratory at the same time and from the same samples as the laboratory-cured specimens.
B.
Faulty Concrete: Failure to comply with any of the specified conditions shall constitute faulty
concrete. Unless otherwise directed by the RE, faulty concrete shall be removed and replaced
with concrete as specified, at no expense to the Corporation.
03350 - 25
C.
Additional Test: If permitted by the RE, additional tests shall be subject to the approval of the
RE at no expense to the Corporation. Load tests, if permitted by the RE, shall be conducted in
accordance with the loading criteria as required by the design of the structure, as determined by
the RE.
D.
Neither the results of laboratory verification tests nor any provision in the Contract Documents
shall relieve the Contractor of the obligation to furnish concrete of the class and strength
specified.
3.13
TESTING FOR WATERTIGHTNESS OF CONCRETE STRUCTURES
A.
All concrete structures designed to contain or convey fluid shall be tested for watertightness by
the Contractor prior to earth backfilling by filling with water to levels approximately what will
be attained during operation and measuring the drop in level due to leakage, if any. These tests
shall be made under the direction of the RE, and if necessary the tests shall be repeated until
watertightness is insured. Perform tests prior to backfilling below grade structures and prior to
installations of any coating.
B.
Rate of filling shall be limited to minimize shock-effect to new concrete construction. Water
shall be held under each condition long enough to satisfy the RE that the structures are
watertight. Structures shall be free of internal or external water leakage.
C.
The total loss of water-level in any basin or flume shall not exceed 0.5in. (13 mm) depth in 24
hours. Leakage shall be located and stopped and the structure again tested until this requirement
is met. If the structure does not meet the test, the Contractor shall repair or replace at the
Contractors own expense, such part of the work as may be necessary to secure the desired
results, as approved by the RE.
D.
Regardless of the rate of leakage there shall be no visible leakage from any concrete structure.
3.14
SPECIAL CONCRETE WORK
A.
Provisions are to be made for the proper bonding of fresh concrete with concrete that has fully
or partially set. Such provisions are to be made of steps, dovetails, or other devices as may be
approved. Whenever new and old concrete work are to be joined, the contact surface of the old
concrete is to be thoroughly cleaned by means of stiff brushes or other tools and by the
application of a stream of water under pressure. The surface is to be clean and wet but free from
pools of water at the moment the fresh concrete is placed. On horizontal joints, special care is to
be taken to remove any laitance, waste mortar, and other substances that would prevent
complete adhesion of the concrete.
B.
Where dowels are required for joining new concrete to existing concrete, they are to be installed
as shown or as directed by the RE.
C.
Concrete areas that are to be surface patched are to be coated with an epoxy patching
compound. The concrete surfaces shall be completely cleaned before applying the patching
compound. The concrete surface is then to be primed by brush coating the patching compound.
After priming, sand is to be added to the compound in a ratio of one part sand to one part
compound, by volume. The sand and epoxy mixture are to be applied by trowel methods. The
application of the patching compound is to conform to the recommendations of the
Manufacturer.
03350 - 26
D.
All mechanical vibrating equipment shall be bedded in non-shrink, nonmetallic grout as

specified in another Subsection of the Specifications.
E.
All anchors, bolts and similar items furnished under other Sections of the Specifications shall be
built into the work. The Contractor shall bolt all fastenings, through fills, into the structural
concrete.
F.
All raised curbs, as shown or noted on the Contract Drawings, shall be formed and constructed.
G.
The Contractor shall apply a chemical bonding agent capable of bonding cement floor topping,
cement stucco, cement mortar or cement plaster to previously placed concrete surfaces. The
materials shall provide a lasting bond between the concrete and the applied finish and shall not
cause any discoloration in the applied finished materials or be affected by freezing, heat, acid or
dampness. The bonding material shall be applied in accordance with the Manufacturer's
directions.
H.
Pre-mixed, non-metallic, non-shrink grout shall be used for grouting bedding plates and column
bases, and as otherwise called for on the Contract Drawings.
I.
The Contractor shall grout under all steel plates with non-metallic, non-shrink grout mixed in
accordance with the Manufacturers written instructions and insure full bearing under all plates.
J.
Cement grout used as channel fills or which is to be swept into position by process equipment
shall conform to these Specifications or to the criteria established by the Manufacturer of the
respective process equipment as applicable. Prior to placing cement grout, a bonding agent shall
be applied to the concrete.
3.15
A.
CLEANING UP
Cleanup shall be undertaken upon completion of the work in this Section. Upon final
completion of all work included herein; all surplus and waste materials resulting from the
concrete and cement finishing work, including all tools and implements employed therein, shall
be removed from the Project Site. The Structures and all portions of the Project Site affected by
work under this Section shall be left in a neat, clean and acceptable condition.
END OF SECTION
03350 - 27
SECTION 03360
CONCRETE FOR PRECAST CONCRETE TUNNEL LINING
PART 1 GENERAL
1.01
A.
1.02
SCOPE OF WORK
This Section includes the supply and placement of concrete for precast concrete tunnel lining
segments for the Tunnel Boring Machine (TBM) tunnels.
RELATED SECTIONS
A.
Tunneling by Tunnel Boring Machines is included in Section 02330.
B.
C.
Reinforcement for Precast Tunnel Linings is included in Section 03370.
1.03
REFERENCES
A.
ACI 117/117R
Standard Tolerances for Concrete Construction and Materials
B.
ACI 211.1
Standard Practice for Selecting Proportions for Normal, Heavyweight,

and Mass Concrete
C.
ACI 214.3R
Simplified Version of the Recommended Practice for Evaluation of

Strength Test Results of Concrete
D.
ACI 301
Specifications for Structural Concrete for Buildings
E.
ACI 305R
Hot Weather Concreting
F.
ACI 306R
G.
ACI 318/318R
Building Code Requirements for Reinforced Concrete and Commetary
H.
ASTM C31
I.
ASTM C33
Concrete Aggregates
J.
ASTM C39
K.
ASTM C42
Obtaining and Testing Drilled Cores and Sawed Beams of Concrete
L.
ASTM C114
Method for Chemical Analysis of Hydraulic Cement
M.
ASTM C143
Standard Test Method for Slump of Hydraulic Cement Concrete
N.
ASTM C150
Portland Cement
03360 - 1
O.
ASTM C156
Test Method for Water Retention by Concrete Curing Materials
P.
ASTM C172
Sampling Freshly Mixed Concrete
Q.
ASTM C192
Making and Curing Concrete Test Specimens in the Laboratory
R.
ASTM C231
Air Content of Freshly Mixed Concrete by the Pressure Method
S.
ASTM C260
Air-Entraining Admixtures for Concrete
T.
ASTM C494
Chemical Admixtures for Concrete
U.
ASTM C618
Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use as a Mineral
Admixture in Concrete
V.
ASTM C666
Standard Test Method for Resistance of Concrete to Rapid Freezing and

thawing
W.
ASTM C989
Ground Granulated Blast-Furnace Slag for Use in Concrete and Mortars
X.
ASTM C1017
Chemical Admixtures for Use in Producing Flowing Concrete
Y.
ASTM C1077
Laboratories Testing Concrete and Concrete Aggregates for Use in

Construction and Criteria for Laboratory Evaluation
Z.
ASTM C1202
Standard Test Method for Electrical Indication of Concrete's Ability to

Resist Chloride Ion Penetration
AA. ASTM C1240
Silica Fume for Use as a Mineral Admixture in Hydraulic-Cement

Concrete, Mortar and Grout
BB.
ASTM C1556
Standard Test Method for Determining the Apparent Chloride Diffusion

Coefficient of Cementitious Mixtures by Bulk Diffusion
CC.
ASTM D75
Sampling Aggregates
1.04
1.05
SUBMITTALS
A.
Samples/Information: The Contractor shall submit the following, to the RE for his approval, a
minimum of 30 days before commencing precast liner production:
1.
Proposed pit and stockpile locations for aggregates and provide access for sampling.
2.
The name and source of all other concrete materials.
3.
Quality Control: Quality control procedures for all aspect of the work referenced in
this Section.
4.
Concrete Mix Designs:
03360 - 2
1.06
A.
1.07
a.
The submission shall include a minimum of ten mix design variations covering
the range of all potential mix designs and curing methods to be employed to
meet the design requirements.
b.
Supplement initial mix design submission with test data as it becomes available.
c.
Adjustments made to the design mixes may require additional tests on the new
mix.
d.
Do not vary the approved mix without written approval.
DELIVERABLES
Records: The Contractor shall provide the RE with the following information for each batch of
concrete used:
1.
Date of batching;
2.
Serial number of each batch;
3.
Amount of concrete in cubic yards;
4.
Time of first mixing of cement and aggregate;
5.
Time that the discharge of load was started;
6.
Time that the discharge of load was completed;
7.
The air temperature when the concrete was placed; and
8.
The test samples taken and the results of the test samples.
INSPECTION AND TESTS
A.
Materials shall conform to ACI 301 and shall be tested by the Contractor for conformance to
requirements of the Contract Documents. The RE may conduct independent tests to confirm
those by the Contractor.
B.
Tests by the Contractor, shall include but not be limited to the following:
1.
Tests of aggregate in accordance with ASTM C 33.
2.
Test for establishing concrete mixes and design of mix.
3.
Concrete cylinder tests.

a.
Six cylinders from each shift's placement and six for each 70 cubic yards of
concrete shall be cured and tested.
b.
Weekly, six additional cylinders shall be taken from the same batch as Article
1.07B.3.a above and cured with the segments.
c.
Two cylinders shall be tested at ages of 7, 28, and 56 days until satisfactory
control of strength is established, when tests at 7 and 28 days only will be
required.
03360 - 3
C.
Preproduction Testing of Concrete:

1.
2.
This clause covers tests which are to be carried out at the preproduction stage only.
The tests have been classified in terms of the level of compliance required:
a.
Compliance Tests Tests to prove that the concrete satisfies and existing
requirement.
b.
Preproduction Trials Tests to establish the criteria which will be used during
production.
c.
Reference Tests Tests which provide information for design or for long-term
confirmation of the more rapid tests.
Compliance Tests:
a.
b.
On aggregates:
1)
Wet sieve analysis.
2)
10% fines values.
3)
Flakiness.
4)
Aggregate chloride content.
5)
Petrography: The petrography tests, because of the specialist knowledge

required in the analysis, shall only be carried out at an external laboratory
approved by the RE. The main purpose is to compare the structure of the
aggregate as delivered to that of samples from the quarry which were
tested previously.
On fresh concrete:
1)
c.
On hardened concrete :
1)
3.
Wet concrete chlorides content If this confirms the summation of the

aggregate chlorides content tests it will not be used during production.
Concrete strength Standard cylinder testing methods to establish 28 day
strength and correlation with 3 day and 7 day strength. Curing as for
production segments.
Preproduction Trials:
a.
On aggregates:
1)
b.
On fresh concrete:
1)
c.
d.
Moisture content.
Vebe To develop a target range of times and assess the controllability
of workability.
On hardened concrete:
1)
Schmidt hammer To calibrate for possible use as comparative NDT

during production.
2)
Weighing of samples Cubes and cores to establish density.
Curing Trials:
03360 - 4
e.
1)
Computer prediction The setting up of a computer model to predict the

cooling regime after leaving the accelerated curing tunnel for given
dimensions of segment, ambient temperature and secondary curing.
2)
Temperature monitoring Segments and cylinders shall be instrumented

with thermocouples and passed through the initial accelerated curing
regime proposed. Monitoring shall continue after demolding with and
without secondary curing to establish the optimum type and period of
curing to avoid thermal shock and rapid drying out. Results shall be
compared with the computer predictions of the temperatures and
dimensions of the segments carried out by the Contractor for different
stages of the curing.
3)
Inspection for cracking For the various cooling regimes visual

inspection (by wetting the concrete) for cracking and inspection of cores
taken from the segment will be made
Durability Tests:
1)
4.
Water permeability tests.
Reference Tests:
a.
b.
Design Parameters:
1)
E value test.
2)
Creep test (on a 90 day cylinder).
3)
Thermal expansion coefficient for use in design and monitoring of

linings.
4)
Drying shrinkage/wetting expansion (on cores).
5)
Concrete compressive strength relationships between 28 day and 90

day cylinder strengths.
6)
Concrete tensile strengths cylinder splitting tests for input to design and
interpretation of joint tests. The cylinders shall be accelerated cured in
the same manner as the segments before being put into a curing tank.
Durability Tests:
1)
Standard absorption test.
2)
Water permeability test.
5.
Summary of Tests Required:
6.
The tests required are summarized in Table 1.5.1. Unless otherwise notified, tests on
concrete shall be carried out on three trial batches.
03360 - 5
Table 1.5.1 Summary of Tests Required

Type of Test
Number of Tests
Sampling
Compliance Tests
Wet sieve analysis
10% fines value, flakiness, and
aggregate chloride content
One representative sample
1 of each
Petrography
Random sample of each size
Cement and FA
Sample every 100 tons
Wet concrete chlorides content
To be as directed by the RE
Cylinder tests
3 at 7 days and 3
at 28 days
Every trial batch
Moisture content
Vebe
Every trial batch
Schmidt hammer
On all
preproduction
cylinders and
segments
Every trial batch
Density
Every cylinder
and core tested
Every trial batch
Curing
2 segments, 3
cylinders
Water permeability
One core per segment for each

test
E value
Creep
Cylinder
Thermal expansion
Drying
expansion
Not less than two cores
Reference Tests
shrinkage/wetting
28 to 90 day cylinder ratio
3 at 28 days, 3 at
90 days
03360 - 6
Every trial batch
Tensile strength
3 cylinders per test batch
Absorption
Random cylinder or core
Water permeability
One core per segment for each

test.
D.
Air entrainment test and slump test shall be taken as is necessary for control checks and
acceptance purposes and, as a minimum, from the same batch of concrete from which test
cylinders are made.
E.
Permeability testing shall be undertaken as follows:
F.
1.
Tests to establish the permeability of the proposed mix designs shall be undertaken in
accordance with Dr. C.D. Lawrence, "Measurements of Permeability" 8th Congress of
Cement, Brazil 1986.
2.
Tests shall be performed on 2-inch thick discs cut from 6- inch diameter cores taken
from panels, produced under similar conditions to the segments, of each of the
proposed design mixes.
3.
Testing shall be undertaken for a period of 42 days at 116 psi pressure.
4.
Cores for testing shall be taken on Days 14, 28 and 42 of the test period.
5.
Upon commencement of segment production permeability testing as specified herein

shall be undertaken on a minimum of 2 of the initial 100 segments produced to verify
the permeability values obtained, prior to the delivery of any segments to the Site.
Chloride Ion Diffusion Testing shall be undertaken as follows:

1.
Testing shall be undertaken in accordance with ASTM 1202 and 1556.
2.
Tests shall be performed on cores taken from panels, produced under similar
conditions to the segments, of each proposed mix design.
3.
Upon commencement of segment production chloride ion diffusion testing as

specified herein shall be undertaken on a minimum of two of the first 100 segments
produced to verify the values obtained from the trial mixes, prior to the delivery of
any segments to the Site
G.
Cooperate with and assist the RE during inspections and tests.
H.
The RE reserves the right to undertake independent testing of the mix or materials.
I.
Segment production shall not commence until consistent test results have been obtained and the
mix design approved by the RE.
03360 - 7
PART 2 PRODUCTS
2.01
MATERIALS
A.
Admixtures: Contractor may include accepted concrete admixtures in the mix. Admixtures shall
be introduced in solution form. All admixtures shall be from a single manufacturer unless the
compatibility of materials from two or more suppliers can be demonstrated.
A.
Portland Cement: ASTM C150, Type II.
B.
Cementitious Hydraulic Slag: ASTM C989, Grade 120.
C.
Fly Ash: ASTM C618, Class F.
D.
Supplementary Cementing Materials: ASTM C618.
E.
Silica fume: ASTM C1240 maximum 10 percent of total cementitious material content.
F.
Coarse Aggregate:
1.
ASTM C33, tested in accordance with the current Los Angeles Abrasion Loss
Specification. Qualifications may be based on historical test results from the
aggregate source.
2.
The maximum petrographic number for the coarse aggregate shall be 140.
3.
Gradation of Coarse Aggregate: ACI 211.1, Appendix 5, A5.3.2.1 or an alternate

grading approved by the RE.
4.
Maximum size: 3/4 inch.
G.
Fine Aggregate: ASTM C33.
H.
All aggregates shall be from a tested source.
I.
Water: Clean and potable, free of impurities detrimental to concrete.
J.
Water Reducing Admixture: ASTM C494, Type A.
K.
Set Retarding Admixture: ASTM C494, Type D.
L.
Set Accelerating Admixture: ASTM C494, Type C.
M.
Air Entraining Admixture: ASTM C260.
N.
Superplasticizer: ASTM C494, Type F.
2.02
A.
CONCRETE MIXES
Produce concrete for all segments in accordance with these requirements:
03360 - 8
1.
Compressive strength at 28 days: minimum 7500 psi.
2.
Cement content: minimum of 520 lb/cy.
3.
Cementitious material content: minimum 695 lb/cy, maximum 900 lb/cy.
4.
Cementitious hydraulic slag: maximum 30 percent of total cementitious material

content.
5.
Fly Ash: maximum 30 percent of total cementitious material content.
6.
Silica fume: maximum 10 percent of total cementitious material content.
7.
Water to cementitious material ratio: maximum 0.35 by weight.
8.
Air entrainment: minimum percentage required to provide a freeze-thaw Durability

Factor of 90 percent in accordance with ASTM C-666, Procedure A.
9.
Slump: minimum 3 inches.
10.
Minimum total supplemental cementitious materials (slag, fly ash, and/or silica fume):
25 percent.
11.
Permeability to water: maximum 10-13 m/s.
12.
The target electrical mean resistance according to ASTM C1202: to reach 500
Coulombs at any time before 120 days from casting
13.
The target chloride diffusion coefficient: to reach 10-12 m2/s according to ASTM
C1556 at any time before 120 days from casting.
14.
Total water-soluble alkali content: not greater than 5.4 lb/cy (Na2O equivalent).
B.
Design concrete so that material will not segregate and excessive bleeding will not occur.
C.
The acceptance of any concrete mix proportion or material, shall not preclude its future
rejection if it is subsequently found to lack uniformity, or if it fails to conform to the
requirements specified, or if its performance is found to be unsatisfactory.
D.
Concrete mix proportions shall be in accordance with ACI 211.1.
E.
Mix concrete in accordance with ACI 301.
PART 3 EXECUTION
3.01
A.
FIELD QUALITY CONTROL

Admixtures
1.
Add admixtures to concrete mix in accordance with manufacturer's recommendations.

Have admixture manufacturer make available, at no cost to the Corporation, upon 72
03360 - 9
hours notice, the services of a qualified, full-time field representative to ensure proper
use of admixtures.
B.
C.
2.
The use of calcium chloride or additional admixtures, other than those specified, is not
acceptable.
3.
Use of admixtures shall comply with ASTM C494.
Source Quality Control

4.
All testing shall be done by the Contractor, in accordance with ASTM C31, ASTM
C39 ACI 214.3R.
5.
Strength test means the average compressive strength of two companion compression
test specimens tested at the same age. If a strength test falls below the specified
strength, the concrete will be considered defective.
6.
Provide a heated, enclosed and locked storage area not less than 65 square feet for
storing concrete samples. Maintain humidity at 100 percent. Maintain the temperature
in the storage area at 73 degrees F 4 degrees F at all times. Provide a shelf in the
storage area for writing tags. Curing should follow proposed segment curing regime
as well as the requirements of ACI and ASTM standards.
7.
Provide transportation for the samples from the point that the samples are taken to the
storage area. Forbid entry to storage area by unauthorized personnel.
Test Procedures and Requirements

8.
The determination of within-batch uniformity shall be based on
10.
Table 1 and shall be based on concrete using normal weight aggregate whose nominal
size does not exceed 3/4 inch. Two sets of tests for uniformity (slump, air content)
Range Between Highest and Lowest

Values of Three Test Samples
Accept if Equal to
Reject if
9.
or Less Than
More Than
Air Content (ASTM C231), percent
0.7
1.0
Slump (ASTM C143), inches
1.4
2.0
shall be carried out prior to a decision on the acceptance of the equipment under tests:
a.
Where the range in each set of tests is equal to or less than the acceptance limit, the
concrete will be considered uniform and accepted;
b.
Where the range of any single set of tests is greater than the rejection limit, the
concrete will be considered non-uniform and shall be rejected;
c.
Where the range of any single set of tests falls between the acceptance and
rejection limits, additional tests shall be made on the next consecutive batch or
load delivered by that unit. If the range of any single set of tests is then greater
than the acceptance limit, the concrete will be considered non-uniform and will be
rejected.
03360 - 10
Table 1 - Determination of Within-Batch Uniformity
Uniformity Test
Air Content (ASTM C231), percent
Slump (ASTM C143), inches
3.02
Range Between Highest and Lowest

Values of Three Test Samples
Accept if Equal to
Reject if
or Less Than
More Than
0.7
1.0
1.4
2.0
PRODUCTION OF CONCRETE
A.
Testing and Inspection Facilities: Provide a soundproof and dust-proof office for the Corporation
in the mixing plant with working space, heat, light, and telephone.
B.
Batching and Delivery Facilities: Provide facilities that conform to the requirements of ACI 301.
3.03
DEFECTIVE CONCRETE
A.
Concrete shall be considered potentially defective if the concrete cylinder test for any group of
segments fails to meet the specified strength. In such cases the concrete in that section may be
checked by the RE by core specimens drilled and tested in accordance with ASTM C42.
C.
If any core specimen has a compressive strength less than the specified strength, the RE shall
have the right to reject the defective group of segments. All costs, including coring, testing, and
replacing shall be borne by the Contractor even if further evaluation of the design allows the unit
to be classed acceptable.
D.
Failure to meet permeability resistance may be cause for concrete rejection.
E.
Failure to meet ionic diffusion and/or electrical resistance target values by a factor of 2 or more
may be cause for concrete rejection.
F.
Concrete will also be considered defective if it is structurally unsound, not watertight,

honeycombed or improperly finished, as determined by the RE. The RE shall have the right to
require replacement, strengthening or correction of the defective group of segments. All costs for
strengthening, demolishing, correcting, and replacing shall be borne by the Contractor.
END OF SECTION
03360 - 11
SECTION 03370
REINFORCEMENT FOR PRECAST CONCRETE TUNNEL LINING
PART 1 GENERAL
1.01
A.
1.02
SCOPE OF WORK
The Work specified in this Section includes, but is not limited to the requirements for the
supply, fabrication and installation of reinforcement cages for precast concrete tunnel lining
segments for the Tunnel Boring Machine (TBM) driven tunnel.
RELATED SECTIONS
A.
Tunneling by Tunnel Boring Machines is included in Section 02330.
B.
C.
Concrete for Precast Tunnel Lining is included in Section 03360.
D.
1.03
REFERENCE STANDARDS
A.
ACI 318/318R
B.
ASTM A496
Standard Specification for Steel Wire, Deformed, for Concrete

Reinforcement.
C.
ASTM A497
Standard Specification for Steel Welded Wire Fabric, Deformed, for

Concrete Reinforcement.
D.
ASTM A615
Standard Specification for Deformed and Plain Billet-Steel Bars for

Concrete Reinforcement.
E.
AWS D1.1
Structural Welding Code Steel.
F.
AWS D1.4
Structural Welding Code Reinforcing Steel.
G.
CRSI
Manual of Standard Practice.
1.04
1.05
SUBMITTALS
A.
At least 30 days before cutting, bending or fixing reinforcement, the Contractor shall submit
proposals for fabrication of reinforcement cages for the REs approval. The proposals shall
include the use and assembly of jigs and prefabrication of sections as necessary to ensure rapid
accurate assembly with positive means of achieving dimensional stability.
03370-1
B.
Shop drawings shall be prints of placing drawings, bar lists, quantities and bar bending details.
The shop drawings shall indicate the name of the fabricator of the bent bars and the name of the
bulk steel supplier and the steel grade.
C.
Certified copies of mill test reports for reinforcing steel and welded wire fabric, showing
physical and chemical analysis, minimum four weeks prior to commencing work.
D.
Test data verifying that the welding procedures develop the full strength of the connected bars.
E.
Welding certificates in accordance with AWS D1.1.
1.06
1.07
A.
Qualifications:
1.
B.
C.
The facility and welders used for welding reinforcing bar cages shall be certified in
accordance with AWS D1.1.
Shop Drawings:
1.
On placing drawings, indicate bar sizes, spacing, location and quantities of

reinforcement, with identifying code marks to permit correct placement without
reference to the structural drawings. Indicate sizes, spacings and locations of chairs,
spacers and hangers. Prepare reinforcing drawings in accordance with the CRSI
Manual of Standard Practice.
2.
All bars shall be provided full length; laps or mechanical splices shall not be accepted.
3.
Show embedments, bolt pockets, and other information that could affect bar
placements.
4.
Substitution of different size bars shall be permitted only upon written approval of the
RE.
Delivery, Storage and Handling:

1.
Reinforcing steel shall be stored off the ground and shall be kept free of mud, dirt, oil,
and contaminants that may adversely affect the performance of the bars. Comply with
ACI 318.
2.
Prefabricated sections shall be stored such that no deformation takes place.
3.
Reinforcing steel shall be stored and handled before, during, and after placement, in a
manner to prevent fouling with dust, grease, form release agents, and other bondbreaking coatings
03370-2
PART 2 PRODUCTS
2.01
MATERIAL
A.
Weldable Reinforcing Steel: Weldable low alloy steel bars, deformed with yield strength of
75ksi conforming to ASTM A496 unless indicated otherwise.
B.
Welded Steel Wire Fabric: Resistance welded in size and spacing shown on Contract Drawings
conforming to ASTM A497 for deformed wire fabric. Provide in flat sheets only.
C.
Cold Drawn Annealed Steel Wire Ties: Conforming to ASTM A82, minimum 0.06-inch
diameter, complete with coating for use with uncoated and coated reinforcing steel.
D.
Cast-in-Place Anchors in Concrete: Threaded or wedge type; galvanized ferrous castings, either
ASTM A 47/A 47M malleable iron or ASTM A 27/A 27M cast steel. Provide bolts, washers,
and shims as needed, hot-dip galvanized per ASTM A 153/A 153M.
2.02
FABRICATION
A.
Do not commence fabrication prior to review of placing drawings by the RE.
B.
Fabricate and bend reinforcing steel in accordance with CRSI Manual of Standard Practice and
in accordance with reviewed placing drawings.
C.
Bend bars cold and only where shown on placing drawings. No bent bar heat shall be permitted.
D.
Cutting and bending tolerances shall be sufficiently accurate to comply with placing tolerances
specified.
E.
Add stiffeners to the cage to prevent movement of the cage in the mold during casting and
during lifting and general movement of the cage.
F.
The Contractor shall demonstrate to the satisfaction of the RE that the reinforcement cage can
be lifted without damage or distortion.
2.03
TESTING
A.
A procedure for testing the strength of structural welded joints shall be submitted by the
Contractor before production begins.
B.
The strength of each structural welded joint shall meet or exceed that specified on the shop
drawings.
C.
During the Work, structural welded joints shall be tested at a rate of two tests per week. The
tests shall be carried out on test pieces taken from completed ladder mats selected by the RE.
03370-3
PART 3 EXECUTION
3.01
WELDING
A.
Bars shown on the placing drawings as being welded into structural mats shall be welded by a
resistance welding process in accordance with AWS D1.4.
B.
The strength of the structural welded joint shall exceed that of the smaller bar in the joint.
C.
There shall be sufficient welds in the cage to ensure that every bar is electrically connected to
every other bar in the cage.
3.02
PLACING
A.
Prior to installation of reinforcing steel, carefully inspect the molds, recess formers, and inserts,
and verify that such work is complete to the point where the installation of reinforcing may
commence.
B.
Place reinforcing steel as shown on the approved placing drawings and in accordance with ACI318/318R.
C.
Minimum cover to reinforcing steel shall be as shown on the placing drawings.
D.
Do not eliminate or displace reinforcement to accommodate hardware to be embedded in

concrete.
3.03
A.
CLEANING
Ensure that reinforcing steel is free from loose mill scale, excessive rust, dirt, oil, or paint.
END OF SECTION
03370-4
SECTION 03380
SHOTCRETE (Optional)
PART 1 - GENERAL
1.01
A.
1.02
A.
SECTION INCLUDES
Requirements for furnishing all labor, materials, tools and equipment, testing, and performing all
operations necessary for the production and application of shotcrete, by the wet-mix method, to
the specified thickness at the locations indicated on the Contractors approved Shop Drawings
and specified herein if chosen by Contractor for use in conjunction with shaft and tunnel breakout/break-in using ground freezing and/or temporary earth support.
REFERENCED SECTIONS
Related Sections: The work of the following Sections is related to the work of this Section. Other
Sections, not referenced below, may also be related to the proper performance of this work. It is
the Contractors responsibility to perform all the work required by the Contract Documents.
1. Section 03000: Concrete
2. Section 03200: Concrete Reinforcement
3. Section 02380: Ground Freezing
1.03
A.
CITED STANDARDS
Referenced Standards: This Section incorporates by reference the latest revision of the following
documents. These references are a part of this Section as specified and modified. In case of
conflict between the requirements of this Section and those of a listed document, the requirements
of this Section shall prevail.
Reference
Title
ASTM A82
ASTM A185
ASTM A615
ASTM C31
ASTM C33
ASTM C39
ASTM C42
Steel Wire, Plain, for Concrete Reinforcement

Steel Welded Wire Fabric, Plain, for Concrete Reinforcement
Deformed and Plain Billet steel Bars for Concrete reinforcement
Methods of Making and Curing Concrete Test Specimens in Field
Concrete Aggregates
Methods of obtaining and Testing Drilled Cores and Sawed Beams of
Concrete
Flexural Strength of Concrete (Using Simple Beam with Third point
Loading)
Ready Mix Concrete
Standard Test Method for Compressive Strength of Hydraulic Cement
Mortars
Sieve Analysis of Fine and Coarse Aggregates
Standard Specification for Portland Cement
Making and Curing Concrete test Specimens in the Laboratory
Air-Entraining Mixtures for Concrete
Time of Setting of Hydraulic Cement Paste by Gillmore Needles
ASTM C78
ASTM C94
ASTM C109
ASTM C136
ASTM C150
ASTM C192
ASTM C260
ASTM C266
03380-1
ASTM C309
ASTM C494
ASTM C566
ASTM C618
ASTM C685
ASTM C1140
ASTM C1141
ASTM C1240
ASTM C1436
ACI 506R
ACI 506.2
ACI 506.3R
1.04
A.
Liquid Membrane Forming Compounds for Curing Concrete

Chemical Admixtures for Concrete
Total Moisture Content of Aggregate by Drying
Coal Fly Ash and raw or Calcined Batching natural Pozzolan for Use as
a Mineral Admixture in concrete
Concrete Made by Volumetric Batching and Continuous Mixing
Standard Practice for Preparing and Testing Specimens from Shotcrete
Test panels
Standard Specification for Admixtures for Shotcrete
Standard Specification for Silica Fume Used in Cementitious Mixtures
Standard Specification for Materials and Shotcrete
Guide to Shotcrete
Materials, Proportioning, and Application of Shotcrete
Guide to Certification of Shotcrete Nozzlemen
QUALITY CONTROL
Contractor Qualifications:
1. The shotcreting work shall be performed by a contractor with a minimum of five years
experience in performing shotcrete work under similar conditions.
a. Provide operators qualified to perform work conforming to requirements of ACI 506R
and 506.3R.
b. Operators of equipment for mixing and application of shotcrete shall be experienced with
minimum five years of experience in operation of similar equipment in the wet-mix
process.
c. The foreperson in charge of the shotcrete operation shall have a minimum of five years
experience of shotcreting application on projects of a similar character, two years of
which shall be as a nozzleperson.
d. Applicants for shotcrete nozzleperson should be certified to ACI C660 for application of
shotcrete to vertical and overhead surfaces for both wet and dry-mix shotcrete. The
nozzleperson shall have served at least six months of apprenticeship of similar
application and or have succefully completed three projects of similar character to this
contract. The nozzleperson shall be able to demonstrate by tests the ability to
satisfactorily gun shotcrete of the required quality before beginning production work.
2. A contractor not meeting the requirements of paragraph 1 herein above shall hire a
shotcreting consultant with a minimum of five years related experience under similar
conditions and who shall be present on a full time basis to monitor and supervise the
shotcreting operation. Hiring a shotcreting consultant will not absolve the contractor of the
requirements to certify the nozzlepersons.
B.
Regulatory Requirements: OSHA safety requirements for working platforms or lifting equipment,
handling shotcrete and admixtures, and spraying shotcrete.
C.
Allowable Tolerance: Thickness of individual layers and tolerances shall be as indicated on the
Contractors approved Shop Drawings.
D.
Mix Design criteria:
03380-2
1. Develop shotcrete mix by laboratory compatibility tests and field trials as specified in Section
1.05E at least 60 days before the actual application of shotcrete.
2. Impact of frozen earth should be considered by Contractor in developing shocrete mix,
performing tests, and application methods prior to RE approval.
3. Perform compatibility tests to determine cements and additives to be used in field trial mixes.
Determine initial and final set time for additive concentrations of varying percentages of
cement content by weight contemplated for use in the work.
4. Proportions of the shotcrete mix shall be equivalent to those of a concrete mix having
between 6.5 and 8.5 bags of cement per cubic yard.
5. Make laboratory and field trial mixes with ingredients identical to those proposed for use in
the work.
6. Ascertain compatibility of ingredients and optimum proportions by developing shotcrete
mixes that have strength and characteristics necessary for actual application.
7. Certification that the ingredients comply with the specifications shall accompany the mix
design.
8. Use approved accelerating admixtures to develop maximum initial and final setting time of 3
and 12 minutes, respectively.
a. Determine time of setting in accordance with ASTM C266 with the following
requirements:
b. Add accelerator to 50 grams of cement in preparation of the paste, together with water to
produce water-cement ratio in varying percentages expected to be used in actual shotcrete
application.
c. Use minimum possible time interval to attain proper mixing without disturbing initial set
of paste.
9. Standard Concrete Cylinder Tests: Choose materials and proportions so that three cast
cylinders, six inches by twelve inches, made with no additives will achieve average minimum
strength at 28 days of 7000 psi. Cast cylinder in accordance with ASTM C192 and test in
accordance with ASTM C39. Cast and test minimum of three cylinders for each combination
of materials proposed.
E.
Field Trials
1. After completion and review of the laboratory tests and approval by the RE, make field trials
using selected mixes to prove capability of equipment, workmanship, and material under field
conditions before actual application of shotcrete.
2. The RE will inform the Contractor, in writing, of his acceptance of the laboratory mixes that
meet the requirements. No shotcrete mix shall be used in field that has not been accepted by
the RE.
3. The exact proportions of ingredients determined based on the trial mixes shall be used in the
actual application of shotcrete and shall not be varied without the written approval of the RE.
03380-3
4. Make field application of each mix selected for field trial on at least three vertical test panels
to simulate construction condition. Preparation and testing of test panels shall comply with
ASTM C1140, except as specified otherwise.
5. All pre-construction test panels shall be at least 20204-1/2. Panels shall be made with
sloped sides.
6. Pre-construction shotcrete shall be gunned in the same position as the work represented. All
panels shall be prepared in the presence of the RE. Panels shall be gunned during the course
of the work by the Contractors regular nozzleperson. After fabrication, test panels shall be
covered and sealed to prevent moisture loss in the same manner as work represented. Label
panels with Contractors name, job number, date and time shot, name of nozzleperson,
shotcrete mix and any additives used and any other pertinent data.
7. Within 24 hours after shooting, obtain and submit a minimum of seven full depth, 3
diameter cores for each panel.
8. Average three cores from each panel to comprise one test.
9. The compressive strength of cores will be evaluated in accordance with ASTM C39.
10. Perform field trial work in presence of the RE.
11. The test specimens shall be prepared in accordance with ASTM C42, except as otherwise
specified. Soaking of specimens before testing is prohibited.
12. Achieve strength as follows:
a.
b.
c.
d.
Average compressive strength of three tests at 24 hours: 2000 psi

Average compressive strength of three tests at three days: 2500 psi
Average compressive strength of three tests at seven days: 4500 psi
Average compressive strength of three tests at 28 days: 6000 psi
13. Nozzleperson Qualification: Produce test panels for each nozzleperson and anticipated
shooting orientatin.
a. Provide test panels wit/without that produces the thickness and most congested area
specified for the structure as specified by RE.
b. Test panels shall be shot using the same nozzleprson, assistant, and equipment that will
be used under the Contract, and with each of the approved concrete mix design and at
orientations to be used under the Contract.
c. Shotcrete used shall be within 1/2 inch of the design slump.
d. Test panels for nozzleperson qualification shall not be shot until the shotcrete mix is
approved.
1.05
A.
SUBMITTALS
Documentation: Before making laboratory compatibility tests, submit detailed plan showing
methods and proportions to be used in such tests. The RE may inspect tests and materials at any
03380-4
time.
B.
Submit notification of pre-construction test panel application 48 hours in advance and deliver test
panels for examination, testing and approval in accordance with Section 1.05.
C.
Samples: On completion of field trial, submit 42 test specimens of each trial mix, seven from
each panel, proposed for use in the work together with relevant data that demonstrates
conformance with specified requirements. These specimens shall be tested by an approved
laboratory under supervision of RE.
D.
Submit to the RE a certification of source of raw materials, certificates of analysis for all cement
to be used, and manufacturers certificates with mix design verifying that materials meet specified
requirements.
E.
Certified test reports without adjustment for type or size of specimen.
F.
Submit documents indicating experience of entity performing the work in previous projects
involving similar types of work in quantity and complexity in accordance with Section 1.05.
G.
Submit documents indicating qualification required for the nozzleman in accordance with Section
1.04.
H.
Submit list of equipment to be used in performing required tasks in Section 1.05 and for
production and application of shotcrete.
I.
Details of proposed methods for control and disposal of waste materials, including waste
shotcrete, rebound and overspray.
J.
Submit methods of storage, transporting, batching and mixing materials.
1.06
A.
PROJECT CONDITIONS
In applying shotcrete containing toxic admixtures, the nozzlepersons and helpers shall wear
appropriate hoods supplied with filtered air free of toxic or objectionable material. Gloves and
necessary protective clothing also shall be worn to protect against dermatitis.
PART 2
2.01
A.
2.02
A.
PRODUCTS
CEMENT
Cement shall be Portland cement in accordance with ASTM C150, Type II.
FINE AGGREGATE
For job site mixing, the aggregate shall conform to ASTM C33 with the exception that the
gradation of both sand and coarse aggregate shall be as specified in ACI 506.2. When damp sand
is used, care shall be exercised that the mix is used in the shotcreting process before hydration of
03380-5
B.
2.03
A.
2.04
cement has rendered the mix unsuitable for placement.

Lightweight aggregate: not permitted.
WATER
Water shall be clean and free of oil, salt, acid, alkali, sugar, plant material, or other substances
injurious to the finished product. Water known to be of potable quality may be used without test.
ADMIXTURES
A.
Concrete admixtures such as water reducing superplasticizers, accelerators, and retarders shall
conform to ASTM C1141. The admixtures shall not contain water soluble chlorides or materials
corrosive to steel and shall not result in other detrimental effects such as cracking or spalling.
Admixtures that reduce the sulfate resistance of shotcrete such as aluminum salts, chlorides, or
nitrate shall not be used. Contractor shall obtain documentation that the proposed admixtures
have demonstrated satisfactory experience in a shotcrete mix of similar proportions.
B.
Air entraining admixtures shall conform to ASTM C260.
C.
Pozzolan materials shall conform to ASTM C618, Class C or F.
D.
Curing Material-Liquid Membrane if required shall conform to ASTM C309 Type 2, Class B
materials.
2.05
PROPORTIONING AND MIXING
A.
If wet-mix shotcrete is transit mixed (truck supplied) it shall conform to provisions of ASTM
C94.
B.
If wet-mix is volume batched and mixed on site it shall conform to provisions of ASTM C685.
C.
In either case, mixes must meet the following strength requirements:

1. Compressive strength as measured by core tests conforming to ASTM C42:
a. Three days: 2500 psi
b. Seven days: 4500 psi
c. Twenty eight days: 6000 psi
2. Flextural strength as measured by core tests conforming to ASTM C78:
a. Three days: 400 psi
b. Twenty eight days: 600 psi
PART 3 - EXECUTION
3.01
A.
EXAMINATION OF SUBSTRATE SURFACES

Examine earth, rock, concrete, and masonry substrate surfaces, as applicable, and determine that
03380-6
such surfaces have been properly prepared.

B.
3.02
Proceeding with shotcrete placement shall imply acceptance of substrate surfaces and conditions
as satisfactory.
PREPARATION OF SUBSTRATE SURFACES
A.
Prepare earth, rock, concrete, and masonry substrate surfaces as applicable in accordance with
ACI 506R, and ACI 506.
B.
Rock surfaces shall be free of loose rock.
C.
To avoid negative impact of frozen soil on shotcrete quality Contractor shall provide appropriate
thickness of sacrificial shotcrete on frozen earth prior to shotcrete within the time designated.
The required sacrificial shotcrete thickness and timing of placement shall be determined by
Contractor and approved by RE.
D.
Drain any freestanding water away from shotcrete operation.
E.
Thickness Pins: Thickness pins shall be used to establish layer thickness and surface plane,
provided such pins do not detrimentally damage substrates. Install pins on 5 foot centers in each
direction.
F.
Shotcrete shall be prepared and applied in accordance with ACI 506R and ACI 506.2.
G.
Enforce personnel safety rules in all areas where shotcrete is to be applied, including dust
protection. As a minimum, nozzlepersons and helpers shall wear gloves, safety glasses,
respirators, and adequate protective clothing during the application of shotcrete.
3.03
EQUIPMENT
A.
Shotcrete equipment shall conform to ACI 506R, Chapter 3. All equipment shall be operated,
tested, and maintained in accordance with the manufacturers instructions. Shotcrete shall be
prepared by the wet mix process.
B.
Aggregate and cement may be batched by weight or by volume. If volumetric batching is used, a
minimum of one weight batching check shall be made every seven operating days to insure that
the specified design mix is being achieved. Weighing equipment shall be capable of batching
with the accuracy specified in ASTM C685. Ready-mix shotcrete complying with ASTM C94 is
acceptable for application by wet-mix process.
3.04
A.
APPLICATION
Operation and Placement Standards. Shotcrete operations and placement shall conform to the
applicable requirements of ACI 506R, Chapter 8, and ACI 506.2, Article 3.3.
B.
Shotcreting shall be suspended if high wind affects application operations, air temperature
approaches freezing and shotcrete can not be protected, or rain would wash out the shotcrete.
C.
Place shotcrete only after the surface preparation is approved by the RE.
D.
Place shotcrete only in the presence of and by methods approved by the RE.
03380-7
E.
In placing the shotcrete, the nozzle of the gun shall be held in a position as nearly as possible at
right angles to the surface against which the shotcrete is to be placed and approximately 3 feet
away from the work face.
F.
The shotcrete should flow from the nozzle in a steady uninterrupted flow. If the flow becomes
intermittent, it should be directed away from the work area until it becomes steady again.
G.
Build each layer by making several passes over the working area. Thickness of each layer shall be
determined by the requirement that sagging of shotcrete shall not occur. Any areas exhibiting
sagging or sloughing shall be carefully removed and replaced without disturbing the adjacent
material.
H.
Where succeeding layers are to be placed, and the first layer has reached its initial set, any
laitance or rebound should be removed by brooming or low pressure air. Any laitance or rebound
that cannot be removed by brooming or low pressure air shall be removed by sand blasting,
followed by low pressure air-water washing. Prior to placing succeeding layers, the underlying
layer shall be thoroughly wetted.
I.
Rebound that may accumulate at the base of the work area shall not be salvaged and reused for
work of this Section but shall be collected and disposed of by the end of the work shift in which it
was created as described in Section 13140.
J.
Unless otherwise directed, pins, or other gauging devices shall be installed by Contractor in the
surface to be shotcreted as a method of positively demonstrating that the required thickness has
been obtained. Such pins shall be located at a center to center spacing of approximately 5 feet.
The pins shall be non-corrosive and shall be so designed as to prevent infiltration of water
through the shotcrete. If the shotcrete is placed in two layers, the shotcrete that accumulates on
the thickness control pins during the first placement shall be cleared off before it is allowed to set.
K.
Every effort should be made to apply shotcrete to the full layer thickness at an individual location
prior to ceasing work at that location. In the event that a construction joint or end of workday
joints are required, joints shall be sloped off to a thin, clean regular edge, preferably at 45 degree
slope. Before placing adjoining work, the sloped portion and adjacent shotcrete shall be
thoroughly cleaned, then moistened, and cured with an air jet.
L.
Unless otherwise shown on the drawings, provide a natural gun finish.
3.06
ADJUSTMENTS
A.
Touch up and restore finished surfaces where damaged by shotcreting.
B.
Remove spilled, splashed or splattered shotcrete from all surfaces.
C.
Remove and replace all shocrete as directed by RE, which lacks uniformity, or exhibits
segregation, honeycombing or delamination, or which contains dry patches, slugs, voids, or sand
pockets.
3.07
A.
CURING AND PROTECTION

When a membrane-forming curing compound is used, it shall be applied at a rate meeting the
03380-8
moisture retention requirement of ASTM C309. Curing compounds shall be applied immediately
after the shotcrete has been placed and finished in a manner that would not disrupt the bond to the
substrata. Curing compounds shall not be applied to shotcrete where additional layers of shotcrete
will be placed later. When a latex material material has been added to the shotcrete mix only a
water based curing compound shall be used.
B.
When a curing compound is not used, wet curing by using fog nozzles, wet burlap, or soaker
hoses shall be maintained for at least seven days or until 70% of compressive strength of
shotcrete is obtained.
1. Wet curing with burlap shall be permitted only when the ambient temperature at the surface
of placement is 40 degree Fahrenheit and is rising.
2. Burlap, if used shall be lapped at edges and ends at least 4 inches and it shall be kept
continuously wet for full curing period.
3. Paper quilt, polyethylene fil or burlap polyethylene sheet, if used, shall be lapped at edges
and ends at least 4 inches and shall have all ends and edges taped to adjacent sheets or
surfaces to completely seal areas to be cured.
4. Before reusing any sheet material, it shall be inspected by the Contractor and all holes or tears
shall be repaired with cemented patches subject to approval of RE.
3.08
A.
TESTS AND INSPECTIONS

Inspection
1. Provide temporaray working platform or suitable lifting equipment meeting OSHA and other
applicable safety requirements for carrying out this inspection.
2. Visual inspection of the shotcrete work, including equipment, materials, forms, embedded
items, placement, finishing, curing, and protection of the finished product will be performed
and recorded by RE.
3. RE can instruct to perform core samples and testing at locations determined by him/her
4. Surfaces may be sounded using a hammer to locate drummy or hollow sounding areas
resulting from rebound pockets or lack of bond. Such hollow sounding areas, voids, sags, and
other defects shall be carefully cut and replaced with succeeding layer.
B.
Quality Control Tests:

1. Test Panels:
a. From each 50 cubic yard of each shotcrete mix, or fraction, thereof, applied in the work
by each crew in each shooting position, fabricate four unreinforced test panels, each 20
inches square and 4 inches thick. Fabricate test panels in accordance with ACI 506.2,
Article 1.6. Properly cure test panels in accordance with ASTM C31 and ACI 506.2.
b. Test panels will be tested and visually examined. Strength of shotcrete will be considered
acceptable when the average of the strength tests, as well as the average of three
consecutive strength tests, representing each shotcrete mix, equals or exceeds the
required 28 days compressive strength tests, and no individual strength test falls below
the required 28 day strength by more than 300 psi. Strength tests will be performed in
accordance with ASTM C42.
c. Adjustments to the mix proportions, requalification of the shotcreting crew, or additional
curing of the shotcrete may be required if either:
1)
The average seven day strength of any two specimens for the shotcrete mix is less
03380-9
2)
than 70 percent of the specified 28 day strength, (three days for highly-early
strength design); or
The average 28 day strength of any two specimens for the shotcrete mix is less than
100 percent of the specified 28 day strength.
2. Test Cores:
a. Should the test panels indicate that shotcrete not meeting the specified requirements has
been produced, Contractor shall take test cores from the areas represented by the test
panels, to determine compliance of the in place shotcrete with the specified requirements.
b. Test cores shall be obtained and tested in accordance with ASTM C42.
c. Three cores shall be taken for each determination of in place strength. Shotcrete in the
area represented by the core tests shall be considered structurally adequate if the average
of the three cores is equal to the least 85 percent of the specified design strength and no
single core less than 75 percent of the design strength. Locations represented by erratic
core strengths shall be retested.
d. Fill core holes with low slump concrete or mortar of same wet-mix design as the placed
shotcete.
C.
Evaluation of in-place shotcrete

1. Remove and replace shotcrete that is delaminated, exhibits laminations, voids, or sand
pockets exceeding the limits for the specified grade of shotcrete. Remove and replace
shotcrete that does not comply with the specified material properties. Repair core holes in
accordance with Chapter 9 ACI 301 and 3.08 B.2.d above. Do not fill core holes in
permanent shotcrete by shooting.
D.
Acceptance
1. RE has the authority to accept or reject shotcrete work. Shotcrete which does not conform to
the Specifications may be rejected either during the shotcrete application process, or on the
basis of tests from either test panels or the completed work.
2. Deficiencies observed during the shotcrete application such as, but not limited to, the
following constitute a cause for shotcrete rejection:
a. Failure to properly control and remove build-up of overspray and rebound;
b. Incorporation of sand lenses, excessive voids, delaminations, sags or sloughing;
c. Failure to apply shotcrete to the required line and grade tolerance.
3. Wherever possible perform remedial work to correct deficiencies while shotcrete is still
plastic.
4. Hardened shotcrete will be examined by RE for any evidence of excessive plastic or drying
shrinkage cracking, tears, feather-edging, sloughs or other deficiencies.
5. If results of compliance tests from shotcrete panels, or assessment of the plastic or hardened
shotcrete indicate non-conformance of the shotcrete, RE will implement a program of
evaluation of the in-place shotcrete. Such evaluation shall include, but not limited to:
a. Extraction of cores from in-place shotcrete at locations selected by RE and testing of such
cores for compliance.
03380-10
b. Checking for delaminations using sounding or other appropriate non-destructive testing

procedures.
6. Rejected shotcrete shall be removed and new shotcrete support rebuilt to the satisfaction of
RE at no cost to Corporation.
END OF SECTION
03380-11
SECTION 03410
PRECAST CONCRETE
PART 1 GENERAL
1.01
SCOPE OF WORK
A.
The Work specified in this Section includes, but is not limited to: the design, manufacture,
delivery and placement of all precast concrete units indicated on the Contract Drawings for shaft
access chambers. The Contractor is responsible for confirming all measurements to ensure that
the finished units will fit into the complete construction.
B.
The requirements of this Section do not apply to the production of the precast concrete tunnel
lining.
C.
It is the responsibility of the manufacturer to produce precast concrete units of the quality and
strength specified, and from the concrete mix designed to suit the manufacturing and project
requirements.
D.
The use of admixtures to prevent weathering or increase workability is acceptable provided that
such admixtures do not cause any deleterious effect to the finished surfaces or the concrete
strength.
1.02
RELATED SECTIONS
A.
B.
C.
1.03
REFERENCE STANDARDS
A.
ACI 301
Standard Specifications for Structural Concrete
B.
ACI 318
Building Code Requirements for Structural Concrete and Commentary
C.
ASTM A185
Standard Specification for Steel Welded Wire Reinforcement, Plain, for

Concrete
D.
ASTM A615
Standard Specification for Deformed and Plain Carbon-Steel Bars for

Concrete Reinforcement
E.
ASTM C31
Standard Practice for Making and Curing Concrete Test Specimens in the
Field
F.
ASTM C33
Specification for Concrete Aggregates
03410 - 1
G.
ASTM C39

Specimens
H.
ASTM C97
Standard Test Methods for Absorption and Bulk Specific Gravity of

Dimension Stone
I.
ASTM C138
Standard Test Method for Density (Unit Weight), Yield, and Air Content
(Gravimetric) of Concrete
J.
ASTM C143
Standard Test Method for Slump of Hydraulic-Cement Concrete
K.
ASTM C150
Standard Specification for Portland Cement
L.
ASTM C260
Specification for Air-Entraining Admixtures for Concrete
M.
PCI MNL-116
Manual for Quality Control for Plants and Production of Structural Precast
Concrete Products.
N.
PCI MNL-120
PCI Design Handbook Precast and Prestressed Concrete.
O.
PCI MNL-123
Design and Typical Details of Connections for Precast and Prestressed

Concrete.
1.04
A.
1.05
DEFINITIONS
Precast Manufacturer: Manufacturer of precast units with qualifications that meet the
requirements defined in these Specifications.
SUBMITTALS
A.
All shop drawings, design data, product data, samples, concrete mix design, tests or other data
are to be submitted by the Contractor to the RE for review and approval prior to constructing the
precast units.
B.
Shop Drawings: Submit Shop Drawings prior to constructing any units showing the following:
1.
Detailed drawings of panels, members, openings, and components showing

dimensions and sections of each.
2.
Quantities, dimensions, and locations of sleeves, anchors, brackets, inserts, reinforcing

steel, lift devices, accessories, and methods of securing same in forms.
3.
Casting, consolidating, and finishing procedures.
C.
Design Data: Submit design data report indicating calculations for loadings and stresses of
precast units signed and sealed by a Licensed Professional Engineer licensed in the State of
New York. The signed and sealed design documents will be submitted to the RE for review and
approval prior to manufacturing any units for inclusion in the Work.
D.
Product Data: Submit manufacturers product data of manufactured products and accessories.
Include manufacturers detailed drawings and dimensions when applicable.
03410 - 2
E.
Samples: Submit sample of concrete with specified finish, 12 inches by 12 inches or larger in
size as appropriate.
F.
Concrete Mix Design: The Precast Manufacturer, through the Contractor, shall submit the
concrete mix design to the RE for review and approval. The RE must be notified in advance of
any changes to be made in the design mixes during production.
G.
Quality Plan: The Contractor shall provide a quality control plan to ensure uniformity of
materials, conformance with accepted mix designs, and compliance with these Specifications.
1.06
A.
1.07
DELIVERABLES
Certificates:
1.
Submit evidence of current plant certification under the PCI Plant Certification
Program or approval by the International Conference of Building Officials (ICBO).
2.
Submit manufacturers certifications of compliance for materials as required by PCI

MNL-116.
3.
For welders, furnish welding certificates or affidavits attesting to the welders

qualifications to perform the indicated and specified welding.
A.
Manufacture precast concrete units in accordance with PCI MNL-116, and applicable
requirements of ACI 318.
B.
Qualifications of Fabricator:
1.
Fabricator of precast concrete products shall be an active and approved participant in

the PCI Plant Certification Program or an ICBO-approved precast fabricator.
2.
Precast concrete work shall be produced in a plant or production facility by a

fabricator who has been regularly and continuously engaged in the manufacture of
precast concrete products.
C.
Qualifications of Welders: Welders shall be prequalified in accordance with AWS D1.1 or

AWS D1.4, as applicable to the work.
D.
Control Samples: All finishes and colors shall match the REs control samples. Control samples
require the REs approval before they may be used as a standard.
1.08
DELIVERY, STORAGE, AND HANDLING
A.
The manufacturer is to protect each precast unit from time of fabrication until it is erected in its
proper place in the structure. After erection, the protection of the precast units becomes the
B.
Precast units are to be handled, transported and stored in a manner to avoid undue strains,
cracking, staining, or other damage. Damaged or defective units are to be repaired or replaced as
03410 - 3
directed by the RE. Units are to be delivered from the plant to the project site in accordance
with the project schedule and installation sequence.
PART 2 PRODUCTS
2.01
MATERIALS
A.
Each material used in the precast concrete units is to be from one source and to match
consistently throughout. The workmanship, color and texture of the precast units is to match the
approved samples.
B.
Precast concrete is to meet the following design criteria:

1.
Cement is to be Portland Cement Type II and conform to ASTM C150-97a,

Specification for Portland Cement.
2.
Fine aggregates are to be natural or manufactured sand, conforming to ASTM C33-97,

Specification for Concrete Aggregates.
3.
Coarse aggregate is to be gravel or crushed stone conforming to ASTM C33-97.
4.
Reinforcement is to be steel wire fabric conforming to ASTM A185-97,

Specification for Steel Welded Wire Fabric, Plain, for Concrete Reinforcement,
70,000 psi yield, or Specification for Deformed and Plain Billet Steel Bars for
Concrete Reinforcement, ASTM A615-96a grade 60, 60,000 psi yield strength.
5.
Mixing water is to be clean and free of any acid, alkali, oil or organic material that
may interfere with the setting of cement.
6.
Air entraining admixtures are to conform to Specification for Air-Entraining

Admixtures for Concrete, ASTM C260 01 and produce between 3 and 5 plus or
minus 1 percent air content by volume when tested in accordance with ASTM C138
01a, Test Method for Unit Weight, Yield, and Air Content (Gravimetric) of
Concrete.
7.
All bearing shims for precast units are to be high impact fire resistant plastic.
8.
Except where other materials are indicated or specified, all metal anchors, dowels,
clamps, inserts, clip angles, anchor plates, bolts, edge channels and other fastening
devices and accessories are to be hot dipped galvanized, cadmium plated or painted.
9.
Wedge inserts are to be Catalog No. 425.6 as manufactured by Heckmann Building

Products, or equal. Wedge inserts are to be of the heavy-duty malleable iron type,
have wedge-shaped holding faces, and be sized for minimum 3/4 diameter askew
head bolts. All wedge inserts are to be provided with holes for nailing to forms.
Wedge inserts are to be installed in precast concrete elements on maximum 2-8
centers, unless a lesser spacing is necessary to meet to the manufacturer's published
allowable working load requirements.
03410 - 4
PART 3 EXECUTION
3.01
GENERAL
A.
The first unit of each type cast is to be subject to the REs inspection at the manufacturers
plant. Approved units are to serve as models for the remainder of the work and be incorporated
in the structure when no longer needed as models.
B.
Examine all parts of the supporting structure and the conditions under which the precast
concrete units are to be erected and installed. Verify the locations of anchors to pre-determine
the accuracy of the installation of each member. Verify site conditions are ready to receive work
and field measurements are as indicated on shop drawings.
3.02
CONCRETE
A.
The specified compressive strength of concrete at 28 days is to be 6,000 psi when tested in
accordance with ASTM C39 96, Test Method for Compressive Strength of Cylindrical
Concrete Specimens.
B.
The water-cement ratio is to be kept to a minimum and the concrete slump is not to exceed 3
when tested according to ASTM C143 03, Test Method for Slump of Hydraulic Cement
Concrete.
C.
Water absorption is not to exceed 5% when tested in accordance with ASTM C97 02, Test
Methods for Absorption and Bulk Specific Gravity of Dimension Stone.
D.
All concrete is to be mixed in a mixer that will distribute the coarse and fine aggregate evenly
throughout the mix. Each batch is to be mixed in proportion by weight.
E.
Concrete is to be handled, conveyed, and placed in the forms by methods that will prevent
segregation of the aggregates. Concrete is to be placed in the form so as not to distort the
reinforcing.
F.
Concrete is to be consolidated in the form by a method of high frequency impact type vibration
to the shape, configuration, and dimensions indicated. Finished products must be free of any
honeycombing or voids.
3.03
CONCRETE TESTING
A.
The Contractor is to pay for all work associated with testing of materials and casting and testing
of cylinders under this section. All test specimens are to be taken from the actual mixes used in
fabrication of the units and are to be tested in accordance with the latest applicable ASTM
Standards in an approved Independent Testing Laboratory. Reports of all tests are to be
submitted to the RE for review and approval. The Corporation is to select the Independent
Testing Laboratory.
B.
A set of five (5) standard test cylinders is to be made for the first precast concrete unit of each
type. Thereafter, a set is to be made for each 25 cubic yards of concrete or less placed in one
day. Three test cylinders of each set are to be tested at 7 days and the other cylinders at 28 days.
Slump tests are to be made for each batch of concrete.
03410 - 5
C.
The sampling, storing and testing of concrete cylinders is to be in accordance with ASTM C172
99, Practice for Sampling Freshly Mixed Concrete, ASTM C138 01a, Test Method for Unit
Weight, Yield, and Air Content (Gravimetric) of Concrete, ASTM C31 96, Practice for
Making and Curing Concrete Test Specimens in the Field and ASTM C39 96, Test Method
for Compressive Strength of Cylindrical Concrete Specimens. Test cylinders below the
required strength will be cause for rejection of the corresponding precast units.
D.
Take two slump tests for every set of test cylinders in accordance with ASTM C143.
3.04
FABRICATION
A.
Forms shall be accurately constructed to produce members to dimension, shape, configuration,

and profile indicated. When not otherwise indicated, construct forms to produce smooth
concrete.
B.
Finishes: Provide finishes for exposed concrete matching approved samples. All precast
products are to have form marks removed using a carborundum stone. The finish surface is to be
bagged using burlap to present a smooth textured and uniform appearance.
C.
Markings: Provide permanent markings in precast units to identify orientation in the structure,
conforming with the markings indicated on Shop Drawings. Imprint the date of casting on each
precast unit where it will not show in the finished structure.
D.
Forms are to be braced and reinforced adequately to withstand, without distortion, all stresses
caused by casting. Form surfaces constructed of absorptive material are to be coated or lined to
produce a non-absorptive surface.
E.
Non-circular precast units are to be of the sizes and shapes indicated on the Drawings. Precast
units shall be designed to withstand soil pressures based on finished grade elevations shown on
the Contract Drawings and shall be designed for a H-20 live load in accordance with AASHTO
specifications. The finished units are to be straight and true with all edges sharp, straight, and
square, and all flat surfaces in a true plane.
F.
Below grade circular precast units shall be designed as per ASTM C478-03a, Standard
Specification for Reinforced Concrete Precast Manhole Sections. Base slab and top slab design
calculations, signed and sealed by a Professional Engineer, licensed in the state of New York,
shall be submitted for all precast manholes.
G.
It is the responsibility of the Precast Manufacturer to carefully engineer the entire reinforcement
assembly. This includes calculations of all stresses and strains due to temperature changes,
erection loads, panel weights, handling, and lifting.
H.
Reinforcing assemblies in all units are to be prefabricated and welded or tied into single units of
proper size and shape. All steel reinforcement is to be kept a minimum of from the edges
and surfaces of precast units.
I.
Concrete reinforcement, lifting devices, clips, concrete inserts, anchorage devices, and devices
for handling and installing precast units shall be placed and secured against movement as
required. Sleeves or special items required in precast units for use by other trades are to be
supplied and located by those trades prior to fabrication of the unit.
03410 - 6
J.
Handling and conveying precast units while curing is to be kept to a minimum and be done by
means of equipment that will avoid bending and shock which might produce incipient cracks or
other defects.
K.
Precast units are to be form-cured for a minimum of 12 hours under conditions to develop
required concrete quality, and minimize appearance blemishes including non-uniformity,
staining, or surface cracking. Temperatures during the curing period are to be maintained at a
minimum of 70 plus or minus 5 degrees F. Following this period, the units are to be allowed to
cure for at least 7 days before shipping.
L.
Failure of the precast concrete manufacturer to meet any of the above requirements is to be
cause for rejection of the product by the RE.
3.05
A.
B.
3.06
TOLERANCES
The casting, camber and dimensional tolerances for precast units are to be maintained in
accordance with the following:
1.
Thickness of unit for below grade elements: Plus 1/4 or minus 0 total.
2.
Overall dimension of length, width, or diameter measurements of below grade units

shall be as follows:
Dimension
Tolerance
0 5
Plus or minus 1/4
5 10
Plus or minus 3/8
10 20
Plus or minus 1/2
3.
Maximum variation from intended camber: Not to exceed 3/32 in any direction.
4.
Maximum misalignment of anchors, inserts or openings: Plus or minus 1/8.
Precast concrete units are to be cast in forms of rigid construction maintaining dimensions
within a tolerance of plus or minus 1/4. The forms are to be accurate in all details with sharp
arises and corners throughout.
INSTALLATION AND SETTING OF PRECAST CONCRETE
A.
Transport and erect precast concrete units in accordance with PCI MNL-116 and as specified
herein.
B.
An experienced representative of the Precast Manufacturer is to supervise the entire installation

of this work, when such supervision is deemed necessary by the RE.
C.
All precast work is to be accurately set in its assigned position, carefully plumbed and aligned
and securely anchored to the structure in accordance with the approved details. Erection is to be
by the Precast Manufacturers personnel skilled in this type of work.
03410 - 7
D.
The Precast Manufacturer is to furnish and install all loose shims, wedges, leveling plates, etc.,
for the support and bearing of precast units where needed.
E.
All precast units are to be delivered to the project site in the cleanest condition possible. During
installation, the utmost care is to be directed to prevent staining or marring of the precast units.
Upon completion of erection, the precast work is to be left clean. Final cleaning at a later date,
if required, is to be the responsibility of the Contractor. Finished surfaces of precast concrete are
to be protected at all times from defacement from welding or other operations by use of shields
properly placed around these operations.
F.
At completion, units shall be plumb, level, and square, true to line, with angles and edges
parallel with related structure lines.
G.
Provide sealant material and application, where indicated, in accordance with the Specifications.
H.
Erect precast concrete units in accordance with indicated erection tolerances. Comply with
erection sequences indicated. Position units to avoid eccentric application of forces, and make
complete and uniform contact with bearing surfaces.
I.
Erect precast units to the following tolerances:

1.
Maximum variation from plane or location indicated on drawings: 1/4 inch.
2.
Maximum offset from indicated alignment between members: 1/4 inch.

END OF SECTION
03410 - 8
SECTION 05000
METALS
PART 1 GENERAL
1.01
SCOPE OF WORK
A.
The Contractor is to furnish all labor, equipment, and materials required to comply with the
intent of the Contract Documents pertaining to metals. All tests, samples shop drawings and
certifications are to be provided in a timely manner in order not to delay the review process or the
construction schedule.
B.
Castings shall meet the requirements of this section and the requirements of Volume 5 of the
specifications. If there is a conflict, the more stringent requirements shall apply.
1.02
RELATED SECTIONS
A.
Metal Fastenings are included in Section 05050.
B.
Metal Fabrications are included in Section 05500.
1.03
REFERENCE STANDARDS
A.
All work performed and materials installed by the Contractor are to be in strict accordance with
the requirements of the latest edition of the following Codes and Standards. In the case of
conflicting requirements in any of the Codes and Standards, the most stringent is to govern.
B.
ASTM A36
C.
ASTM A48
Specifications for Gray Iron Castings
D.
ASTM A53
Standard Specification for Pipe, Steel, Black, and Hot-Dipped, Zinc-Coated,

Welded and Seamless
E.
ASTM A123
Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel

Products
F.
ASTM A143
Practice for Safeguarding Against Embrittlement of Hot-Dip Galvanized

Structural Steel Products and Procedure for Detecting Embrittlement
G.
ASTM A167
Specification for Stainless Steel Bars and Shapes
H.
ASTM A193
Specification for Alloy-Steel and Stainless Steel Bolting Materials for HighTemperature or Pressure Service and Other Special Purpose Applications
I.
ASTM A194
Specification for Carbon and Alloy Steel Nuts for Bolts for High-Pressure and
High-Temperature Service, or Both
J.
ASTM A276
Specification for Stainless Steel Bars and Shapes
05000-1
K.
ASTM A307
Specification for Carbon Steel Bolts and Studs, 60,000 psi Tensile Strength
L.
ASTM A325
Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum
Tensile Strength
M.
ASTM A500
Standard Specification for Cold-Formed Welded and Seamless Carbon Steel

Structural Tubing in Rounds and Squares
N.
ASTM A536
Specification for Ductile Iron Castings
O.
ASTM A563
Specification for Carbon and Alloy Steel Nuts
P.
ASTM A653
Specification for Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron AlloyCoated Galvannealed) by the Hot-Dip Process
Q.
ASTM A992
Standard Specification for Structural Steel Shapes
R.
ASTM B6
Specification for Zinc
S.
ASTM B221
Specification for Aluminum and Aluminum-Alloy Extruded Bars, Rods,

Shapes, and Tubes
T.
ASTM F436
Specification for Hardened Steel Washers
U.
ASTM F959
Specification for Compressible-Washer-Type Direct Tension Indicators for

Use with Structural Fasteners
V.
Occupational Safety and Health Administration
W.
American Institute of Steel Construction - Specifications for the Design, Fabrication and
Erection of Structural Steel for Buildings, eighth edition.
X.
American Society of Civil Engineers - Proceeding Paper 970, Aluminum Alloys.
Y.
Aluminum Association - Aluminum Construction Manual
Z.
American Welding Society AWS D1.1 - Structural Welding Code
AA.
All applicable local, State and Federal Building Codes.
BB.
National Association of Architectural Metal Manufacturers - Metal Bar Grating Manual
CC.
New York City Building Code
1.04
1.05
SUBMITTALS
A.
Shop drawings shall be submitted as required by each Specification Section.
B.
Shop drawings shall show complete details and schedules for the fabrication and shop assembly
of members; and details, schedules, procedures and diagrams showing the sequence of erection.
05000-2
The REs review of shop drawings shall be for general considerations only. Compliance with
requirements for materials, fabrication, and erection of structural steel shall be the Contractors
responsibility.
C.
Included in the shop drawings submission shall be details of cuts, connections, camber, holes, or
other pertinent data. The Contractor shall indicate welds by standard AWS symbols and show
size, length, and type of each weld. He shall also provide setting drawings, templates, and
directions for the installation of anchor bolts and other anchorages to be installed by others.
D.
All shop drawings, tests, samples or other required preliminary information are to be submitted
for the review and approval of the RE prior to the fabrication and/or delivery of materials to the
Site, as per the requirements of the Specifications.
1.06
1.07
PART 2 PRODUCTS
2.01
ALUMINUM
A.
Unless otherwise noted, aluminum is to be 6061 T6 alloy fabricated in accordance with the
American Society of Civil Engineers (Proceeding Paper 970). Aluminum is to have a mill finish,
unless otherwise specified.
B.
Where aluminum comes in contact with other metals, the Contractor is to provide gasket material
over the entire contact surfaces.
2.02
IRON
A.
Cast iron castings are to be of tough, close grained gray iron, free from blowholes, shrinkage and
cold shuts. They are to be sound, smooth, cleaned and free from blisters and defects. Materials
for iron castings are to conform in all respects to ASTM A48 for Class 30B castings, except as
otherwise designated.
B.
Ductile iron castings are to be of nodular iron, free from blowholes, shrinkage and cold shuts.
They are to be sound, smooth, clean and free from blisters and defects. All material for ductile
iron castings are to conform to ASTM A536 for Grade 65-45-12, except as otherwise designated.
C.
Wrought metals and castings are to be sandblasted or ground smooth.
2.03
STEEL
A.
Structural Steel hot-rolled W-shapes shall conform to ASTM A992. Structural Steel hot-rolled
S-shapes, C-shapes, MC-shapes, and angles shall conform to ASTM A36. Materials are to be
free from loose mill scale, rust pits, or other defects affecting their strength and durability.
B.
Structural steel products are to be safeguarded against embrittlement in accordance with ASTM
A143. Malleable iron is to be safeguarded against impertinent by pre-annealing.
05000-3
C.
All base metal is to be thoroughly cleaned using appropriate solvents and wire brushes prior to
pickling.
D.
Zinc for galvanizing is to be of any grade conforming to ASTM B6. All galvanizing is to be
done by the hot-dip process in conformity with all requirements of ASTM A123 and American
Hot Dip Galvanizers Association, Inc. The coating shall have an average weight of 2.0 ounces
per square foot.
E.
Stainless steel is to conform to ASTM A167 and ASTM A276. Bolting materials are to conform
to ASTM A193.
F.
Unless otherwise shown on the Contract Drawings, all stainless steel is to be Type 304.
G.
Bolts and nuts are to conform to the U.S. Standards and are to be clean cut and have well-fitted
threads.
PART 3 EXECUTION
3.01
GENERAL
A.
In general, for the fabrication of all metal work items which will be exposed to view, the
Contractor is to use only materials which are smooth and free of surface blemishes including
pitting, seam marks, roller marks, rolled trade names and roughness. Contractor shall remove
such blemishes by grinding prior to cleaning, treating and application of surface finishes
including zinc coatings.
B.
To the greatest extent possible, bolts and inserts are to be placed before the concrete is placed or
has been built, except where expansion bolt usage is permitted.
C.
Welds are to be electric welds and are to be in accordance with best recognized practices.
D.
All shapes and assemblies are to be of accurate dimension and free from any defects.
E.
Work is to be accurately fabricated according to approved details with straight, true edges, sharp
angles and smooth surfaces, free of pits and scratches. Curves are to be smooth and even.
F.
Work is to be amply strong and rigid with sound, strong, secure joints. Exposed joints are to be
precise and close fitting.
G.
Fastenings are to be concealed where possible. Exposed welds are to be ground smooth.
Exposed rivets, bolts and screws are to be countersunk. Provide lock washers or lock nuts for all
bolts. Use galvanized fastenings and accessories for galvanized metal.
H.
The Contractor is to do all drilling, tapping, cutting and fitting of miscellaneous metal necessary
for installation of or attachment of engaging work.
I.
Castings with weight variations exceeding 5% less than that which might be expected due to the
casting dimensions will not be accepted. The Contractor is to furnish all equipment which would
be necessary for weighing castings in the presence of the RE.
05000-4
J.
Metal items set in concrete are to be placed and securely anchored to the concrete forms prior to
placing of concrete. Where metal items are to be placed in the concrete at a later date, openings
are to be provided of adequate size and shape to accommodate those items to be placed. Metal
items to be attached to concrete and/or masonry are to have inserts, sleeves, or other devices
provided and placed in the work as it progresses.
K.
Castings, metal shapes and assemblies are to be set in place true, level and plumb and shall be
securely anchored to the materials in which they are inserted.
L.
All aluminum in contact with concrete or masonry is to receive a heavy coating of bituminous
paint with care taken to protect the aluminum finish on exposed sections. All aluminum surfaces
are to be fully protected during and after erection.
M.
The Contractor shall substitute shapes of different size or weight than those indicated on Contract
Drawings, when it is apparent that the shapes specified cannot be furnished within the time
allowed by the Contract, or until mill orders are placed, provided the character of the work will
not materially change. The Contractor shall make said substitutions without additional
compensation.
3.02
TESTING
A.
All elements supplied and/or erected may be subject to inspection and laboratory or field tests for
strength, durability, appearance or other considerations. Tests are to be performed under separate
contract, unless specifically mentioned to be included in this Division of the Specifications.
B.
The tests are to be those which would be required by the RE. Testing is to be paid for by the
Corporation.
C.
Such inspections and tests are not to relieve the Contractor of responsibility for providing
materials and fabrication procedures in compliance with specified requirements.
D.
The Contractor shall notify the RE in writing one week in advance of the starting of fabrication
and/or erection of the steel members in order that the necessary inspection of the work may be
made.
E.
The RE shall have free access, and the Contractor shall provide same, to all points where
materials for this Project are being fabricated or erected and all materials, equipment and
workmanship shall be subject to inspection, tests and approval by the RE.
F.
The RE reserves the right to reject any or all units delivered or included in the construction which
do not meet the specified requirements itemized or construed to be included in the preceding
paragraphs. Cost incurred due to rejected materials or improper construction are to be borne by
the Contractor.
3.03
A.
COORDINATION OF WORK
Before starting erection, the preparation of shop drawings and fabrication, the Contractor is to
take field measurements where possible. He is not to delay the job progress and is to allow for
the trimming and fitting wherever taking field measurements before fabrication might delay
work. The commencement for work will be interpreted as acceptance of the underlying
materials. Any inaccuracies shall be reported to the RE in writing.
05000-5
B.
Those materials, once delivered, are not to be used without notification from the REs Field
Representative.
C.
It is to be the Contractor's responsibility to determine exactly how and when this work will be
affected by the work of other subcontractors in this Project.
D.
The Contractor is to satisfy himself as to the compatibility of those elements being delivered with
the actual physical construction by measurements or other means. No element is to be modified
without the modification being reviewed by the RE or the authorized representative.
E.
The Contractor is to be held responsible for the accurate location of all his metal work. He is to
engage the necessary services required to lay out the work accurately in the field and establish all
grades, levels and locations for his work. He is to see that all items of his work which are to be
built into other construction are installed at the proper time and that these items are correctly
located and maintained in such a location during the course of the construction.
F.
Any misfit due to errors in locations and inaccuracies in the setting of items or attachment of
metal work is to be removed and made good in a manner as the RE will direct and at the expense
of the Contractor.
3.04
FABRICATION
A.
The Contractor is to preassemble items in the shop to the greatest extent possible to minimize
field splicing and assembly. He is to disassemble units only as necessary for shipping and
handling limitations. He is to clearly mark all units for reassembly and coordinated installation.
B.
The Contractor is to use materials of the size and thicknesses shown or, if not shown, of the
required sizes and thicknesses to produce strength and durability in the finished product. He is to
work to dimensions shown or accepted on the shop drawings, using proven details of fabrication
and support. The Contractor is to use the type of materials shown or specified for the various
components of the work.
C.
All work shall be fabricated in ample time so as not to delay the progress of the work and shall be
delivered to the Project Site at such time as required for proper coordination.
D.
The Contractor is to form all exposed work true to line and level with accurate angles and
surfaces and straight sharp edges. He is to ease exposed edges to a radius of approximately
1/32, unless otherwise shown. He is to form bent-metal corners to the smallest radius possible
without causing grain separation or otherwise impairing work.
E.
The Contractor is to weld corners and seams continuously, complying with AWS
recommendations. At exposed connections, the Contractor is to grind exposed welds smooth and
flush to match and blend with adjoining surfaces. The Contractor shall not weld, cut or abrade the
surface of exterior units which have hot dip galvanized after fabrication and are intended for
bolted or screwed field connections.
F.
The Contractor is to form exposed connections with hairline joints, flush and smooth, using
concealed fasteners, wherever possible. He is to use exposed fasteners of the type shown, or if
not shown, Phillips flat head countersunk screws or bolts.
05000-6
G.
The Contractor is to provide for anchorage of the types shown, coordinated with the supporting
structure. He is to fabricate and space anchoring devices to provide adequate support for their
intended use.
H.
The Contractor is to cut, reinforce, drill and tap all metal work as indicated to receive finish
hardware and similar items.
3.05
STORAGE AND PROTECTION OF MATERIALS
A.
All materials are to be effectively protected from injury which would harm their structural or
appearance qualities. Such protection is to be provided during fabrication, delivery, erection and
until the work is finally accepted.
B.
Materials are to be stored in such a manner that they are completely protected from dirt, water
and other materials.
C.
All metal work received at the Project Site is to be placed upon substantial shores or blocking
furnished by the Contractor. Shores or blocking are to be of sufficient size and strength to
prevent any metal work from touching the ground, and to facilitate the later removal of the
material. Each piece is to be placed so that water cannot stand thereon, and so that bending under
its own or superimposed weights or from any other causes will not damage the piece. The
acceptance of material improperly stored is to be entirely at the discretion of the RE.
D.
The Contractor is to use care in handling and erecting all materials and is to support materials
properly at all times to insure that they will not be bent, twisted or otherwise damaged. The
Contractor is to notify the RE, in writing, before installation, of any defects or damages that
cannot be corrected in the field and the material is to be returned to the shop, or new parts
furnished, as the RE directs. The Contractor is to pay all expenses if such defects or damages are
due to his negligence.
3.06
SPECIAL REQUIREMENTS
A.
All special requirements, which pertain to specific areas of metals constructions, are to be as
specified in the particular Section of the Specification relating to that work.
B.
Details for construction of metal work may be indicated on the Contract Drawings. In the
absence of specific details, the Contractor is to employ the best industry standard practice and
conform to all applicable local, State and Federal Building Codes as minimum acceptable
standards.
C.
Metal items which are to be embedded in concrete or masonry and which are to be placed in the
formwork before the concrete is placed or masonry set are to be furnished and delivered for
setting and installation by the Contractor.
D.
The Contractor is to provide the necessary holes in all steel for the attachment of work by others.
He is to obtain all necessary information regarding any holes and detail the steel accordingly.
E.
The Contractor is to cooperate with the other trades regarding all parts of this work which are in
any manner related to the work of others. He is to arrange and execute his work in such a
manner that the work of others will not be delayed. The Contractor is to be responsible for all
damage to the work of others caused by the installation of his work. Any work or materials
05000-7
damaged because of carelessness, negligence or lack of precaution on the part of the Contractor
is to be removed and made good at the expense of the Contractor.
3.07
INSTALLATION
A.
The Contractor is to provide anchorage devices and fasteners where necessary for securing all
metal fabrication to in-place construction including threaded fasteners for concrete and masonry
inserts, toggle bolts, through-bolts, lag bolts, wood screws and other connections as required.
B.
All cutting, drilling and fitting for the installation of all metal fabrication is to be performed by
the Contractor. All work is to be set accurately in location, alignment and elevation, plumb,
level, true and free of rack, measured from established lines and levels. He is to provide
temporary bracing or anchors in formwork for items which will be built into concrete, masonry
or similar construction.
C.
The Contractor is to fit exposed connections accurately together to form tight hairline joints. He
is to weld connections which will not be left as exposed joints, but cannot be shop welded
because of shipping size limitations. All exposed joints are to be ground smooth and shop paint
coats are to be touched-up. The Contractor is not to weld, cut or abrade the surfaces of exterior
units which have been hot-dipped galvanized after fabrication, and are intended for bolted or
screwed field connections.
D.
The Contractor is to comply with the AWS Code for procedures of manual shielded metal-arc
welding, appearance and quality of welds made, and the methods used in correcting welding
work.
E.
Cleaning and touch-up painting of field welds, bolted connections and abraded areas of the shop
paint or galvanizing on all metal work are to be as specified in another Division of these
Specifications.
3.08
A.
3.09
A.
SHOP PRIMING
Shop priming of metal work is to be compatible with the finished painting system, where
applicable, as specified in another Section of these Specifications. The shop priming is to be
included as a part of the delivered metal.
CLEANING UP
The Contractor is to remove any rubbish that may accumulate from time to time as the RE will
order and upon completion of the work, is to remove all rubbish occasioned as a result of the
operation and leave the premises in a condition acceptable to the RE.
END OF SECTION
05000-8
SECTION 05050
METAL FASTENINGS
PART 1 GENERAL
1.01
SCOPE OF WORK
A.
Furnish and install all metal fastenings as shown on the Contract Drawings and/or as specified
herein.
B.
All fasteners are to be of the best industry standard quality. They are to be chosen for suitability
according to strength and durability, and appearance where exposed. Fasteners are to be of the
same quality as, or better than, the materials which they fasten. Particular fasteners are described
in more detail in other sections and Divisions of these Specifications. Fasteners shown on the
Contract Drawings are to be furnished and supplied as detailed
C.
The Contractor is to furnish all labor, equipment, and materials required to comply with the
intent of the Contract Documents pertaining to metals. All tests, samples shop drawings and
certifications are to be provided in a timely manner in order not to delay the review process or the
construction schedule.
1.02
RELATED SECTIONS
A.
Metals are included in Section 05000.
B.
1.03
1.04
1.05
SUBMITTALS (NOT USED)
1.06
1.07
PART 2 PRODUCTS
2.01
A.
2.02
METAL FASTENERS
All fasteners exposed to weather, or used in aluminum work, are to be stainless steel. Fasteners
used for interior steel work are to be steel. Accessories, such as washers, are to be the same
material and quality as the fasteners, and are to be appropriately sized. All bolts are to be of
sufficient length that at least two threads are exposed after the nuts are tightened.
TRIM PIECES
05050-1
A.
Trim pieces used in conjunction with fasteners, or for concealment of connections, are to match
the adjacent materials in terms of material and finish. Trim pieces are to be supplied where
required for a neat, complete appearance, and are to be installed with quality workmanship. Trim
pieces are to completely conceal any gaps or joints which they close off.
PART 3 EXECUTION
3.01
GENERAL
A.
All joints between dissimilar materials which react electrolytically are to be separated with
appropriate insulators, such as micarta strips, or protected with zinc chromate primer, as directed.
B.
All metal fastenings are to be installed in conformance with the Manufacturers

recommendations and with the best practices in the construction industry
END OF SECTION
05050-2
SECTION 05500
METAL FABRICATIONS
PART 1 GENERAL
1.01
SCOPE OF WORK
A.
Metal fabrications include but are not limited to items such as ladder safety posts and other such
items which may require special fabrication to satisfy design intent.
B.
Castings shall meet the requirements of this section and the requirements of Volume 5 of the
specifications. If there is a conflict, the more stringent requirements shall apply.
1.02
RELATED SECTIONS
A.
Metals are included in Section 05000.
B.
Metals Fastenings are included in Section 05050.
1.03
REFERENCE STANDARDS
A.
the requirements of the latest edition of the following Codes and Standards. In the case of
conflicting requirements in any of the Codes and Standards, the most stringent is to govern.
B.
Aluminum Association - Aluminum Construction Manual
C.
American Society of Civil Engineers - Proceeding Paper 970
D.
American Society for Testing and Materials
E.
ASTM A48
Specification for Gray Iron Castings, Class 25
F.
ASTM A167
Specification for Stainless and Heat-Resisting Chromium-Nickel Steel Plate,

Sheet and Strip
G.
ASTM A193
Specification for Alloy-Steel and Stainless Steel Bolting Materials for HighTemperature Service
H.
ASTM A276
Specification for Stainless and Heat-Resisting Steel Bars and Shapes
I.
ASTM A536
Specifications for Ductile Iron Castings
J.
ASTM B221
Specification for Aluminum Alloy Extruded Bars, Rods, Shapes, and Tubes
K.
American Welding Society - Structural Welding Code
L.
National Association of Architectural Metal Manufacturers - Metal Bar Grating Manual
05500-1
M.
Occupational Safety and Health Administration
N.
1.04
1.05
SUBMITTALS
A.
Shop drawings, tests, certifications and product literature are to be submitted for record and
approval purposes. No fabrication, delivery or installation is to begin without the REs review
completed.
1.06
1.07
PART 2 PRODUCTS
2.01
GENERAL
A.
Aluminum in contact with concrete, masonry or dissimilar metals is to be protected by paint such
as zinc chromate or a bituminous coating, or by isolating micarta strips where appropriate.
B.
Aluminum work is to be mill finished.
C.
Materials used in site improvements, such as catch basins, drain inlet and manhole frames and
covers are specified in another Section of these Specifications.
D.
All joints between dissimilar materials, which react electrolytically, are to be separated with
appropriate insulators, such as micarta strips, or protected with zinc chromate primer, as directed.
2.02
A.
2.03
A.
LADDER SAFETY POST

Shall be LadderUP model LU-4, as manufactured by The Bilco Company, or equal. Post
shall be high-strength aluminum 6061-T6 square tubing, with a mill finish. Post shall be
retractable, and shall automatically lock when fully extended. Post shall extend at least 42
above top of hatch in raised position, and shall bear a pull-up loop at the top end. Provide a
stainless steel spring balancing mechanism to allow for a smooth, controlled operation when
raising and lowering the safety post. Spring nuts shall be galvanized steel; all other mounting
hardware shall be Type 316 stainless steel. Product shall come pre-assembled from the
manufacturer.
PLATES AND FRAMES
All aluminum construction 6063 T6 material; frames to be 3 minimum thickness with Z
anchors at two foot (2) maximum centers; plates to be checkered diamond point pattern or raised
profile and of sufficient thickness to withstand 300 pounds per ft.2 live load or mid-point 600
pound concentrated load with a deflection limited to L/240; provide stainless steel counter sunk
screw fasteners at two foot (2) maximum centers; smooth all edges; checkered plates to be as
manufactured by Alcoa, or equal.
05500-2
2.04
A.
2.05
A.
2.06
A.
CASTINGS
Watertight, cast iron or ductile iron; manhole frames and covers, valve boxes, and other castings
of like nature to be as manufactured by Campbell Foundry Company, or equal.
FASTENERS AND SUPPORTS
Fasteners of stainless steel nuts, bolts and washers; sufficient in size and number to transmit all
loads normally anticipated. Supports are to be threaded rod, end-thread rod or rolled structural
elements of aluminum; all suitably sized and located to carry or support intended loads.
SPECIAL FABRICATIONS
Steel, aluminum or stainless steel shall be detailed in accordance with best industry practice and
suitable for the use intended.
PART 3 EXECUTION
3.01
A.
GENERAL
All work is to be performed in strict conformance with OSHA, NAAMM, ASCE, AA, AWS,
ASTM, Local Building Codes, Safety Codes and the Contract Documents.
END OF SECTION
05500-3
SECTION 06600
PLASTIC FABRICATIONS
PART 1 GENERAL
1.01
A.
1.02
A.
1.03
SCOPE OF WORK
Furnishing and installation of all fiberglass reinforced plastic (FRP) products and fabrications as
indicated on the Contract Drawings and specified herein. FRP products and fabrications include,
but are not limited to, FRP gratings and FRP ladders.
RELATED SECTIONS
REFERENCE STANDARDS
A.
ALI A14.3
American Ladder Institute (ALI) American National Standard for Ladders

Fixed Safety Requirements
B.
ASTM D635
Standard Test Method for Rate of Burning and/or Extent and Time of Burning
of Plastics in a Horizontal Position
C.
ASTM D638
Standard Test Method for Tensile Properties of Plastics
D.
ASTM D696
Standard Test Method for Coefficient of Linear Thermal Expansion of Plastics

Between -30 degrees C and 30 degrees C With a Vitreous Silica Dilatometer
E.
ASTM D732
Standard Test for Shear Strength of Plastics by the Punch Tool
F.
ASTM D790
Flexural Properties of Unreinforced and Reinforced Plastics and Electrical

Insulating Materials
G.
ASTM D1148
Standard Test Method for Rubber DeteriorationDiscoloration from

Ultraviolet (UV) and Heat Exposure of Light-Colored Surfaces
H.
ASTM D2344
Standard Test Method for Short-Beam Strength of Polymer Matrix Composite

Materials and Their Laminates
I.
ASTM D4000
Standard Classification System for Specifying Plastic Materials
J.
ASTM E84
Standard Test for Surface Burning Characteristics of Building Materials
K.
International Building Code
L.
M.
NFPA 101
Life Safety Code
06600-1
N.
29 CFR 1910.27 U.S. Department of Labor, Occupational Safety and Health Administration,
Construction Standards and Interpretations, 29 CFR Part 1910 Occupational
Safety and Health Standards, Subpart D Walking-Working Surfaces, 27
Fixed Ladders.
1.04
1.05
SUBMITTALS
A.
Submittal shall be provided a minimum of 14 days prior to commencing FRP fabrication.
B.
No fabrication, delivery or installation of FRP fabrications is to begin without the REs review
and approval of the following submittals:
1.06
A.
1.07
1.
FRP Manufacturers qualifications as specified herein.
2.
Manufacturers product literature, specifications, and color charts.
3.
Manufacturers Instructions: Manufacturer's recommendations for shipping, handling,

erection procedures, and care and maintenance upon completion of installation.
4.
Shop drawings: Fabrication and installation drawings and details for FRP fabrications.
Include plans, elevations, sections, and details of FRP fabrications and their connections
indicating dimensions, construction methods, design tables, materials of construction, and
other data that is needed to complete the review. Show anchorage and all accessory items.
Provide templates for anchors and bolts specified for installation.
5.
Test Reports:
a.
Ultraviolet Testing.
b.
Flame Spread.
c.
Rung capacity.
6.
Certificates: Manufacturers sample warranty.
7.
Product samples: Two samples of each type of product proposed under this Section.
DELIVERABLES
Manufacturers Warranty.
A.
the latest requirements of the governing Reference Standards listed above.
B.
Materials are to be installed in conformance with the best practices in the construction industry.
C.
Manufacturer is to warranty all FRP products against defects in material and workmanship for a
minimum of 5 years.
06600-2
D.
E.
FRP Manufacturer Qualifications:

1.
All items provided under this Section shall be furnished only by manufacturers having
experience in the design and manufacture of similar products and systems.
2.
FRP Manufacturer is required to have a minimum of 10 years experience in

manufacturing FRP products.
3.
FRP Manufacturer is to be certified to ISO 9001.
Ladders and Ladder Safety Cages:

1.
F.
Gratings:
1.
1.08
The design, fabrication, and installation of ladders and safety cages shall fully comply
with NFPA 101, 29 CFR 1910.27, and ALI A14.3. The ladder shall also be capable of
supporting an ultimate concentrated vertical load of 1,200 pounds applied at the mid-span
of the rung. Manufacturer shall provide supporting test data for rung capacity.
Design live loads of FRP gratings shall be in accordance with the International Building
Code and the New York Building Code, and shall not be less than 300 pounds per square
foot uniformly distributed or a mid-span concentrated load of 600 pounds. The deflection
shall be limited to span/180.
PRODUCT DELIVERY, STORAGE, AND HANDLING
A.
Manufactured materials shall be delivered in original packages, containers, bundles, or pallets

bearing the label of the Manufacturer, clearly marked and identified relative to the complete
system. Adhesives, resins, and their catalysts and hardeners, shall be packaged separately and
labeled as such, and shall be stored in a dry indoor location.
B.
Protection is to be provided to all FRP materials to prevent abrasion, cracking, chipping, twisting,
bending, breaking or damage of any other kind during fabrication, delivery, storage, handling,
erection and until the work is finally accepted.
C.
Store all FRP materials in a manner that they are completely protected from dirt, water and other
materials and to prevent damage due to over exposure to the sun.
D.
Use care in handling and erecting all FRP materials and support materials properly at all times.
E.
The Contractor is to notify the RE in writing, before installation, of any defects or damages that
cannot be corrected in the field and the material is to be returned to the Manufacturer, as directed
by the RE. The Contractor is to pay all expenses if such defects or damages are due to his
negligence. The acceptance of material improperly stored is to be entirely at the discretion of the
RE.
F.
Any materials that, in the opinion of the RE, have become damaged are to be promptly removed
from the Project Site and replaced with new materials at no additional cost to the Corporation.
PART 2 PRODUCTS
06600-3
2.01
A.
MATERIALS
All plastic fabrications, unless noted or specified otherwise, are to be manufactured using a
pultruded process utilizing either an isophthalic polyester or a vinyl ester resin with ultra-violet
(UV) inhibitor additives. A synthetic surface veil is to be the outermost layer covering the
exterior surfaces. Submit UV Testing results and documented protection with:
1.
Integral UV inhibitors in the resin.
2.
A synthetic resin rich surfacing veil, meeting or exceeding the requirements of ASTM
D1148.
B.
Fire rating: Resins used in the construction of FRP products are to be self-extinguishing, per
ASTM D635, and have a Class 1 flame spread rating of not more than 25, according to ASTM
E84.
C.
Materials used in the manufacture of FRP products are to be new stock of the best quality and are
to be free from all defects and imperfections that might affect the performance of the finished
products, including: foreign inclusions; delaminations; blisters; resin burns; air bubbles; and pits.
Make all finished surfaces of FRP products smooth (except for ladder rungs and top surface of
grating), resin-rich, free of voids and dry spots, cracks, crazes or unreinforced areas.
D.
Anchors, bolts, nuts, washers, brackets, clips, and accessories: Type 316 stainless steel.
E.
All FRP fabrications shall be integrally pigmented safety yellow.
F.
Structural shapes shall have the minimum longitudinal mechanical properties as follows:
Property
Tensile Strength
Tensile Modulus
Flexural Strength
Flexural Modulus
Flexural Modulus-Full Section
Short Beam Shear
Shear Modulus-Transverse
Coefficient of Thermal Expansion
Value
Units
30,000
psi
2,5000,000
psi
30,000
psi
1,800,000
psi
2,800,000
psi
4,500
psi
450,000
psi
0.000008 in/in/F
ASTM
D638
D638
D790
D790
n/a
D2344
n/a
D696
G.
After fabrication, all cut ends, machined edges, holes, and abrasions of plastic shapes are to be
sealed with a compatible resin coating for maximum corrosion resistance.
H.
Clearly identify components per ASTM D4000.
I.
Available Manufacturers: Subject to compliance with the requirements of this Section,

manufacturers offering products that may be incorporated into the Work include: Fibergrate
Composite Structures, Inc.; Strongwell; and Delta Composites, LLC.
2.02
MOLDED GRATING
06600-4
A.
One-piece, molded, corrosion resistant grating with a permanent, integral nonskid grit top
surface. All gratings to be of integral construction and to be provided with all openings required
for piping and equipment.
B.
Square mesh pattern, 2-inch by 2-inch grid.
C.
Bearing bars and cross bars shall be at least 2-inches deep with tops and bottoms of bearing bars
and cross bars in the same plane. Bearing bars and cross bars shall be at least 5/16-inch wide and
tapered to provide self-cleaning.
D.
Provide stainless steel hold-down saddle clips at maximum 4-feet centers on all gratings with a
minimum of 4 per panel.
E.
Provide frames of minimum 3-inch thick fiberglass reinforced plastic with Z anchors at
maximum 2-feet centers with a minimum of 3 per side.
F.
All gratings are to be factory cut.
2.03
LADDER
A.
Provide FRP ladders and ladder safety cages, including cage hoops, brackets, and all other
structural shapes composed of reinforced fiberglass components and resin in qualities, quantities,
properties, arrangements and dimensions as necessary to meet the design requirements and
dimensions specified in the Contract Documents.
B.
The ladder side rails are to be continuous pultruded 1-3/4-inch square tube with a minimum wall
thickness of 1/4-inch. The rungs shall be 1-1/4-inch diameter pultruded structural shapes,
continuously fluted to provide a non-slip surface. Rungs that are gritted as a secondary operation
are not permitted. Rungs are to penetrate the tube sidewall of the ladder side rails in the
centerline of the side rails. Mechanically attach all ladder rungs to ladder side rails by use of 18-8
stainless steel rivets and chemically bond with epoxy resin.
C.
Ladder wall and floor mounts shall be fabricated from pultruded angles, 3/8-inch minimum
thickness.
D.
Provide and install ladder with extendable safety post as shown on the Contract Drawings and
specified in Section 05500.
2.04
LADDER SAFETY CAGES
A.
Provide primary hoops at the top and bottom of the safety cage, spacing to be no more than 20feet. Provide secondary intermediate hoops with spacing no more than 4-feet between primary
hoops. The hoops shall be attached to the rails in a manner which provides hand clearance
throughout the length of the ladder. All cage hoops to be a minimum 3-inches wide by 1/4-inch
thick.
B.
Safety cage vertical bars shall be either 1-1/2 inch wide by 5/8 inch pultruded I-beam shapes or
2-inch wide by 3/16-inch pultruded straps.
C.
Safety cage hoops and brackets to be manufactured by the open mold hand lay-up process.
06600-5
PART 3 EXECUTION
3.01
PREPARATION
A.
Examine the areas and conditions in which the work of this Section is to be installed, including
the condition of the substrate to which the item is to be attached.
B.
Do not proceed with the work until unsatisfactory conditions have been corrected.
3.02
FABRICATION
A.
All FRP fabrications are to be shop-fabricated and assembled in the largest practical sizes
suitable for shipment.
B.
Ladders and Safety Cages: Fully shop assemble ladders. Test assemble safety cages; drill and fit
to ensure proper field assembly. Leave safety cage brackets attached with bolts to the ladder for
shipping, but disassemble ladder cage components. Package and ship each set of cage
components with each respective ladder. Field attach hoops to the brackets.
3.03
INSTALLATION
A.
All FRP fabrications are to be assembled and installed in strict accordance with approved
assembly drawings and procedures provided by the FRP Manufacturer.
B.
Fabricated items to be securely fastened plumb and true to lines and levels. Provide anchorage
devices and fasteners where necessary for fastening fabricated FRP items to cast-in-place
concrete.
C.
Field cutting and drilling, if required:

1.
Field cut and drill FRP products with carbide or diamond tipped bits and blades.
2.
All field cut and drilled edges, holes and abrasions shall be sealed with a catalyzed resin
compatible with the original resin in accordance with the FRP Manufacturers
recommendations.
3.
Provide adequate ventilation during all drilling, cutting, and resin application procedures.
END OF SECTION
06600-6
SECTION 13000
TUNNEL AND SHAFT SAFETY
PART 1 GENERAL
1.01
A.
SCOPE OF WORK
The Contractor shall be responsible for initiating, maintaining and supervising all safety
precautions and programs in connection with the Work. The Contractor shall take all necessary
precautions for the safety of, and provide the necessary protection to prevent damage, injury or
loss to:
1.
All employees on the Work and other persons who may be affected thereby.
2.
All the Work and all materials or equipment to be incorporated therein, whether in
storage on or off the site.
B.
Contractor shall comply with all applicable laws, ordinances, rules, regulations and orders of
any public body having jurisdiction for the safety of persons or property or to protect them from
damage, injury or loss. Erect and maintain, as required by the conditions and progress of the
Work, all necessary safeguards for its safety and protection. Notify owners of adjacent utilities
when prosecution of the Work may affect them. All damage, injury or loss to any property
caused directly or indirectly, in whole or in part, by Contractor, any Subcontractor or anyone
directly or indirectly employed by any of them or anyone for whose acts any of them may be
liable, shall be remedied by Contractor, except damage or loss attributable to the fault of
Contract Drawings or Specifications or to the acts or omissions of the Corporation or RE or
anyone employed by either of them or anyone for whose acts either of them may be liable, and
not attributable, directly or indirectly, in whole or in part, to the fault or negligence of
Contractor. Contractors duties and responsibilities for the safety and protection of the Work
shall continue until such time as all the Work is completed and RE has issued a notice to
Corporation and Contractor that Work is acceptable.
C.
All Work shall conform to the requirements of the Occupational Safety and Health Act
(OSHA).
D.
The tunnel and shafts conditions are assessed in the GBR as Non-Gassy; however the minimum
testing requirements prescribed herein shall be undertaken to confirm these conditions.
E.
No separate payment shall be made for the Work included herein, and all costs in connection
therewith shall be included in the cost of the structure or item to which it pertains.
F.
No section or description in these documents shall be construed to replace, modify or supersede

requirements of other codes, specifications and/or ordinances referenced throughout the
document. If a conflict occurs between the referenced regulations and these documents the
more stringent shall govern.
13000-1
1.02
A.
1.03
RELATED SECTIONS
This Section applies to all Sections of the Contract Specifications.
REFERENCE STANDARDS
A.
OSHA U.S. Department of Labor, Occupational Safety and Health Administration,

Construction Standards and Interpretations, 29 CFR Part 1926, including Section 1926.800
Underground Construction and its referenced subparts and sections.
B.
All other applicable Corporation, Local, State, and Federal code requirements and regulations in
effect at the time of construction
1.04
ABBREVIATIONS
A.
CGA
Combustible Gas Analyzer.
B.
CIH
Certified Industrial Hygienist.
C.
HASP
Health and Safety Plan.
1.05
SUBMITTALS
A.
Safety Officer - A resume of the qualifications of the Safety Officer must be submitted thirty
(30) days prior to the start of any site work. This resume shall include a description of the Safety
Officers experience, education, and special safety and first aid courses completed, and safety
conferences attended, and shall indicate that the individuals possess safety experience in heavy
construction and underground construction.
B.
Health and Safety Plan (HASP) 30 days prior to the commencement of site work, submit full
health and safety plan to the RE in accordance with OSHA requirements. A Certified Industrial
Hygienist (CIH) shall verify the HASP.
C.
In addition to the specific OSHA requirements The Health and Safety Plan shall include but not
be limited to:
1.
Description and procedures of site security arrangements emphasizing shaft openings.
2.
Induction Training to be provided to employees and visitors and means of recording

personnel that have been trained.
3.
Schedule of Planned Tool Box Training Talks and means of recording personnel that
have been trained.
4.
Tunnel and shaft emergency evacuation procedures in the event of fire, flood, oxygen
deficiency or presence of gas. The HASP shall also address eventuality of
evacuation/rescue in the case of collapse, accident or other significant events.
5.
Tunnel Boring Machine Cutterhead Entry Procedure including detailed Compressed

Air Procedures including the requirements of Section 02416.
13000-2
D.
6.
Hot Work Permit system for control of welding and burning operations in the
underground works. This shall include a system for the control and monitoring of
locations of gas bottles in the shafts and tunnel.
7.
Job Hazard Analysis for all major activities.
8.
Personal protective equipment requirements.
9.
Methods of Dealing with Contaminated Material, if any.
Flood contingency plans for shafts shall be in accordance with this Specification Section.
1.06
1.07
A.
The Contractor shall have the sole responsibility for the safety of persons engaged on the
project and the sole liability for injuries to, or death of persons, or damage of property during
the entire construction period.
B.
The Contractor shall have on hand at all times sufficient materials and equipment in good
condition and in good working order for all emergencies that are likely to arise to secure the
safety of all personnel and structures.
C.
All work shall be performed in accordance with all Corporation, Local, State, and Federal
requirements including OSHA requirements with particular reference to 29 CFR 1926.800,
Subpart S entitled "Underground Construction". Should there be any conflict or discrepancies
between these Specifications and OSHA requirements, the more stringent requirement shall
govern.
D.
Safety Officer:
1.
The Contractor shall be responsible for the safety of the Contractors employees,
Corporation and REs personnel and all other personnel at the site of the Work. The
Contractor shall have a competent, OSHA-certified Safety Officer(s) on the job with
an appropriate office on the job site to maintain and keep available safety records and
up-to-date copies of all pertinent safety rules and regulations.
2.
The Safety Officer shall:

a.
Report directly to the Contractors Project Manager.
b.
Ensure compliance with all applicable health and safety requirements of all
governing legislation.
c.
Schedule and conduct safety meetings and safety training programs as required
by law and this Specification for all personnel engaged in the work.
d.
Post all appropriate notices regarding safety and health regulations at locations
that afford maximum exposure to all personnel at the job site.
e.
Post the name, address, and hours of the nearest medical doctor; names and
addresses of nearby clinics and hospitals; and the telephone numbers of the fire
and police departments.
13000-3
f.
Post appropriate instructions and warning signs with regard to all hazardous
areas or conditions.
g.
Have proper safety and rescue equipment adequately maintained and readily
available for any contingency. This equipment shall include items such as: fire
extinguishers, first aid kits, safety ropes and harnesses, stretcher, life savers,
oxygen breathing apparatus, resuscitators, gas detectors, oxygen deficiency
indicators, explosion meters, and any other equipment mandated by law.
h.
Make inspections at least once daily in accordance with an inspection checklist

report form to ensure that all machines, tools and equipment are in safe
operating condition; that all work methods are not dangerous; that all work
methods are free of hazards; and that emergency egress routes remain free from
obstruction.
i.
Submit to the RE copies of all inspection checklist report forms, safety records
and all safety inspection reports and certifications from regulating agencies and
insurance companies.
j.
Notify RE of any accident immediately, followed by a detailed written report

within twenty-four (24) hours.
k.
Notify the RE immediately in the event of a fatal accident.
l.
Notify RE of any accident claim against the Contractor or any Subcontractor

immediately, followed up by a detailed written report on the claim and its
resolution.
m.
Review safety aspects of the Contractors submittals as applicable.
E.
All personnel entering the job site, any shaft, or tunnel, shall be required to wear approved
safety hats as well as protective and hi-visibility clothing, footwear, eyewear, ear protectors and
other equipment as required by OSHA and as outlined in the Contractors Health and Safety
Plan. The Contractor shall maintain, on site, a sufficient number of safety hats and other
personnel protective equipment for the use of visitors. The Contractor shall supply the
Corporation and REs personnel with the same equipment to ensure a common standard.
F.
Where work is in progress in a tunnel or for excavations more than 10 feet in depth, the
Contractor shall provide as a minimum the following safety equipment:
1.
Adequate stretcher units placed in convenient locations adjacent to the work;
2.
Oxygen deficiency indicators;
3.
Carbon Monoxide testers;
4.
Hydrogen Sulfide detectors;
5.
All personnel entering the underground works shall be issued with an OSHA/MSHA
approved self rescuer of the Self Contained type such as the Oxyboks manufactured
by Draeger Safety or other approved equivalent.
6.
All personnel entering the underground works shall be issued with an MSHA
approved personal cap lamp or light source, which shall be carried at all time.
13000-4
G.
No employees shall be allowed to work in areas where concentrations of airborne contaminants

exceed federal threshold limits. Respirators shall not be substituted for environmental control
measures and shall be used only as prescribed by OSHA.
H.
The Contractor shall provide lighting in accordance with OSHA requirements for the entire
length of the tunnel. Light shall be adequate as determined by the RE, to permit proper
inspection of all operations at all times. Minimum lighting consisting of 60-Watt light bulb at 40
feet spacing shall be maintained during all working hours. The intensity of the lighting required
by applicable regulations for tunnel excavating operations shall be increased as required by the
RE for concrete placement and for final cleanup. Open flame lights shall not be used unless
approved by the RE.
I.
The Contractor shall maintain the shafts and tunnel air in a condition suitable for the health of
the workers at all times. Ventilating plants shall be of ample capacity as a minimum in
conformance with OSHA requirements, and shall be installed and operated while work is in
progress in the tunnel and at other times as may be necessary.
J.
The entire ventilating system shall be maintained in a good condition and shall be under the
direction of an employee experienced in tunnel ventilation operation and maintenance. A supply
of fresh air shall be furnished for the quick removal of fumes and dust generated by tunnel
operations. The exhausted air shall be washed and filtered to remove excess dust particles
resulting from excavation, before discharge to the atmosphere.
K.
The Contractor shall provide continuous monitoring for gases as required by OSHA. The
Contractor shall take all possible safety precautions as the work progresses under these
conditions and shall increase ventilation to the extent that explosive and toxic mixtures are not
allowed to form.
L.
Tunnel and shaft excavation machines shall have an automatic shut-off that shall be activated if
dangerous levels of gases are detected.
M.
The Contractor shall install temporary covers on shafts during periods of construction inactivity
at the shaft sites. The shaft covers may be grated where the shaft is to be used as a ventilation
inlet, and shall be designed by the Contractor to prevent accidental entry of personnel or debris
into the shafts.
N.
All shafts shall be enclosed with a security fence which shall be secure at all times. All storage
areas and workshops shall be so segregated so that their use during times of site inactivity does
not compromise the security of the shaft area. The fence shall have all necessary gates and
entrances with keys furnished to the RE for all locking devices. In addition, the Contractor shall
provide barricades at the top of shafts in accordance with OSHA requirements, and shaft covers
as specified herein.
O.
Lights, barricades, signs, and watchmen shall be provided and maintained to properly protect
the public, the workers, and the work against injury or damage.
P.
Internal combustion engines other than mobile diesel powered equipment shall not be used
underground. All diesel powered mobile equipment used underground shall be as prescribed in
OSHA and be operated in compliance with OSHA regulations. The Contractor, upon request
shall submit proof of certification to the RE. All internal combustion equipment allowed under
13000-5
this section shall be operated in such a manner as to prevent health hazards to personnel from
exhaust fumes.
Q.
All haulage equipment such as hoists, cages, and elevators in operation in excavations and
shafts shall conform to all requirements described in OSHA.
R.
Conduct all tunneling operations by methods and with equipment that shall positively control
dust, fumes, vapors, gases, fibers, fogs, mists, or other atmospheric impurities in accordance
with OSHA requirements.
S.
Fire Prevention and Control: All underground construction shall be performed in accordance
with the applicable fire prevention and control requirements of OSHA, and Local fire
department ordinances.
T.
Noise and Dust Control: Control noise and dust in accordance with applicable federal, state,
local and Corporation laws, safety codes, regulations and ordinances.
U.
Muck Handling: Equip muck trains with acceptable braking systems and safety chains to
prevent runaway trains. Muck trains shall have audible and visual warning systems to signal
train movements. The train operators shall verify no personnel are in harms way prior to starting
or stopping the trains. Provide spill protection and emergency cut offs for muck conveyor
systems.
V.
The Contractor shall maintain the stability of the excavation around the periphery of all
underground Work.
W.
The Contractor shall provide a ladderway at the TBM launching shaft to allow access to the
works and assist in emergency evacuation. The ladderway shall be installed once shaft
excavation has been completed or as directed otherwise by the RE.
X.
The Contractor shall provide a tally board and brass tags for all personnel including the RE. The
tally board shall be mounted at the top of the shaft near the entry point and all personnel shall be
required to indicate using their own unique brass tag whether or not they are underground.
Y.
Safe working conditions including adequate lighting and proper ventilation shall be maintained
at all times in all locations of the underground works to allow for safe working of personnel
remote from the tunnel boring machine or working face.
Z.
Subsurface Gases:
1.
The Contractor shall anticipate that combustible and toxic gases may be encountered
during tunneling operations and construction of the shafts and shall take the necessary
measures to provide for safety during tunneling and shaft operations which, at a
minimum, comply with all OSHA regulations and in particular with the requirements
set forth in the recently revised regulatory 29 CFR Part 1926.800, Subpart S entitled
Underground Construction. The Contractor shall also provide the following:
a.
The Contractor shall install and maintain gas analyzers and continuously
monitor for combustible, noxious and toxic gas at each working heading and at
other locations where gases may accumulate, as well as at any other locations
required by OSHA. Each tunnel/shaft boring/excavating machine shall be fitted
with a combustible gas analyzer (CGA) that continuously monitors methane
13000-6
and other flammable gas concentrations at the excavation face. The CGA shall
sound audible alarms and activate warning lights when methane or other
flammable gases are detected in excess of 10% of the lower explosive limit
(LEL).
b.
The gas analyzers shall be connected so as to de-energize electrical circuits on

the tunnel boring machine and other electrical circuits or devices not wired for
hazardous conditions when combustible gas concentrations exceed a designated
threshold (not more than 20 percent of their lower explosive limit). Portable
CGA shall be provided as a backup to the equipment mounted unit(s).
c.
The Contractor shall provide continuous ventilation to exhaust gases and dust
from all excavations directly to the outside air, as well as deliver fresh air to all
working headings and at intervals along the tunnel as required.
d.
In addition, the Contractor shall provide adequate ventilation and suppression

measures to the face of the heading to prevent accumulation of dust, fumes,
mists, vapors or gases.
e.
The Contractor shall monitor the exhaust for toxic and explosive gases and shall
extend the pipe 10 feet or more, or as required by Local Regulations above
existing grade to disperse any gas encountered. Monitoring shall be done at
least once at the beginning of each shift, and shall be increased if gas is
encountered to a frequency agreed to with RE until clear.
f.
In addition to the ventilation requirements described above, provision shall be

made to increase ventilation air volume to control gas concentrations.
g.
Special equipment and procedures shall be used as required to ventilate

restricted areas where work is in progress, e.g., in front of the Tunnel Boring
Machine cutterhead. The Contractor shall submit a specific cutterhead entry
procedure.
h.
TBM safety equipment refer to Section 02315 Earth Pressure Balance TBM
and/or Section 02316 Slurry TBM, as applicable.
i.
Nothing in these requirements shall be construed to conflict with or otherwise

diminish the Contractor's obligations to comply with OSHA regulations.
AA. Water in Tunnel and Shafts:

1.
The Contractor should make due provision for the handling and control of the
expected quantities of water based on Contract Documents.
2.
In the event of a storm resulting in flood elevations greater than a 100-year flood level
as described in the GBR or when such flooding is imminent in the vicinity of the shaft,
the Contractor shall implement contingency measures to stabilize and protect the shaft
excavation. The Contractor at the commencement of the Work shall propose such
measures for agreement by the RE.

PART 3 EXECUTION (NOT USED)
END OF SECTION
13000-7
SECTION 13060
SHAFT CONSTRUCTION
PART 1 GENERAL
1.01
A.
1.02
SCOPE OF WORK
The Work specified in this Section includes the construction of the Staten Island Launching
Shaft and Brooklyn Receiving Shaft. As part of this shaft construction work, the Contractor is
responsible for:
1.
Constructing the shafts at the locations and to the minimum dimensions indicated on
the Contract Drawings;
2.
Furnishing of all labor, tools, equipment, superintendence and materials necessary to

fully construct the shafts including tunnel break-out and tunnel break-in as shown on
the Contract Drawings;
3.
Installing and monitoring geotechnical instrumentation;
4.
Providing maintenance and remedial work to shaft support systems;
5.
Controlling water ingress to shafts;
6.
Control surface and groundwater in and around shafts;
7.
Protecting and/or relocating utilities as required;
8.
Providing temporary shaft covers and site fencing during periods of inactivity;
9.
Providing temporary restoration of Shore Road Park following completion of the

receiving shaft construction and prior to reception and removal of the tunnel boring
machine.
10.
Removing and replacing surface items as necessary, and
11.
Backfilling the shafts with concrete after installation and testing of steel water mains
as shown on the Contract Drawings.
RELATED SECTIONS
A.
B.
C.
D.
13060-1
E.
F.
G.
H.
I.
Backfill Concrete in Shaft and Tunnels is included in Section 03301.
J.
K.
L.
Removal and Treatment of Tunnel and Shaft Construction Water is included in Section 13120.
M.
N.
O.
1.03
1.04
DEFINITIONS
1.05
Unwatering: Removal of water from inside the shaft excavation without impacting the
surrounding groundwater elevation.
1.06
SUBMITTALS
A.
Provide a comprehensive Method Statement and shop drawings detailing the method of
construction and excavation for the both project shafts. The following documentation shall be
submitted in detail to the RE for approval at least 30 days prior to the commencement of any
operations on site:
1.
Location and limits of shaft working sites.
2.
Installation of shaft support in relation to excavation plan.
3.
Complete specifications for all equipment, methods, and procedures proposed to be

used for the shaft excavation, support and removal of spoil from the shafts, and
installation of the base slab including the following minimum information:
a.
Manufacturers technical specifications and working drawings, including

design, dimensions, method of operation, model number, machine power and
capacity, expected performance and maintenance requirements.
b.
Description of features designed or selected to be compatible with expected site

restrictions and clearance requirements.
c.
The manufacturers product information, machine details and working

arrangement drawings, specifications, operating procedures, and other data
13060-2
pertinent to the performance of the equipment for the anticipated rock mass and
ground water conditions.
4.
d.
Description of the muck handling system, lighting and ventilation systems and
proposed water control and monitoring provisions.
e.
Description and drawings for plant and equipment layout, safety systems and
other ancillary equipment.
f.
Temporary and back-up power systems.
g.
Schedule and sequencing.
Shaft excavation under water:

a.
The Contractor shall determine the elevation of water within the shaft to be
maintained during shaft excavation and include calculations to verify the
stability of the shaft, surrounding ground, adjacent structures and utilities, and
groundwater elevation.
b.
Details and locations of piezometers required to verify that the groundwater

elevation around the shaft is not adversely impacted during shaft excavation.
c.
Measurement of shaft bottom elevation during excavation.
d.
Contingency plans to deal with:
e.
5.
1)
Obstructions.
2)
Bottom heave.
3)
Drawdown of surrounding groundwater elevation.
4)
Open joint or other abnormality in the slurry wall panels.
Details of activities required to be undertaken by divers and OSHA compliant

procedures and equipment.
Tremie concrete base slab:

a.
Preparation prior to installing reinforcement.
b.
Installing reinforcement in shear key locations and placing base slab

reinforcement.
c.
Tremie concreting of base slab.
d.
Details of activities required to be undertaken by divers and OSHA compliant

procedures and equipment.
6.
Unwatering the shaft.
7.
Procedures for controlling water ingress from shaft walls and slab during unwatering
of shaft.
8.
Details of shaft temporary cover, site fencing, and temporary restoration of Shore
Road Park for the Brooklyn Shaft following completion of shaft construction and prior
to reception and removal of the TBM.
13060-3
B.
Refer to Related Work Sections for other required submittals including shaft support, muck
removal, maintenance and drainage.
1.07
1.08
A.
The Contractor shall comply with all restrictions set as conditions under which the easement or
permission was granted to the Corporation to perform the work of this Contract.
B.
The Contractor shall inspect the locations where the shafts are to be built to be familiarized with
the conditions under which the Work shall be performed. The omission of any details necessary
for the satisfactory prosecution of the Work in its entirety, which may not appear herein, shall
not relieve the Contractor of its full responsibility.
C.
A complete description of expected ground and groundwater conditions is provided in the

Geotechnical Baseline Report (GBR).
D.
The Contractor shall provide, install and monitor any additional piezometers required to
monitor the groundwater elevations around the shafts during shaft construction.
E.
The Contractor shall be responsible for the protection of all utilities encountered during the
work of this Contract. The known utilities are shown on the Contract Drawings and the
Contractor shall take every precaution when working near the utility to locate and protect these
utilities. All damage to existing utilities shall be the sole responsibility of the Contractor and
the Contractor shall replace, repair, remedy, or compensate for all damages at no additional cost
to the Corporation.
F.
All shaft work shall be performed in accordance with all applicable Corporation, Local, State
and Federal regulations, codes, and standards.
G.
The Contractor shall verify that the shaft linings account for all expected surcharge loading,
including construction loading, storage or stockpiling of material etc. It shall be the
responsibility of the Contractor to ensure that the design shown on the Contract Drawings can
adequately and safely carry any and all loads that may be applied to the linings during
construction. Design checks shall be prepared by a licensed Professional Engineer registered in
the state of New York.
H.
For any alternative proposed by the Contractor for shaft excavation, support and any other
Work related issues including shaft enlargements, the following criteria shall be utilized for the
purposes of preparing the alternative design:
1.
The Contractor shall submit full design stamped and sealed by a licensed Professional
Engineer registered in the state of New York for the REs approval. The design shall
include shop drawings and detailed descriptions of any modifications and restoration
to the permanent works that are required for the proposed alternative design.
2.
The shaft linings shall be designed based on anticipated soil, rock, and groundwater
loadings and conditions described in the Geotechnical Baseline Report (GBR). The
primary shaft linings shall account for all expected surcharge loading, including
construction loading, storage or stockpiling of material etc. It shall be the
13060-4
responsibility of the Contractor to ensure that any alternative design can adequately
and safely carry any and all loads that may be applied to the linings. The load factor to
be applied to ground loads and hydrostatic loads shall be 1.6 in accordance with ACI
318.
1.09
3.
The Contractor shall not perform any alternative or additional work before approval in
writing by the RE.
4.
The Contractor shall design any alternatives to the designs or any modifications to the
designs shown on the Contract Drawings to accommodate the Contractors selection
of construction technique at no additional cost to the Corporation. Any approvals or
comments given by the Corporation or RE to any procedure, operation, or
construction methods do not relieve the Contractor from full responsibility for the
adequacy and safety of the proposed excavation, support and any other Work Related
issues.
TOLERANCES:
A.
Slurry wall construction Refer to Section 02310 Shaft Support Slurry Walls.
B.
Variation from Plumb:
C.
1.
Center of shaft: Within plus or minus 0.1 feet.
2.
Top elevation of shaft: Within plus or minus 0.1 feet.
3.
Location of panel at grade: Within plus or minus 0.1 feet of theoretical or plan
location.
Tolerances- Variation in Plan Diameter.

1.
Excavation/ shaft Support: +2 percent of the designed diameter.
PART 2 PRODUCTS
2.01
EQUIPMENT
A.
The Contractor shall select and use equipment capable of performing the shaft construction
including excavation and support requirements. REs approval of equipment, material or
resources shall not relieve the Contractor of the entire responsibility for performing the specified
Work to the required quality and in a timely manner in compliance with the Contract
requirements.
B.
All excavation equipment shall be supplied by recognized manufacturers in the tunneling and
shaft industry. Use of experimental equipment is at Contractor's own risk. Experimental
equipment is defined as any equipment which has no historical performance data for the Work
to be performed. The Contractor shall be aware of the scheduling for this project and select
equipment capable of achieving the required schedule.
13060-5
C.
An inventory shall be maintained of replacement parts and accessories recommended by

equipment manufacturers to ensure continued functioning of all essential shaft excavation and
support equipment.
PART 3 EXECUTION
3.01
GENERAL
A.
All shafts shall be suitably lined and supported as shown on the Contract Drawings. The shafts
shall be plumb, of strong and safe construction, and shall be equipped with stairways, ladders,
and/or elevators conforming to OSHA requirements.
B.
The methods of constructing the shafts are at the option of the Contractor subject to review and
approval by the RE.
3.02
A.
3.03
SHAFT SUPPORT
Refer to Section 02310 Shaft Support Slurry Walls for support requirements.
SHAFT EXCAVATION
A.
Jet grout ground treatment for the tunnel break-out and tunnel break-in locations shall be
installed prior to commencing excavation of the shaft.
B.
Excavations shall be made to the lines, grade, and dimensions shown on the Contract Drawings
or approved otherwise by the RE.
C.
The shaft excavation shall be done in such manner as to provide adequate support at all times to
conduits, structures, or adjacent roads so as to offer no hazard to train, truck or automobile
operations. Bracing and shoring shall be substantial and safe, and all work shall be done in full
conformity and subject to the inspection of all affected parties. If and when required and to the
degree necessary, the Contractor shall provide additional support as may be necessary.
D.
All materials encountered shall be regarded as unclassified and shall be excavated, regardless of
the nature thereof, and all excavated material shall be removed and disposed of as described in
Section 13140 Muck Disposal. Excavation shall be confined to within the limits of the shaft
and as required for the type of construction to be used and in such manner as to minimize any
settlement of the ground near the shaft.
E.
Shaft excavation under water:

1.
Excavate the shaft under water while maintaining the agreed water level within the
shaft.
2.
The Contractor shall monitor the piezometers surrounding the shaft during shaft
excavation and shall implement the approved contingency plan should any trigger
levels be reached.
3.
Shaft bottom elevation shall be measured continuously during excavation and

periodically during periods of stoppage. Implement the approved contingency plan
should bottom heave be apparent.
13060-6
3.04
A.
SHAFT TREMIE BASE SLABS

Preparatory works prior to placing base slab concrete by tremie method shall include:
1.
Cleaning of slurry walls at location of base slab.
2.
Connection of shear key reinforcement bars.
3.
Installation of base slab reinforcement.
B.
Shaft base slabs shall be placed by the tremie method as shown on the Contract Drawings.
C.
Shaft base slab concrete and associated submittals shall be in accordance with Section 03350
Cast-in-Place Concrete.
3.05
SHAFT UNWATERING
A.
Once the tremie concrete base slab has achieved the design strength the shaft shall be dewatered
slowly.
B.
Unwatering shall proceed at a slow, controlled rate and the discharge flow rates and volumes
shall be monitored and recorded. Water level inside the shaft shall be monitored and recorded.
C.
The Contractor shall monitor the piezometers surrounding the shaft on a continuous basis
during unwatering.
D.
If there are any signs of leakage or drawdown of the groundwater elevation surrounding the
shaft during unwatering the unwatering shall stop and corrective measures shall be implemented
immediately.
3.06
MAINTENANCE AND PROTECTION OF SHAFT DURING TUNNELING
A.
Once the shaft base slab has been installed the Contractor shall promptly and continuously
control water inflow and dispose of all water from any source that may accumulate in the shaft.
This shall include all necessary pumping, bailing, draining and sedimentation prior to discharge.
Contractor shall use grouting of the shaft walls to reduce infiltration of water in the shaft, if
required. Alternately, Contractor can pipe or otherwise divert water to sumps and pump out.
B.
Provide flood protection of shafts to an elevation 3-feet higher than the 100-year flood level as
described in the GBR. In the event of a storm resulting in flood elevations greater than a 100year flood level or when such flooding is imminent in the vicinity of the shaft, the Contractor
shall implement contingency measures to stabilize and protect the shaft excavation.
C.
Protection of the Brooklyn Shaft prior to reception and removal of the TBM:
1.
Provide a temporary shaft cover to prevent entry of foreign objects into the shaft.
2.
Provide and install a security fence surrounding the shaft and include sufficient
signage and security measures to prevent unauthorized access into the shaft either
deliberately or by accident.
13060-7
D.
Temporarily restore Shore Road Park around the Brooklyn Shaft site prior to reception and
removal of the TBM.
END OF SECTION
13060-8
SECTION 13120
REMOVAL AND TREATMENT OF TUNNEL CONSTRUCTION WATER
PART 1 GENERAL
1.01
SCOPE OF WORK
A.
The Work specified in this Section includes but is not limited to the design, furnishing,
installing, maintaining, operating, monitoring and removing of temporary systems installed to
remove and treat tunnel construction water, including water infiltration, during tunnel and shafts
construction, regardless of the source.
B.
The method of handling, conveying and removing tunnel construction water shall be by
whatever means necessary and acceptable to the RE to obtain satisfactory working conditions
and maintain progress of the work.
C.
Provide all labor and materials for building dams, weirs, sumps, pumps, discharge lines, and
flow control structures, and furnish and install all equipment required to control, handle,
monitor, instrument and convey tunnel construction water.
D.
Overlapping or redundant, independent discharge lines and intermediate, independent, or

redundant sump pumps to convey tunnel construction water from the tunnel.
E.
Tunnel construction water pumping stations are required in the bottom areas of each shaft.
F.
Provide daily testing of water quality to demonstrate compliance with the requirements of this
Section.
1.02
RELATED SECTIONS
A.
B.
C.
D.
E.
F.
G.
H.
Temporary Tunnel and Shaft Ventilation and Utilities is included in Section 13130.
13120-1
1.03
REFERENCES STANDARDS (NOT USED)
A.
Federal Regulations, 29 CFR Part 1926, Standards-Excavation, Occupational Safety and Health
Administration (OSHA).
B.
State Pollutant Discharge Elimination System (SPDES) permit, Chapter X Division of Water
Resources.
1.04
DEFINITIONS
A.
Tunnel Construction Water: All water, whatever the source, pumped from shaft and tunnel
excavations.
B.
Treatment Facility: All sediment ponds, sediment and oil removal systems, package plants, mix
tanks, or other treatment facilities used to treat tunnel construction water, including all
chemicals required to cause flocculation and sedimentation, change the pH, and any other
treatment required to meet the discharge requirements.
1.05
SUBMITTALS
A.
Submit shop drawings, descriptions, and a work plan narrative of the proposed ground water
and surface water control facilities including, but not limited to, equipment, methods, standby
equipment and power supply; instrumentation layouts; provisions for measuring pumped water
as required; and monitoring procedures. A schedule of installation and details of the system
operation shall also be submitted. A contingency plan and options shall also be submitted.
Submittal may take into consideration that staged expansion of pumping facilities is reasonable.
Plan should discuss remedial measures, whether grouting will be used, and should describe how
water drainage will be integrated with placement of concrete backfill in shafts and tunnel.
Resubmit as appropriate if the system is modified during installation or operation.
B.
Submit shop drawings of temporary tunnel and shaft sump locations, and pump and discharge
piping layouts.
C.
Proposed methods and locations for disposal of removed tunnel construction water.
D.
Submit manufacturers instructions and technical details for pumps, water meters, flow
measuring devices, and other water management systems equipment.
1.06
DELIVERABLES
A.
Maintain and submit, on a weekly basis, shift records including daily pump discharge quantities
from metering stations at each shaft.
B.
Submit a summary table upon completed initial installation for each section of work, showing
piezometer locations by station, installation depths, baseline piezometric elevation readings, and
piezometric control elevations.
C.
Submit an updated summary table of piezometric elevations on a weekly basis. Show the
piezometric elevations obtained from daily monitoring during pumping operations.
13120-2
1.07
A.
The Contractor shall be prepared to remove tunnel construction water from the shafts and the
tunnel.
B.
Provide drainage of seepage water and surface water in shafts, tunnel or excavations, as well as
water from any other source entering the excavation. Excavation drainage may include
placement of drainage materials, such as crushed stone, together with sump pumping. Size
sumps and pumps for expected infiltration levels allowed in the specifications.
C.
Modify operations if they cause or threaten to cause damage to new construction, existing site
improvements, adjacent property, adjacent water wells, or if they affect potentially
contaminated areas.
D.
Provide piezometers conforming to the requirements of Section 02495 Instrumentation and

Monitoring, as necessary, to monitor piezometric elevations for excavations and in accordance
with the following:
E.
1.08
1.
Provide at least one piezometer for each shaft. Install additional piezometers as
necessary at maximum 100-foot spacing around the periphery of the excavation, or as
defined by the RE.
2.
Existing piezometers installed for the Contractors use may be incorporated into the
groundwater control plan. All existing piezometers shown on the Contract Drawings
shall be grouted by the Contractor upon completion of the project, regardless of
whether or not they are incorporated into the groundwater control plan.
3.
Upper piezometer pipe shall be removed to at least 2 feet below grade (in non-paved
areas) and the ground surface shall be restored to match the adjacent ground surface.
On completion of construction, decommission piezometers and monitoring wells installed

during the design phase studies that were left for the Contractors monitoring and use as per
Section 02495 Instrumentation and Monitoring.
ENVIRONMENTAL REQUIREMENTS
A.
Comply with all regulations for removal of tunnel construction water.
B.
Comply with all applicable OSHA, Federal, State and Local regulations when encountering
groundwater believed to contain hazardous substances.

2.01
EQUIPMENT AND MATERIALS
A.
The Contractor shall select the equipment and materials to meet the requirements of removing
and treating the tunnel construction water. Drainage systems may include any pumping
equipment deemed necessary by the contractor.
B.
Maintain equipment in good repair and operating order.
13120-3
C.
Arrange for standby equipment and materials such that the drainage systems are available at all
times.
D.
Piezometers shall conform to the requirements of Section 02495 Instrumentation and

Monitoring.
PART 3 EXECUTION
3.01
A.
Treatment facilities shall be designed, furnished, and operated to permit discharging into surface
waters, storm sewers, drains, or ditches in accordance with the more stringent requirements of
all applicable Corporation, Local, State and Federal codes, laws, regulations and ordinances,
and the following:
1.
Water leaving the treatment facility shall have a pH ranging from 6 to 9 and no oil or
grease shall be present.
2.
Water leaving the treatment facility shall have a turbidity level less than or equal to 75
NTU.
3.
The turbidity in the receiving waters shall not be increased by more than 25 NTU.
B.
Remove water infiltration from the tunnel and shafts during excavation. Place and size tunnel
construction water pumping stations at the base of the shaft to handle required flows specified
in Contract Documents plus any extra capacity required to handle the Contractor-supplied water
and any fire protection flows at each shaft location.
C.
Install, operate, and maintain the drainage system in a manner compatible with construction
methods and site conditions. Notify the RE in writing of any changes made to accommodate
field conditions and changes to the Work.
D.
Remove system components, when drainage is no longer required.
3.02
MAINTENANCE AND OBSERVATION
A.
Conduct daily maintenance and observation of systems.
B.
Replace inoperable or damaged system components as necessary to maintain operation.
C.
Allow some point of discharge or other means for the RE to verify water turbidity and to obtain
samples for chemical testing of the discharge water at any time.
3.03
A.
3.04
A.
MONITORING AND RECORDING

Observe and record pump discharge quantities from metering stations at each shaft on a daily
basis.
DISPOSAL OF WATER
Tunnel construction water leaving the treatment facilities shall be handled, treated and
discharged in accordance with the requirements of this Section.
13120-4
B.
3.05
The location of the treatment facilities and discharges shall be as agreed with the RE to coincide
with the Contractors plans for its proposed site layout.
CLEANUP AND RESTORATION
A.
Sumps in the tunnel and shaft areas shall be cleaned of settled sediments and filled with backfill
concrete in accordance with Section 03301 Backfill Concrete in Shaft and Tunnels.
B.
Grout and abandon piezometers and monitoring wells in accordance with all applicable
regulations and following requirements of Section 02495 Instrumentation and Monitoring.
3.06
A.
EMERGENCY PREPAREDNESS
When the Contractor is excavating and encounters large amounts of water draining into the
excavation, immediate steps shall be taken to control the water source. Large amounts of water
requiring control shall be defined as those that adversely affect the performance of the work
under this Contract and/or amounts that have the potential of resulting in improper operation of
sedimentation basins, treatment systems, or causing a loss or damage to adjacent properties.
END OF SECTION
13120-5
SECTION 13130
TUNNEL AND SHAFTS TEMPORARY VENTILATION AND UTILITIES
PART 1 GENERAL
1.01
A.
SCOPE OF WORK
The Work specified in this Section includes but is not limited to the design, procurement,
installation, operation, maintenance, and removal of all temporary facilities required for the
tunnel construction including the following:
1.
Ventilation, cooling, dust removal and maintenance of acceptable air quality and
environmental conditions, including the provision of sufficient ventilation flow for
dispersion, dilution and exhaust of contaminated materials which may enter the tunnel
through groundwater flows and seepage.
2.
Lighting along the length of tunnel, in shaft bottom areas, in shafts, and in the vicinity
of all equipment for safe operations.
3.
Mine paging/communication system in shafts and tunnel.
4.
Water and compressed air supply for construction, fire protection, and other use in
shafts and tunnel.
5.
Electric lines and transformers as required for operation of lighting, communications

equipment and other construction equipment such as Tunnel Boring Machines
(TBMs), conveyors, pumps and ventilation equipment.
6.
Emergency generator(s)/power for operation of pumps, ventilation systems and safety

equipment in case of general power outage.
7.
Components for hanging, fastening, and securing the facilities.
8.
Heating facilities and spot coolers, as required.
9.
Sanitary facilities at the tunnel headings and at the bottom of the construction shafts.
10.
Tunnel walkway and shaft emergency egress stairway.
11.
Fire extinguishers and cabinets
12.
Refuge areas.
13.
Tunnel lining attachment details for temporary facilities.
14.
Construction rail track details.
B.
Procurement of electrical power, potable water, sewer services, and sanitary facilities shall be
the Contractors responsibility.
C.
Shafts and tunnels assessed gas hazard classification Refer to Section 13000 Tunnel and
Shaft Safety.
D.
All work specified in this Section shall be the Contractor's responsibility. All work shall comply
with all applicable federal, state, local and Corporation codes, laws, regulations and ordinances.
13130-1
1.02
RELATED SECTIONS
A.
Temporary Utilities is included in Section 01510.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
1.03
REFERENCE STANDARDS
A.
OSHA U.S. Department of Labor, Occupational Safety and Health Administration,

Construction Standards and Interpretations, 29 CFR Part 1926, Underground Construction
and its referenced subparts and sections.
B.
MSHA U.S. Department of Labor, Mine Safety and Health Administration, 30 CFR Part 7,
Subpart B, Brattice Cloth and Ventilation Tubing.
C.
NFPA National Fire Protection Association 241 - Standard for Safeguarding Construction,
Alteration, and Demolition Operations, August 29, 1993.
D.
NFPA National Fire Protection Association 70 - National Electrical Code, 2005
E.
All other applicable Corporation, Local, State, and Federal code requirements and regulations
applicable in effect at the time of construction
1.04
1.05
SUBMITTALS
A.
The following shall be submitted to the RE at least 60 days before commencement of operations
The following specific information shall be provided:
1.
Tunnel and Shaft Ventilation Plan:

a.
Layout, details and specifications for all ventilation components, including but
not limited to: locations, sizes, manufacturers operating manuals, operating
configurations, ducting, methods of joining lengths of duct together, method of
13130-2
suspending the ducts, noise attenuation devices, fan noise performance data, fan
pressure / performance curves, control and operating systems, as well as backup
systems for electrical power and controls in event of loss of power or other
failure of the system to continuously provide the specified minimum airflow in
the tunnel and shafts at all times.
1.06
A.
1.07
A.
b.
Details of all airflow and pressure monitoring equipment together with a

schedule for proposed air quality measurements at the face and at other working
areas away from the face. Sample of report format for air flow monitoring and
ventilation system performance
c.
Ventilation system designer qualifications.
2.
Layout, details and specifications of all the tunnel utilities.
3.
Temporary lighting plans, details, circuiting, etc.
4.
Details and layout of all water flow monitoring equipment to be installed to provide
data on the volumes of water used in the Contractors operations, which is
subsequently collected, pumped and treated as construction water as defined in
Section 13120 - Removal and Treatment of Tunnel Construction Water. All flow
monitoring data shall be submitted electronically, in a form acceptable to the RE on a
weekly basis.
5.
Proposals for emergency response in the event of a fire in the tunnel or shaft, with an
assessment of the likely heat release rate and location of potential fires. The contractor
shall demonstrate that safe egress is possible in the event of a fire in the tunnel.
6.
Details and layout of communications system.
7.
Details of gas monitoring devices in addition to those provided on the TBM.
8.
Fire protection systems and devices.
DELIVERABLES
All data from the Air Monitoring Program including the following documentation shall be
submitted in a format agreed by the RE during the construction period both electronically and
hard copy:
1.
Air quality measurements shall be submitted on a daily basis during excavation, lining
and pipe installation and backfilling.
2.
All airflow monitoring and ventilation system performance data shall be submitted
both electronically and hard copy on a weekly basis
3.
All tunnel construction water flow monitoring data shall be submitted both
electronically and hard copy on a weekly basis.
A firm with a minimum of three years of experience, all in the last five years, designing
ventilation and electrical facilities for tunnel construction, shall design the facilities under the
direction of a professional engineer registered in the State of New York. The firm shall be
operated and maintained by personnel with a minimum of three years of experience within the
last five years.
13130-3
B.
Electrical equipment including switches, panel boards, transformers, receptacles, motors,

lighting, etc. shall be suited for the applicable gas hazard classification.
C.
Air Monitoring Program: The Contractor shall monitor air quality at the excavation face, the
TBM and elsewhere as appropriate in accordance with OSHA Regulations. Monitor airflow
measurement data to demonstrate that the ventilation system is providing airflow in compliance
with the minimum requirements outlined in these specifications.
PART 2 PRODUCTS
2.01
MATERIALS AND EQUIPMENT
A.
Materials may be new or used; shall be adequate for purposes intended; and shall satisfy
requirements for codes and regulations pertaining to the system. Tunnel and shaft support
equipment and materials, including but not limited to utilities, shall be made of such materials
and maintained in such a manner so as not to impair production or expose workers to safety
hazards due to deterioration of the components or support equipment. Equipment and utilities
within the tunnel and shafts shall also be so designed, fabricated, maintained and operated in
such a manner to avoid accidents due to explosion or fire.
B.
Select equipment and components that will be resistant to water damage and deterioration under
the conditions of the Project.
C.
A Siamese connection, or approved equal, shall be provided at the shaft top and check valve
with fire drops located at the base of each shaft and every 500 ft along the tunnel for fire
departments use.
D.
Select sizes of fan(s) to provide as a minimum the minimum required airflow at the inlet. The
proposed ventilation system should not be reliant on the use of underground fans, with the
exception of any fan or fans for flow reversing arrangements. If underground fans are proposed,
details shall be provided for the control and prevention of re-circulation of air.
E.
Select ventilation duct design for maximum airflow and minimum air leakage and resistance to
fire hazards. Total leakage along the duct line shall not exceed one half of the air volume flow in
the duct at the inlet. All bends shall be formed of rigid duct materials.
F.
Ventilation ducting and brattice cloth shall be fire-resistant to MSHA, Part 7 of Title 30 Code of
Federal Regulations. If the Contractor proposes to use the ventilation system to control smoke
during a fire, the duct shall be capable of remaining intact in the event of a fire to the extent
required for the proposed smoke control system.
G.
Tunnel ventilation fan(s) shall be explosion proof and shall continue to operate during an air
monitor alarm condition.
H.
Air monitoring equipment shall be provided for the applicable gas hazard classification in
accordance with OSHA 1926.800 and NFPA 241.
PART 3 EXECUTION
13130-4
3.01
DESIGN
A.
Systems shall be installed in a neat and orderly manner, made structurally, mechanically and
electrically sound, maintained to provide safe, continuous service at required times and to the
minimum requirements outlined in these specifications, and modified and extended as work
progresses.
B.
Fresh air shall be supplied to all underground work areas in sufficient amounts to prevent any
dangerous or harmful accumulation of dust, fumes, vapors, or gases in accordance with OSHA
requirements. The design of the ventilation system shall consider at least the following:
C.
1.
Safety consideration dictated in referenced and all applicable codes and standards.
2.
Quantities of air required by OSHA.
3.
Provision for reversible airflow. Wherever possible, the proposed ventilation system
should not be reliant on the use of underground fans, with the exception of any fan or
fans for flow reversing arrangements.
4.
Dispersion and dilution of contaminated gases and flammable, explosive or other

hazardous gases or materials.
5.
Tunnel or shaft Geometry: Depth, length, cross section.
6.
Ambient Conditions: External summer and winter climate, in-situ ground temperature
and water infiltration.
7.
Maximum number of personnel in tunnel or shaft, including Contractors,

Corporations and REs personnel.
8.
Number and types of equipment in the tunnel or shaft, and their effects on air quality
and temperature including sizes of diesel and electrical motors to be used throughout
the duration of the project.
9.
Methods of cooling TBM motors; water sprays for dust control; ventilation of tunnel
face; and removal of dust from the ventilation air.
10.
Friction losses, loss of air through duct leakage, minimum air velocity in the tunnel.
11.
Phasing of the systems as the shaft and tunnel advances, and during removal of TBM
and installation of pipelines and concrete
12.
Local ventilation requirements at locations of welding, concrete placement, and

elsewhere, as required.
13.
Fire resistance and electrical safety.
14.
Sizes of diesel and electrical motors used in underground equipment during

excavation and lining operations.
15.
Air quality in the tunnel.
16.
Contaminated groundwater or gases and flammable, explosive or other hazardous

gases or materials.
17.
Special provisions for battery charging facilities, if any.
The location of ventilation duct inlets and outlets shall be such that recirculation is prevented.
Surface duct inlets and outlets shall be at least 50 feet from any shaft or other opening.
13130-5
D.
3.02
The Contractor shall design lighting and illumination system in the shafts and tunnel and any
other general work area during all operations in accordance with OSHA regulations and the
National Electrical Code (NFPA 70).
OPERATION
A.
Spot coolers and air-conditioned enclosures shall be provided as appropriate for the
environmental conditions and as required for personnel comfort and operation of electronic and
other equipment.
B.
Control of the ventilation systems shall be at ground surface; appropriate delays and interlocks
shall be provided for proper sequencing and operation of fans, including reversal of fans.
C.
The exhaust/intake of the fans shall be kept clear of surface engine exhausts and at least 50 feet
from the edge of the shaft.
D.
Ground all electrical equipment.
E.
Lighting and ventilation facilities shall be left in the tunnel and shafts until all work has been
completed and accepted, after which, they and all loose or projecting hangers and supports shall
be removed. Ventilation ducting may be removed on completion of excavation, providing that
positive through-tunnel ventilation is achieved by means of a bulkhead and ventilation fans, or
other arrangements such as a jet fan.
3.03
FIRE SAFETY
A.
General: Appropriate portable fire-suppression equipment shall be provided in all underground

work areas in accordance with NFPA 241.
B.
Conveyor Systems:
1.
Vertical conveyors, if employed, shall be outfitted with a deluge system or approved

equal, and the drive motor stations of horizontal conveyors shall be protected either
by water or dry chemical protection. Booster drives, splicing stations, tail pulleys, and
other fixed pieces of equipment on vertical and horizontal conveyors and related
assemblies used underground shall be protected by fixed fire sprinklers or other
means. The sprinkler system design shall include a Siamese connection or approved
equal for an alternate water source. Provide means of testing all systems. Testing shall
be performed two times a year.
2.
Test samples of the conveyor belt materials to be used, shall be tested by a recognized
testing laboratory to determine the exact fire propagation index. The results of the
tests shall be used for emergency planning purposes.
3.
All belt conveyors used underground shall be equipped with pulley slippage systems
designed to shut down the belt if sliding friction develops between the drive pulley(s)
and the belt. The slippage system shall be inspected in accordance with the
manufacturer's recommendations.
4.
All conveyor belt systems shall be equipped with interlock(s) compatible with all
conveyor system components, which shall shut down belt conveyors if any conveyor
in the system should stop or reduce its normal speed or upon activation of a conveyorrelated fire protection system.
13130-6
C.
5.
Fixed combustible materials shall be either metal guarded from contact by conveyor
belt(s) or located at least half the width of the belt for an idler or pulley. Machinery
guarding in the drive area and at other points along the belt shall be of noncombustible material.
6.
Belt conveyors shall utilize structures that do not provide a deck between the upper
and lower strands of belt except at necessary transfer points and belt splicing
locations. Structures at transfer points and belt-splicing locations shall not be
constructed in a manner, which will cause hazardous accumulations of material.
Communication Systems:
1.
Voice communication shall be provided between the surface and underground work
areas at all times. The communications system shall be by a fixed wire or telephone
system. Suitable protection shall be provided for each communication device location.
The distances between communication devices along the tunnel alignment shall not
exceed 500 feet.
2.
Each field office of the RE shall be provided with one fixed-wire device or telephone
device as directed by the RE dedicated to maintaining communication with the
underground work area at all times.
3.
Fixed communications wiring and equipment shall be located away from fire sources
such as, but not limited to, transformer and conveyor systems.
4.
Fixed wire communications equipment along the tunnel alignment shall be located as
to avoid unnecessary reaching or climbing on the tunnel walls for access.
5.
Where radio system(s) are used for emergency communications, repeater systems
shall be so installed and located as to ensure uninterrupted and audible
communications between the surface and underground work locations.
6.
All communications equipment shall be tested weekly and a record of the tests
maintained by the Contractor for the duration of the work.
D.
Electrical Systems: Electrical power supplying critical operating equipment to support

evacuation of persons from the underground work area(s) such as, but not limited to, hoisting,
pumping, communications, and hauling equipment, shall be provided with backup supply
systems. All electrical transformers used underground shall be of the dry type. Further
requirements for TBM electrical supply and backup supply are given in Section 01510 and
02330.
E.
Drainage Systems: The drainage system in underground work areas of the tunnel shall be
designed and installed as to accommodate the maximum expected sprinkler and/or fire hose
discharge, groundwater and all construction water used by the Contractor. All Contractorsupplied flows into the underground works shall be separately and continuously metered at the
top of each shaft. The Contractor shall ensure that pumping capability is maintained during an
air monitor alarm situation when electrical systems are shut down.
3.04
A.
CLEANING
Upon completion of the work, all temporary lighting, tunnel track system, ventilation equipment
and utility lines shall remain the property of the Contractor and shall be removed from the site.
13130-7
B.
All areas disturbed by the installation shall be restored to a condition satisfactory to the RE,
including patching of any anchorages in final concrete lining.
END OF SECTION
13130-8
SECTION 13140
MUCK DISPOSAL
PART 1 GENERAL
1.01
A.
1.02
SCOPE OF WORK
The Work specified in this Section includes but is not limited to disposal of all muck and
excavated material removed from the Project. The Contractor shall be responsible for locating
off-site locations for muck disposal including all necessary conveyance, permitting and ultimate
disposal of muck and excavated material from the work sites to the satisfactory of the RE.
RELATED SECTIONS
A.
Environmental Protection is included in Section 02270.
B.
C.
D.
E.
F.
G.
1.03
1.04
DEFINITIONS
A.
Muck: Muck consists of materials generated in excavating the tunnel and shafts.
B.
Excavated Materials: Consists of soil generated from surface excavations.
1.05
SUBMITTALS
A.
Submit the muck disposal and excavated material disposal plans and locations, on site and offsite, with shop drawings as necessary to the RE at least 30 days prior to start of excavation.
Include, as a minimum, a listing of all required mitigation and avoidance measures, noise
control measures, conveyor system location and descriptions, location of stockpiles, drying
areas and all other measures proposed for handling of muck, final grading, and site restoration
plans.
B.
Submit proposed haul routes from each shaft site for any material that is to be disposed to REs
approved locations. Haul routes within the Corporations property shall conform to the
requirements of the Corporation.
13140-1
1.06
DELIVERABLES
A.
Submit copies of all permits that are required by and obtained from federal, state and local
governing authorities for disposal of muck and excavated materials.
B.
Documentation from disposal facility confirming acceptance of conditioned tunnel spoil.
1.07
A.
The Contractor shall adhere to all applicable ordinances, codes, statutory rules and regulations
of federal, state and local authorities.
PART 2 PRODUCTS
2.01
MATERIALS AND EQUIPMENT
A.
Vehicles used for hauling and disposing of excavated material and muck shall be properly
muffled, provided with full bed liners to minimize noise, and shall have covers. Vehicles shall
not impose loads that may damage existing utilities and structures.
B.
Conveyor systems shall be designed to operate safely and quietly while withstanding all
operating and wind loads. The systems shall be designed to minimize spillage and to control
dust and noise. Special precautions such as total enclosure safety screening shall be employed
along the elevated portion of the system.
PART 3 EXECUTION
3.01
A.
Temporary placement of materials at locations other than the construction sites for the
convenience of the Contractor shall be allowed only with the written approval of the
Corporation and shall be removed and placed as specified prior to final completion of the work.
B.
Erosion control measures such as hay bales and/or silt fences shall be installed around
excavated materials, which are temporarily stockpiled awaiting transport. Water shall be applied
to control dust.
C.
Noise levels and dust control shall comply with all applicable federal, state and local codes,
laws, regulations and ordinances. Operations shall be conducted to minimize the impact of noise
and dust to the residents in the vicinity of the work. All surface equipment shall be equipped
with noise suppressors. Equip compressors with silencers on intake lines. All gasoline, diesel or
air-powered equipment shall be equipped with silencers or mufflers on exhaust lines. Storage
bins and hoppers shall be lined with materials that deaden sound.
D.
Material to be disposed shall be tested in accordance with Corporation specifications and local
regulations and specifications, as required.
E.
The Contractor shall undertake all necessary measures, such as temporary drying areas, to
ensure that material complies with the applicable requirements prior to transfer to the off-site
disposal areas.
13140-2
F.
3.02
Haulage vehicles shall be covered at all times when transporting muck.

CLEANING
A.
Remove waste materials and restore all sites.
B.
At the completion of the work, fill areas accepted by the Corporation shall have a neat
appearance and shall be graded to drain to drainages to prevent erosion, in accordance with
Section 02270 Environmental Protection of Volume 2 of these Specifications.
END OF SECTION
13140-3
SECTION 13200
PRE-CONSTRUCTION AND POST-CONSTRUCTION INSPECTIONS
PART 1 GENERAL
1.01
1.02
SCOPE OF WORK
1.
The Work in this Section includes but is not limited to the requirements of the
Contractor to perform pre-construction and post-construction inspections for
structures, houses, buildings and other facilities as described herein.
2.
All pre-construction inspection reports shall be submitted to the RE prior to

commencement of excavation at any of the two shaft sites, or commencement of the
tunnel excavation.
RELATED SECTIONS
A.
B.
C.
D.
1.03
1.04
1.05
SUBMITTALS
A.
The Contractor shall submit pre- and post-construction inspection reports as described in this
Section.
1.06
1.07

PART 3 EXECUTION
3.01
INSPECTIONS
1.
Prior to the start of shafts excavation, the Contractor shall conduct pre-construction
inspections for structures, roads, sidewalks, houses, utilities and other facilities
located within 100-ft of shaft locations and 50-ft of each side of the tunnel land
13200-1
centerline alignment, in whole or in part. At the Brooklyn Shaft site, this shall include
inspection of park property located within Shore Road park.
B.
C.
For both tunnel and shaft pre-construction surveys:

1.
Pre-construction inspections shall be undertaken by qualified specialists, approved by

the RE and the Contractors insurance carrier retained for this purpose by the
Contractor to observe the condition of existing structures, utilities, and facilities in the
vicinity of the Work at required intervals. The pre-construction inspections shall
thoroughly document all existing damage or defects to both the interior and exterior of
all structures, houses, buildings or facilities. The interior conditions of all portions of
all structures, including all walls, partitions, floors and ceilings shall be thoroughly
documented by diagrams, transcribed notes and photographs to show the location and
extent of existing damage deterioration and cracks including their dimensions, extent,
and other relevant features. A minimum of 10 interior and 30 exterior photographs
shall be taken for each structure or facility. Close-up, detailed color photographs shall
be taken of all cracks, deterioration and other observable effects in the exterior
portions of all buildings and other property improvements including, but not limited
to, retaining walls, driveways and sidewalks. The size of all color photographic prints
shall be 4 inches by 6 inches, minimum.
2.
The Contractor shall prepare and deliver to the RE prior to the start of construction at
each site, three (3) bound copies of each of Contractors pre-construction inspections
containing all field notes taken, sketches and diagrams prepared, color prints produced
from negatives of all photographs obtained together with a schematic plan indicating
where photographs were taken, descriptions and reports, all signed and witnessed by
those taking part in the inspection. The Corporation will, upon request, present one of
these copies to the property owner or responsible party for each property or utility
affected. Thereafter, as construction progresses, the Contractor shall re-inspect as
often as necessary in the opinion of the RE to verify the adequacy of Contractors
construction methods for prevention of damage and to obtain sufficient evidence for
use in defense against possible claims for damage from third parties. Contractor shall
also re-inspect all properties where Property owners claim that damage is occurring as
a result of the Contractors construction operations. Three (3) copies of all data
obtained by the Contractor from each re-inspection shall be promptly (within three
days of re-inspection) delivered to the RE. The Corporation will, upon request, present
one of the submitted copies to the property owner or responsible party for each
property or utility affected.
For both tunnel and shaft post-construction surveys:

1.
Post-construction inspections shall be undertaken by qualified specialists, approved by

the RE and the Contractors insurance carrier retained for this purpose by the
Contractor to observe the condition of existing structures, utilities, and facilities in the
vicinity of the Work within 30 days of the completion of any section of work such that
includes tunneling activities. The post-construction inspections shall thoroughly
document the condition of the interior and exterior of all structures, houses, buildings
or facilities. To facilitate the inspection use shall be made of the pre-construction
inspection to identify any changes in condition. Photographs of all items noted on the
pre-constriction inspection shall be taken from the same locations. Any damage noted
that was not included in the pre-construction inspection shall be thoroughly
documented by diagrams, transcribed notes and photographs to show the location and
13200-2
extent of damage deterioration and cracks including their dimensions, extent, and
other relevant features. Close-up, detailed color photographs shall be taken of all
cracks, deterioration and other observable effects in the exterior portions of all
buildings and other property improvements including, but not limited to, retaining
walls, driveways and sidewalks. The size of all color photographic prints shall be 4
inches by 6 inches, minimum.
2.
The Contractor shall prepare and deliver to the RE, within 14 days of undertaking the
inspection, three (3) bound copies of each of Contractors post-construction
inspections containing all field notes taken, sketches and diagrams prepared, color
prints produced from negatives of all photographs obtained together with a schematic
plan indicating where photographs were taken, descriptions and reports indicating
whether any additional damage has been observed or if previously identified defects
have become worse, all signed and witnessed by those taking part in the inspection.
The Corporation will, upon request, present one of these copies to the property owner
or responsible party for each property or utility affected.
D.
Nothing contained herein shall relieve the Contractor of responsibility for claims arising from
Contractors construction operations. Failure to inspect any structure, whether or not required
by these Contract Documents or inadequacy of the inspections shall not relieve the Contractor
of Contractors responsibility. The Contractor shall indemnify the Corporation and the RE from
such claims. The Contractor shall engage the services of an experienced, independent, licensed
RE to evaluate any claims that may arise as a result of construction operations. The RE may
reject the claims specialist, if the RE has reason to believe that there exists material ownership
interests between the claims specialist and the Contractor and/or evaluation consultant and/or
there exists relationships other than Contractor/sub-Contractor among the aforementioned
entities, or for other reasons.
E.
In the event that any property owner denies access for the survey of structures and facilities
within the specified limits, the Contractor shall notify such property owner, by certified mail, on
the intent of the survey. If after 2 weeks, access is still denied, the Contractor shall notify the
property owner once again by certified mail, stating that this is final notification. Submit to the
Corporation copies of all correspondences between the Contractor and the property owner(s).
The Corporation, upon review of the submitted correspondences may waive requirements set
forth in this Section. However, the Contractor is fully responsible for claims and damage arising
from Contractors construction operation regardless of property location.
END OF SECTION
13200-3

Syphon TBM Specs2009

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CITY OF NEW YORK

BOROUGH OF BROOKLYN AND STATEN ISLAND

THE REPLACEMENT OF THE

NEW YORK CITY

NEW YORK CITY

VOLUME 3 TUNNEL AND SHAFTS

NEW YORK CITY ECONOMIC DEVELOMENT CORPORATION

DIVISION 1 - GENERAL REQUIREMENTS

Introduction Volume 3....................................................................... 01003-1 to 01003-4

DIVISION 2 - SITE WORK

Control of Groundwater and Surface Water ......................................... 02145-1 to 02145-3

Concrete Formwork .............................................................................. 03100-1 to 03100-6

DIVISION 4 MASONRY (NOT USED)

DIVISION 5 METALS (NOT USED)

Metals.................................................................................................... 05000-1 to 05000-8

DIVISION 6 - WOOD AND PLASTICS

Plastic Fabrications ............................................................................... 06600-1 to 06600-6

DIVISION 7 - THERMAL AND MOISTURE PROTECTION (NOT USED)

DIVISION 8 - DOORS AND WINDOWS (NOT USED)

DIVISION 9 FINISHES (NOT USED)

DIVISION 10 - SPECIALTIES (NOT USED)

DIVISION 11 - EQUIPMENT (NOT USED)

DIVISION 12 FURNISHINGS (NOT USED)

DIVISION 13 - SPECIAL CONSTRUCTION

Tunnel and Shaft Safety........................................................................ 13000-1 to 13000-7

DIVISION 14 - HANDLING EQUIPMENT (NOT USED)

DIVISION 15 MECHANICAL (NOT USED)

DIVISION 16 ELECTRICAL (NOT USED)

Volume 1 Front-end Contract Documents

Volume 2 Common Technical Specifications

Volume 3 Tunnel and Shafts Technical Specifications

Volume 4 Siphon Chlorination Station Technical Specifications

Volume 5 Land Piping Technical Specifications

Volume 6 Geotechnical Reports

Volume 7 Permits and Approvals

This introduction is pertinent to Volume 3 Tunnel and Shafts Technical Specifications. In

Permits and approvals are covered in Volume 7 Permits and Approvals.

Mobilize to site, initiate shop drawings submittals, establish work site.

Manufacture and supply tunnel lining segments to site.

Construct Brooklyn receiving shaft (must be completed prior to launch of TBM),

Landscaping, site cleanup and demobilization is covered in other specification volumes.

PART 2 PRODUCTS (NOT USED)

LUMP SUM ITEM

Products wasted or disposed of in a manner that is not acceptable.

Products determined as unacceptable before or after placement.

Products not completely unloaded from the transporting vehicle.

Products remaining on hand after completion of the Work.

Loading, hauling and disposing of rejected Products.

PART 2 PRODUCTS (NOT USED)

MINIMUM SCHEDULE OF VALUES FOR TUNNEL AND SHAFTS

SCHEDULE OF VALUE NO. G-1 - MOBILIZATION AND DEMOBILIZATION AND

After Final Acceptance of the work by Corporation, the remainder of total

SCHEDULE OF VALUE NO. TS-1 SITE WORK AT STATEN ISLAND SHAFT

including protection of existing utilities; temporary and or permanent relocation of

SCHEDULE OF VALUE NO. TS-2 SITE WORK AT BROOKLYN SHAFT

SCHEDULE OF VALUES NO. TS-3 INSTRUMENTATION AND MONITORING

SCHEDULE OF VALUES NO. TS-4.1 STATEN ISLAND SHAFT OPTION 1 SLURRY

SCHEDULE OF VALUES NO. TS-4.2 STATEN ISLAND SHAFT OPTION 2 GROUND

SCHEDULE OF VALUES NO. TS-5 CONTROL OF WATER AT STATEN ISLAND

SCHEDULE OF VALUES NO. TS-6.1 BROOKLYN SHAFT OPTION 1 SLURRY WALL

SCHEDULE OF VALUES NO. TS-6.2 BROOKLYN SHAFT OPTION 2 GROUND

SCHEDULE OF VALUE NO. TS-7 CONTROL OF WATER AT BROOKLYN SHAFT

SCHEDULE OF VALUE NO. TS-8 - TUNNEL BORING MACHINE MOBILIZATION