Conti Environmental, Inc, July 27,1998July 27,1998 Randy Sturgeon U.S. Environmental Protection Agency Region III 1650 Arch Street Philadelphia, PA 19103-2029 RE: Draft Work Plans

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Conti Environmental, Inc,July 27,1998

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MMAVERICK

MAVERICKConstruction Management Services, Inc.

July 27,1998

Randy SturgeonU.S. Environmental Protection AgencyRegion III1650 Arch StreetPhiladelphia, PA 19103-2029

RE: Draft Work PlansGalaxy/Spectron Site

Dear Randy:

Please find enclosed a copy of the draft works plans for the removal action construction at theGalaxy /Spectron Site located in Elkton, Maryland for your review and approval. Included in thispackage are the draft Health and Safety Plan, Erosion and Sediment Control Plan, and the ProjectExecution Plan. Per your request, a copy of each plan has been sent directly to the MarylandDepartment of the Environment and the U. S. Army Corp of Engineers.

We are targeting August 10, 1998 for mobilization to the site. If there is anything we can toexpedite the approval of these work plans, please do not hesitate to call on us.

If you have any questions, please contact me at (508) 733-2900 or page me at (800) 505-4740.

Si

•loreConstruction Manager

cc: Michael Parr (w/o attachments)Rick Grills, MDE (w/attachments)Ramon Benitez, USAGE (w/attachments)

P.O. Box 60700King of Prussia, PA 19406610-783-6202610-783-6231 FAX R R 3 0 0 U 8 5

197M Boston Post Road WestSuite 356

Marlboro, MA 01752508-485-7872

FAX 508-485-8340

GALAXY / SPECTRON SITE

ELKTON, MARYLAND

REMOVAL ACTIONEXECUTION PLAN

July 27,1998

TABLE OF CONTENTS

CONTI ENVIRONMENTAL, INC

SECTION DESCRIPTION PAGE NO.

I. Introduction 1

II. Pre-Con struct ion Meeting 3

III. Mobilization 3

IV. Fence Removal and Reinstallation 5

V. Clearing and Grubbing 6

VI. Water Management 7

VII Demolition 11

VIII . Site Grading 12

IX. Installation of Concrete Cast-In-Place Cone. Walls 13

X. Groundwater Collection System 16

XI. Barrier Layer 17

XII . Protective Cover 19

XIII. Habitat Restoration 21

XIV. Demobilization 23

XV. Traffic Control Plan 24

GALAXY / SPECTRON SITEELKTON, MARYLAND

REMOVAL ACTIONEXECUTION PLAN

CONTI ENVIRONMENTAL, INC

I. Introduction /

A. Project Objective:The objective of this project is to physically separate the surface water flow in theLittle Elk Creek from the subsurface dense non-aqueous phase liquid (DNAPL)impacted subsurface flow and to isolate, collect, and treat the DNAPL-impactedsubsurface flow, however permanent treatment system installation is not part ofthis contract. This objective shall be accomplished by isolating the surface waterflow in the creek, constructing grounHwatep cutoff walls atW upstream anddownstream limit of the remedy, installing a groundwater collection system,installing a barrier layer along the stream bed, and installing a protective coverwithin the creek channel over the barrier layer, and reconstructing the riparian andstream habitat. Conti Environmental, Inc. (CEV) will perform this work inaccordance with the approved 100% Design plans and specifications as submittedby Advanced GeoServices Corp. to the USEPA.

A complete set of Contract Documents will be maintained in CEV's on-site fieldoffice as a Project Record / As-Built set of plans. The documents will be labeledas such and will not be used for any other purpose and will not be removed fromthe trailer under any circumstances. This set will be updated regularly as workprogresses on the site. At the conclusion of the project, the plans will beforwarded to the Construction Manager as a formal submittal per the requirementsof Section 01050 of the Contract Documents.

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B. Project Team p \CEV organizational plan for thi galaxy/Spectron site is based upon fielding anexperienced, independent project management team supported by key Corporatemanagers. The CEV project team consists of personnel experienced in hazardouswaste site and Superfund remediation. The key personnel to be assigned to thisproject are outlined below. Resumes of the key personnel can be found in CEV'sProposal to Maverick Construction Management Services, Inc. dated jmW *> 1998.

• Mr. James V. Stewart: Vice President of Operations• Mr. John Czapor: Director of Environmental Services• Mr. Al Aballo: Corporate Health and Safety Officer• Mr. Robert Scerbo: Project Estimator• Mr. Paul Dutko: Quality Control Officer• Mr. Leonard Nicaretta: Project Superintendent• Mr. Andrew C. Weber: Project Engineer/Manager• Mr. Carlos Narciso: Labor Foreman• Mr. Bruce Henderson: Health and Safety Officer (Haz-Tech Corp.)• Site Field Engineer: T.B.D.

C. Sequence of Major OperationsRemoval Action Construction at the Galaxy/Spectron site involves numerousoperations including but not limited to the following items. Each item will bediscussed in detail within this report:

• Submittals: Work Plans, Health and Safety Plan, etc.• Preconstruction Meeting• Mobilization• E&S Controls• Clearing and Grubbing• Water Management• Demolition• Site Grading /• Installation of Concrete^ casX-In-Place Concrete Walls

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Groundwater Collection SystemWater Diversion SystemInstallation of Barrier la>jerInstallation of Protective LayerConstruction of Gabion WallsHabitat RestorationDemobilization

II. Pre-Construction Meeting

Prior to mobilization at the site, a Pre-Construction Meeting will be held at alocation, date and time determined by Maverick Construction Service, Inc.(Construction Manager). This meeting will serve multiple purposes including butnot limited to the following:• Introduce the Project Team• Review the Project Schedule• Review the work plans (Including the Health and Safety Plan)• Review the Health and Safety Plan ( Including the Air Monitoring Plan)• Discussion of required/non-required permits: Both at the Local & Gov't levels• Mobilization Issues: Field Office Coordination

Material laydown areas will be located on the Plant property including under theexisting canopy and on the non-plant side (east side) adjacent to Little Elk Lane.

CEV intends to mobilize several pieces of equipment to be included with theinitial activities. These will include a Komatsu PC-400 Excavator, Komatsu WA-400 Loader or equal, 37-P Dozer, Combination Loader/Excavator, D300 RearDump truck and a Tool Container. Equipment mobilized on-site will be keptwithin the Plant property.^

Water on site will be handled in the followin&4nanner. Drinking water will besupplied by a service such as Great Bear, de^onning water will be clean upstreamwater held in a 5000 Gal Tank on-site. A portable handwashing station will beset-up adjacent to the trailer compound along with an emergency eye wash station.

CEV will acquire the services of a Maryland Licensed Surveyor to perform c ' : ,/•survey operations on site. The Surveyor's qualifications will be submitted to theConstruction manager for review and approval. Upon approval, the Surveyor willmobilize on site, establish survey control per Plan Sheet No. 1 of the approved100% Design and set the clearing limits at the direction of CEV and theConstruction Manager. The trees within the clearing limits which are to remainwill be clearly marked with survey ribbon. The Surveyor will establish thebaseline survey and confirm the existing topography. The Surveyor will beresponsible for maintaining site control throughout the project and layout of themajor work operations/!.e. Groundwater Collection System, Concrete Walls, RockAnchor Locations, etc/^The field equipment utilized by the Surveyor will 1> "̂'enable him to collect necessary data in the field and download at their office inpreparation of required As-Builts.

All required health and safety and environmental monitoring will be implementedprior to the start of intrusive activity. The "kick-off meeting will incorporate thisSite Specific Training and will be conducted by the Site Safety and Health Officer.CEV will monitor the perimeter of the site with photo-ionization detectors'(PID's)equipped with warning alarms to indicate when action levels are exceeded. Adetailed discussion of perimeter monitoring will be included with the Site Healthand Safety Plan under separate coyer, /

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Guy wires on existing utility poles within the Plant property which may interferewith the proposed work will be relocated at the direction of Delmarva PowerCompany. The guy wires will be realigned by the Engineering DepartmentDelmarva to remain out of the work area.

CEV will utilize the services of a Licensed Security Company to watch the site'during non-working hours, including weekends. The guard will be located inCEV's field trailer, but will be required to walk the site outside the exclusion zoneon a hourly basis. A log will be kept in the field trailer for the/guards to inputtheir findings from the site surveillance. A meeting betweerfathe ConstructionManager, CEV and the Security Company will be held on-site prior to the start of •work activities to establish standard operating procedures to be followedAll gatesto the site and plant will be locked at all times during non-working hours \

t*During work hours, all visitors will be directed to sign in at the ConstructionManager's field office trailer. Signs will be posted at the south gate to directvisitors to the trailer. The gate on the north end of the Plant will be closed andlocked except for material deliveries. Areas of the Plant property will be closedoff for access with the use of orange safety fence. These areas would include anyunsafe buildings, tanks, etc.

IV. Fence Removal and Reinstallation

The existing 6' high chain link fence will be removed as required to provideaccess to the site for the remedial activities. The removed fence will be stored on-site. CEV will make every effort to leave existing fencing intact until necessary toremove it to progress with operations. Temporary fencing will be utilized for sitesecurity in those areas where the permanent fence is removed. The exclusionzones will be delineated with orange safety fence to avoid unauthorized entry.Permanent fence will be reinstalled around the Plant upon the completion of theremedial action

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V. Clearing and Grubbing

Upon completion of the Erosion and Sedimentation Controls and theestablishment of work limits by construction survey, CEV will begin clearing and

x._ grubbing operations. Refer to the Erosion and Sediment Control Plan for the'-^proposed limits of clearing. Any trees within the clearing limits which are to

remain will be clearly marked with survey ribbon. Clearing will commence onthe non-site side of property at the north end and progress in a southerly direction.

^ CEV will work with the Construction Manager and the Engineer to review the*h areas to be cleared. CEV will take measures to identify and protect trees not

^ designated for clearing, and will only clear those trees that are absolutely/

grinder operation, CEV will dispose of the poly working pad with the lastcontainer.

VI. Water Management

A. Stream Diversion System InstallationAfter soil erosion control devices and clearing and grubbing are performed, CEVwill install its water flow management devices to allow for further work in thestream bed. CEV proposes to utilize two electrical submersible pumps. Eachpump is rated at 5,000 gallons per minute. Our proposed combination of pumpscan handle water flow up to 10,000 gallons per minute. This is more thanadequate to handle the stream base flow of approximately 8,100 gallons perminute. The water from the pumps will be channeled through an 18" diameterhigh density polyethylene (Butt Fused) header pipe. The discharge line will beinstalled on the plant side of the site and CEV will completely bypass the workarea, discharging the water on the concrete surface at the top of the downstreamdam. This bypass and discharge operation will be continuous throughout theproject. The discharge line will include a high velocity discharge sock, made ofwoven geotextile, to prevent siltation at the discharge point. CEV will visuallyinspect/monitor the discharge for sediment and turbidity. The two pumps at theupstream locations will also be equipped with filter socks as stated previously inSection IV. Please refer to the Erosion and Sediment Control Plan for adescription of the erosion and sediment control devices proposed to use during thewater diversion operation.

CEV is cognizant of the concern the neighbors may have regarding the noise levelof the pumps. The equipment to be used on this project will be newer, quieterrunning machines. Sound suppression technology has advanced considerably overthe recent years and CEV believes the noise levels should not be a problem forthe neighbors. The pumps will be equipped with automatic controls to assure'overpumping' does not occur. The water level above the upstream dam will notbe lowered below required elevations. The pumps will be set into location andremoved from the creek via 75 Ton Crane. The crane will be operated by alicensed crane operator. The CEV foreman will be the sole person responsible forhand signals to direct the operator. The crane will be set on the access road on the



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non-site side of project. No additional clearing should be necessary to the pumpsin position.

One pump will be located within the existing concrete sump along the westernside of the creek above the upstream dam. The existing floodgates will beutilized in diverting water into the sump. As a contingency, if the floodgates arenon-operational, CEV will set the pump in the low point of the middle of thestream above the dam on a steel plate to minimize sediment disturbance. As asecondary control of sediment, the steel plate will be equipped with a 12" highwelded steel edging perpendicular to the plate around the perimeter. The secondpump will be situated in the plunge pool at the base-of the upstream dam. Eachpump will also be equipped with a 'screen' on the intake to prevent sedimentintrusion. The two pump discharge lines will be installed in a manifoldarrangement allowing both lines to discharge to the 18" header lineyr

The discharge/bypass line will be run on grade with the exception of theconstruction entrance(s). At these points the pipe will be buried below a steelplate for protection. The discharge line will be installed below the ProvidenceRoad Bridge. The discharge line will be anchored along the plant side withstainless steel straps around the pipe and secured to the ground with metal pins.The discharge pipe will be set on the upper concrete apron of the lower dam withthe discharge end extending beyond the apron over the dam and with a 180 degreebend the effluent will discharge against the face of the downstream dam. The wallface will act as an energy dissipater, thus causing no additional scouring or erosionat the base of the downstream dam. The piping will be secured to the existingdownstream dam via stainless steel straps around the pipe anchored with HiltiConcrete Anchors or a similar product. The discharge end of the pipe will have asteel cage constructed around it to prevent anyone from getting to close to theactive discharge. The steel cage will be anchored to the dam in the same fashionas the discharge pipe.

Per the contract plans, at the limit of work at the south end of the project thereappears to be an area which will pond water due to the existing grades. This areais approximately 90 feet north of the downstream dam. Following the base flowdiversion, CEV will divert water from outside the work area on the south bymeans of a portable 3" pump discharging to the top concrete apron on the



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downstream dam via a rubber or canvas hose. The sediment precautions discussedwith the upstream diversion will be consistent with this downstream pumpingoperation. Subsequent to the ponded water diversion, CEV will then excavate asmall trench to allow future stormwater buildup to flow around the south east endof the downstream dam. The existing topography is ideal for such a diversion.The area has a gradual elevation change and is currently lined with boulders andriprap sized stone. CEV will restore the area when work is complete to its naturalcontours.

Upon completion of the required work within the streambed, the pumps will beturned off, the bypass pipes disconnected and flow will be allowed to return to thecreek. The water flow will be visually monitored to ensure the design isfunctioning satisfactorily

B. Groundwater EncounteredDuring construction of the cast-in-place concrete walls and the groundwater^'collection system, CEV will open cut the trenches and displace any waterencountered during excavation with concrete for the walls and stone aggregate forthe groundwater collection system, The displaced water will dissipate within thework area. The subgrade will be graded to slope toward the site into a smallchannel with stone to allow water to flow through the work area to thesedimentation trap.

If any groundwater is collected during intrusive work activities, CEV willmaintain a small water treatment system that/consists of one 20,000 gallon fractank with a multi-media sand and carbon

Sampling of the effluent will be performed at a frequency satisfactory to Marylandsurface water discharge requirements.

CEV will e§ja5lish a monitoring program for the water treatment plant satisfactoryto M.D.E. CEV will provide MDE with a schematic of the proposed treatmentsystem coupled with a brief analysis of the potential loading to the system.Specifically, CEV will evaluate existing data to determine representativeconcentrations of organic compounds in the groundwater. Based on thisinformation, CEV will project the loading to the plant for a given volume of waterand, in consultation with the treatment plant vendor, develop an estimated volumeat which breakthrough of the carbon unit would occur. CEV will also performsome analysis to meet applicable Discharge Monitoring Requirements; this willconsist of analysis for selected representative compounds. This sampling wouldoccur at the discharge of the first carbon canister, which would serve the dualfunction of monitoring forcarbon breakthrough and ensuring overall compliancewith discharge li

Collection and treatment of water will only be necessary when a localized area cannot be drained and_wiHJmpede on the progress of specific tasks of the project. Forexample, during construction of the lower cutoff wall, any groundwaterencountered will be pumped via a small portable pump to the treatment plant forprocessing. ~-j

C. Jersey Barrier DiversionUpon completion of the cast-in-place concrete cutoff walls and the GroundwaterCollection System, CEV will continue to utilize the pumps to keep the streambeddry; however, at this point, CEV will install a precast "Jersey" barrier curbdiversion on the longitudinal anchor wall with an initial diversion section angledfrom the upstream cutoff wall allowing for redirection of water, as required. Aspreviously stated, the two pumps will be constantly diverting water at a maximumrate of 10,000 GPM, if a rain event causes water to come over the dam it is notanticipated that the volume will breach the jersey barrier diversion systemadjacent to the upstream cut-off wall. At this point in construction, it is verycritical to direct the water flow in the stream after a rain event. The ability toredirect the flow is critical to ensure that sections of completed work are not


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destroyed after a significant rain event. CEV would direct water to the "wide"side to allow for construction of the first phase of work in the "narrow" side of thestream. CEV will reverse direction of the stream flow after the "narrow" side ofthe stream is completely constructed and secured, as specified.

X

Installation of thejersey barrier system is as follows; an excavator will place each20' length oj/#arrier on top of the longitudinal wall proceeding from the north tothe south-t/ The barriers will be installed end to end in a tongue and groovefashion.The precast holes on the bottom flange on side of the barrier facing the east sidewill line up with the center 'slot' in the longitudinal wall. A piece of wood will beinstalled in each precast hole to anchor the barrier to the wall. A small amount offill will be graded under the west facing side of the barrier to stabilize and leveleach section of barrier. Steel pins will be installed through the holes in the bottomflange to anchor the barrier to the streambed. 6-mil poly will be placed under thefill and run up and over the top of the barrier. CEV expects this procedure to beadequate to keep anticipated rain events from affecting the construction area,however if a 'flood' should breach the system, CEV will have the geotextileworking mat installed in disturbed areas to prevent sediment transfer and the waterwill run as it does now. After the water has subsided CEV will resume work in theconstruction area. Upon completion of the 'narrow' side gabion work, the jerseybarrier system will be relocated from the 'wide' side to the 'narrow' side in orderto divert the flow of water, as necessary to the 'narrow' side. Anchoring thebarrier with steel pins will not be done due to the fact the gabion mats will beinstalled at this point on the narrow side.

VII. Demolition

CEV will dismantle the foptbfidge and will salvage/store the material on site onthe Plant pro^ejly-^^-Jfee^butments and piers will be demolished with a backhoe-mounted hydraulic breakbr^Jhetubble will be sized to a 4" - 8" dimension. Allrubble wilrbrsteam cleaned and stored on site for use during restoration( • -^activities. The centerpfer from the Providence Road Bridge appears to becompletely removed to date, however CEV will confirm and if necessary the


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footing will be demolished to 6" below the liner suj>grade. The chain link fencearound the small block building and the transformer will be removed and stored asnecessary. The transformer area, and small blodc Building will be demolishedabove grade only, as required. A PC-400 Excavaior will be used to raze thestructures and load into roll-off containers. The work will be performed fromwithin the Plant property. Water within the 5000 Gallon on-site tank will beavailable for dust suppression if necessary. The debris will be sampled and uponanalytical results of the samples, a disposal facility will be identified andsubmitted to the Construction Manager for approval. The roll-off containers willbe covered and located within the plant property out of the way of day to dayactivities.

VIII. Site Grading

A. Remove Large Boulders and Rubble form Stream BedLarge Boulders and Rubble will be removed as required to meet the subgradespecification. An excavator will load the boulders / rubble onto the screen locatedin the streambed. The screen will segregate the stone and at which time the largerstone will be steam cleaned within the stream bed, placed on poly and stockpiledfor use later in the project as gabion stone, or construction of the Boulder Islands.Additional boulders/rubble will be deposited within the plunge pool below theupstream dam. The steam cleaning operation will generate very little water withinthe streambed and the removed sediments will also be deposited within thestreambed.

The east side (non-site) side of the property from the stream bank to the locationof the proposed longitudinal wall will be rough and fine graded in the sameoperation due to the absence of any groundwater collection system on the eastside. Therefore CEV will install the working mat as the grading operationprogresses down the east side. The mat will be anchored wjthjjtakes . Followinginitial grading of the wide side (or west side) of the site^ (bouldeP/riibBle) CEV willinstall the working mat to minimize sediment disturbance. As previously stated insection IV, the subgrade will be sloped to the plant side to facilitate drainage.

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B. Cut / Fill OperationThe amount of grading will be minimized to maintain the natural irregularityexisting within the creek, however some cutting/filling of the creek bed and bankmaterials will be necessary in order to provide a stable base for support of the linerand the gabion mat/wall. The cut/fill operation will be performed to achieve thegrades shown on the approved 100% Design drawings. Prior to construction ofthe concrete walls or the groundwater collection system, the grading will be rough,adequate to be able to perform these operations on grade. During and afterconstruction of tlie concrete walls and the installation of the groundwatercollection system ̂ Stream bed sediments will be cut and screened with a PortableReed Screen-Alr^quipped with a 2" deck and a 3/4" deck. The screeningoperation will be performed as a dry operation. CEV proposes to perform thescreening operation within the streambed. Material will be segregated accordingto size and stored and stockpiled for future use or reinstalled in areas requiring fill.Material between 2" and 3/4" will be utilized around the collection system,however availability of this produced size may not be consistent therefore it maybe necessary to bring in an approved stone source during the collection systeminstallation. For more information on the groundwater collection system seeSection X.

IX. Installation of Cast-In-Place Concrete WallsInstallation of the Upstream and Downstream Cut-Off Walls are intended toprovide rigidity and stability against static and dynamic forces, provide awatertight anchorage of the barrier layer and cutoff the horizontal movement ofwater into the removal action area from upstream and prevent the escape of waterfrom within the removal action area of the downstream limits. The longitudinalwall will define the limits of the temporary secondary channel. The top of thelongitudinal wall will be flush with the top of the gabion mat and will separate the

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barrier components of the primary and secondary channels. The cross-streamwalls will extend the width of the channel, between the site side stream bank andthe opposite bank. Construction of the Cast-In-Place Concrete Walls will beperformed after the water bypass system has been installed.

A. Upstream and Downstream Cut-Off WallsExcavate the 'lower' section of the wall to the top of the altered rock. CEV willdig in layers until the altered rock has been identified. The altered rock will bejudged by the on-site Resident Engineer. A concrete pump will be setup adjacentto the excavation, concrete will be tremied into the trench to form a monolithicbase wall. The concrete will be placed with a 4 - 5"' slump to ensure a tight sealacross the top of the rock. A mechanical concrete vibrator will be used toconsolidate the concrete during the placement operation. An experienced concretelaborer will insert the vibrator in quick vertical movements careful not to 'move'the concrete laterally with the vibrator thus causing possible segregation of theconcrete. A backhoe will continually be cleaning the top of the rock with thebucket ahead of the concrete operation. Two PVC water stops will be installed ontop of the monolithic base as per Addendum 2 detail. During construction of thebase pour, 6" dia corrugated steel sleeves will be installed from the bedrock to thesurface. These sleeves will allow the rock anchors to be installed after the wallhas been poured.

Upon completion of the monolithic base wall, CEV will construct the 'middle'section of the wall. This section is reinforced with ASTM a 615, Grade 60deformed reinforcing bars, typical for all rebar on this project. This section willbe cfree formed' as was the base section. The excavated earth walls will act as theform work thus allowing construction to continue without having to strip theforms and backfill the wall. The reinforcing steel will be lowered into place byuse of a backhoe. The rebar will be installed as a pre-assembled cage. Theconcrete will be placed using a concrete bucket on a PC-400 Excavator. A PVCwater stop will be installed along the top of this section in a similar fashion as wasdone with the base section.Note: A 2'-3" wide strip of 45 mil Geomembrane will be inserted 6" into theconcrete as it is cast to act as a tie-in for the barrier system Geomembrane. Thisstrip will be inserted by hand at the time of the pour. The concrete vibrator willensure proper consolidation around the geomembrane. In order for the strip to


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remain in the concrete 6", the end of the strip will be tied-off with steel wire tothe adjacent rebar dowels for the top section . Once the concrete has 'set', thewire ties will be cut and the three inches at the end of the strip will be cut off inorder to have a smooth edge in which to weld to later with the geomembranework. See Section XII for more details on the placement of the Geomembrane.

Rock Anchors:Rock Anchors will be installed within the 6" dia sleeves installed during the basepour at a 10' on centers. CEV will use a track mounted rig to drill the 2" +/- holethrough the 'middle' and base sections and into the intact rock approximately 2'.Each anchor shall consist of a single 1" dia threaded rod with a mechanical anchorassembly that can be expanded after insertion into the drilled hole to provideanchorage to intact rock. Each rock anchor shall be fitted with a heavy duty hexnut, washer and 8" square x 1" thick steel plate. The drilling operation is notexpected to generate dust, however if does becomes a nuisance problem, CEV willsuppress the dust with the same clean diverted stream water being used to keep thegeomembrane moist. The entire assembly will be grouted in place and concurrentwith the grouting operation the anchor assembly will be tightened down enablingthe mechanical anchor assembly to 'lock' the intact rock. See Attachment No. 2for manufacturers installation and grouting procedure.

Following the installation of the rock anchors, CEV will form the 'upper' sectionof the upstream and downstream cutoff walls. This section will be 2' wide by 1'high with a 1" wide by 6" deep slot running lengthwise on top of the wall. Thisslot will used during water diversion operations as previously stated within thisreport. Following proper curing, CEV will strip the forms. CEV will castconcrete samples in standard molds to be taken to an approved laboratory andstrength tests performed. CEV will report the test results to the CQA Monitor.

B. Longitudinal and Mid-stream Anchor WallsThe construction of the longitudinal wall and the mid-steam anchor walls will bein a similar fashion as the upstream and downstream cutoff walls. The depth ofthese walls are much shallower than the cutoff walls and therefore theunreinforced monolithic base pour will not be required on the longitudinal and

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'cross' walls. CEV will excavate to the proposed bottom of the wall at whichpoint, a licensed Surveyor will layout the locations of the rebar anchors, staggered10' on centers. CEV will drill for the rebar anchors in the following manner;Auger through the stream sediment, insert a 6" dia steel sleeve inside the augerand pull out the auger. Install rock drill bit and proceed to drill through the alteredgranitic gneiss material and proceed into the intact granitic gneiss layer 2'. Uponcompletion of the drilling, CEV will grout the hole from the drilling and insert the#8 rebar anchor to extend approximately 18" above the bottom of the wall. Theexcavated wall area will then be cleaned prior to placement of the reinforcing steelor the 4000 psi concrete. CEV will insert a 2' wide strip of 45 mil Geomembraneinto the 'green' concrete 6" for future tie-in to the barrier system. See Section XIIfor more detail on the placement of the 45 mil Geomenbrane. A PVC water stopwill be installed longitudinally on top of this section of the wall prior to theconstruction of the top section.

CEV will form the top section of the longitudinal wall and the mid-stream walls inthe same fashion as the top section of the cutoff walls. The 1.5' wide by 1' deepsection will be formed including the 1" wide by 6" deep slot. CEV is consideringthe use of inserts for the anchor bolts into the concrete. The bolts would be placedat 6" O.C. during the formwork and would be incorporated into the concrete pour.The batten strip would the be installed over the bolts after the forms have beenstripped. Reinforcing steel will be installed and 4000 psi concrete placed. CEVhas extensive concrete placement experience and as always will provide a highquality end product.

X. Groundwater Collection System

The groundwater collection system will be situated within the prepared subbaseand beneath the barrier layer. A licensed Maryland Surveyor will layout thelocation of the collection system. After excavation, the geotextile will beinstalled, the stone will be placed on top of the fabric and the piping will then beinstalled per the grades of the approved 100% design. The system will consist of2 rows parallel to the stream flow and the connecting laterals of 6" dia corrugatedpolyethylene pipe with smooth interior walls and perforations installed parallel to



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the stream alignment and The pipes will be backfilled with 3/4" - 2" stone. Thisstone may be generated from the subbase grading or the collection systemexcavation or may be from an approved off-site source. A non-woven geotextilewill be wrapped around the stone/pipe. The 6" perforated pipes will collect thegroundwater and tie into non perforated pipe which will be installed perpendicularto the stream alignment. The system will drain to 3 High Density Polyethylene(HDPE) Manholes located on the Plant side. CEV will install 8" non-perforatedcorrugated polyethylene conveyance pipe between the manholes. This pipe willbe component of a future on-site water treatment system which is not currentlypart of this contract.

XL Barrier LayerThe approved design for this project separates the streambed reconstruction into 2layers; the Barrier Layer which is on top of the prepared subbase and theProtective Layer which sits on top of the Barrier Layer. Both Layers will bedetailed within this report. It is CEV's intention though to construct both layers ora 'complete' system on any given day during this phase of the project. Severalsafeguards have been installed to bypass and redirect water in the event of a rainevent, however, to ensure that a section of previously completed work is notdamaged or entirely destroyed by a rain event. CEV will complete only a limitedfootage of system each day but the system will be complete encompassing boththe Barrier and Protective Layers. If a rain event should overcome our diversionsystems then the water will simply flow over the streambed as the intended designcalls for not causing any damage to previously constructed work. CEV will ceaseoperations on further work in the streambed until the rain event has passed.

The Barrier Layer is comprised of three components: A geotextile working matwhich will be a 7.5 oz non-woven geotextile and be installed on top of theprepared subbase, a geosynthetic clay liner (GCL) installed on top of thegeotextile working mat and a 45 mil scrim reinforced polypropylenegeomembrane to be installed on top of the GCL.

1. Geotextile Working Mat



R R 3 0 0 5 0 3

The geotextile working mat will be a 7.5 oz. non-woven geotextile laid out overdisturbed areas as well as the prepared subgrade.

2. Geosynthetic Clay layer (GCL)The geosynthetic clay layer will be laid out and installed per the manufacturer'srecommendations. The materials will be placed with the membrane side facingdown. A 12" overlap between rolls will be maintained as per contract documents..The GCL will be kept dry at all times, including stockpiled material. Uponplacement of the GCL, the 45 mil scrim reinforced geomembrane will be installedon top in a timely fashion to prevent the GCL from becoming saturated. Theleading edge of the GCL will be protected from the elements overnight or duringwork stoppages.

3. 45 mil Scrim Reinforced GeomembranePrior to installation of the geomembrane, CEV will submit a field panel layoutplan depicting the orientation of the panels and identifying each panel and seam.Upon approval of the panel layout plan, CEV will commence placement of thegeomembrane over the GCL. Panels will be laid out and the seams welded in atimely fashion. Panels will overlap by 4" with the upstream panel over thedownstream panel.

Seaming:Each morning during geomembrane placement, CEV will run a test Seam. Thetest seam will be verified on the field tensiometer. Upon approval of the testseam by the CQA Monitor CEV will prepare the seams. The seams will becleaned as necessary prior to work. As the seaming operation progresses, Non-Destructive testing will be performed by CEV and witnessed by the CQA. Thepurpose of the testing is to verify seam continuity. All tests will be recorded byCEV documenting the date, weather, seam location , name of tester and result oftest. If a test fills, corrective action will be done to the seam and a new test will beperformed. The Non-Destructive Testing will be performed with a Vacuum Boxin accordance with ASTM D4437.

Galaxy/Spectron Remedial Action Conti Environmental Inc.Removal Action Execution Plan(Draft) 05/01/98

Page 18

RR30050U

Destructive Testing: CEV will have an independent laboratory destructively testfield seam samples. The tests will be performed at a frequency of one test per 500If of seam. The sample location shall be selected by the CQA Monitor.

System Anchorage: CEV will furnish and install a continues batten bar at thegeomembrane termination along the concrete walls. The batten will be 2" wide,3/8' thick stainless steel, with 3/8" diameter holes centered along the length of thebar at 6" spacing per contract documents.

CEV will pre-drill the anchor bolt holes, install the anchor bolts and place theflexible seal over and around the anchor bolts. The geomembrane will then beplaced over the anchor bolts with at least 4" from the edge of the geomembrane.The batten bar will be installed immediately on top of the geomembrane andsecured with the nuts and washers.

A secondary seal system will be installed after installation of the anchor bolt /batten bar assembly. A 12" wide strip of 32 oz geocushion will be laid along thelength of the batten and the geomembrane strip previously cast into the concretewill be pulled across the batten and welded to the primary geomembrane liner.

XII. Protective CoverThe Protective Cover system consists of three components; 16oz. non-wovengeotextile, 32 oz, geocushion and the gabion mat. The Protective Cover will beinstalled above the Barrier layer.

1. Geotextile: CEV will install a 16 oz. non woven polypropylene geotextile overthe 45 mil geomembrane. The geotextile will extend up the 1' side of the topsection of the concrete walls and the proposed gabion mat. The geotextile will beplaced with 6" overlap between rolls and the seams will be sewn per therequirements of the contract documents..



H R 3 0 0 5 0 5

2. Geocushion: The geocushion will be a 32 oz. geotextile placed over the 16 oz.geotextile. The geocushion rolls will be laid with a 6" overlap per roll. The seamswill be sewn per the requirements of the contract documents.

3. Gabion Mats and Gabion Baskets: The gabion mat represents the top layer ofthe protective cover. The mat will be installed on top of the 32 oz. geocushion.The mats will be pre-assembled on the site within the material laydown area onthe Plant property and transported to the installation location. The initial layout ofthe gabion baskets will be a Licensed Maryland Surveyor according to the controland locations presented in the Approved 100% Design. Additional on-goinglayout required will be performed by a combination of the Surveyor and/or CEVpersonnel. The mats will be set into place and secured per the requirements of theapproved 100% Design. The bottom of each mat to be placed over the barrier layerwill be visually inspected to ensure that mesh barbs are turned up or trimmed toavoid puncture of the geomembrane. The mats (and Baskets) will be secured toeach other by means of PVC coated steel 'Hog' Rings. As an additionalprecautionary measure, CEV will place 12" wide strips of a mat material under theside edges of each basket. This will aid in the protection of the geomembranebelow. The mats will be anchored to the concrete walls in the following fashion;the 16 oz. geotextile previously installed will be pulled up tight to the concretewall, the mat will be placed up against the geotextile/wall. The mat will besecured to the wall drilling hole for 3/8" dia anchor bolt at 12" on centers,installing the bolts, placing a steel batten strip 3/8" thick by 6" wide by 2'-10"long over the bolts thus anchoring the mat to the wall.

Gabion baskets to be used in the wall construction will be assembled and installedin a similar fashion as the gabion mats. The baskets will be erected on the Plantproperty, transported to the intended location, secured to other baskets/mats perthe requirements of the contract documents.

The gabion stone will be placed in accordance to the requirements of the approved100% Design. CEV will place the gabion stone by several methods; mechanicalconveyor, Rubber Tired Loader and in the hard to reach areas the stone will behand placed. The mechanical conveyor is the most efficient means of loading, thevariable controls of the speed of the conveyor can be such that it can be sloweddown to such a pace as to install one stone at a time if necessary. This control will



A R 3 0 0 5 0 6

ensure that the underlying fabrics and geomembranes are not damaged during theloading operations. The conveyor will be set off to the side and can be extendedto reach to most lengths required by this project.. CEV has extensive experiencein the installation and loading of gabion baskets and mats and every effort will bemade to maintain the integrity of the lower materials. The grout strips within thegabion mats will be constructed in a continuous fashion during the gabion work,the gabion mats will be installed, stone placed and by use of a small grout pump,the grout will be placed throughout the stone filling all voids. The groutingoperation will be carefully performed in order to keep area clean of excessivegrout. See Section XIV for detail regarding the Habitat Restoration including theplacement of planting soil and/or sand within the gabion mats.

XIII. Habitat RestorationHabitat restoration work will involve the re-establishment of the benthic andriparian habitat of Little Elk Creek and the surrounding areas to be impacted bythe removal Action. CEV will perform the following operations in an effort tosatisfy the requirements of the contract documents.

Prior to restoration activities, CEV will remove all foreign materials and looseobjects from the gabion surfaces or the area of Zone A. Zone A activities willinclude the preparation of the ground surface to a depth of 3" in the soil. Thiswill be accomplished by a combination of disking and hand raking wheremachinery is inaccessible. The final grade of Zone A surface will conform to thegrades within the contract documents.

Zone D sand fill substrate will be constructed after Zone A but before Zones B &C, which receive the planting soil substrates. Fill sand will be introduced over thechannel bottom to the limits of the contract documents. The sand will be mixed inwith the gabion stone prior to placement in the baskets. The balance of sandnecessary to fill the voids per the Approved 100% Design will be installed by asmall combination rubber tire machine and washed in with the clean upstreamwater within the 5000 Gallon on-site tank. The water used for this operation andthe sediment encountered will be collected in the proposed sedimentation traplocated adjacent to the downstream dam. As stated in the Erosion and Sediment

Galaxy/Spectron Remedial Action Conti Environmental, Inc.Removal Action Execution Plan(Draft) ' 05/01/98

Page 21

R R 3 0 0 5 0 7

Control Plan, accumulated sediment will be cleaned from the sedimentation trapand incorporated into the work.

Zones B & C substrates will be constructed after Zones A & D have beencompleted. Areas of gabion mat extending from the water side edge of Zone Cconstruction to the uphill end of the gabion structure bordering Zone A willreceive a secondary fill of Planting Soil. The Planting Soil will be installed perthe requirements of the contract documents. The soil will be premixed with thegabion stone on-site prior to placement within the gabion baskets. SF mat will beinstalled on the inside of all exposed outside faces of gabions. The SF mat will besecured per the requirements of the contract documents.

Zone C Bank construction will include the installation of the Biolog system. Thebiologs will be installed with wire tie-downs, Planting Soil placed to top of biologon the land side. This soil backfill will be placed by PC 220 excavator reachingover and placing to ensure no equipment on top of the biologs. The CF mat willthen be placed over the biolog and the planting soil and secured down per therequirements of the contract documents. Installation of Plants are not part of thiscontract.

Location of the Boulder Islands will be at the direction of the CQA Monitor. Theinstallation process is as follows; place boulder with a maximum 6' in width withlong axis parallel to flow. The boulders will be placed with the PC-220 or PC-400Excavators. 3' diameter sack gabions will be installed around the upstream sideend of the boulder as per the contract documents. The sack gabions will besecured with underlying gabion mats via wire ties. The double biolog systemwithin the Boulder Islands will be installed per the detail on Plan Sheet No. 17 ofthe contract documents. The installation methodology will be of similar fashionas the biologs within Zone C banks.

The Riffle Zones locations will be at the direction of the CQA Monitor. TheRiffle Zones will consist of stones placed in rows parallel with the flow andintersecting rows perpendicular to the flow creating a braided pattern. The stoneswill be between 12" and 48" in diameter and situated from largest to smallestheading downstream.


RR300508


XIV. DemobilizationUpon completion of all closure activities, the site will be demobilized. Alldecontamination liquids and waste materials will be fully characterized anddisposed of off-site as appropriate. The storage and tool containers will beremoved and miscellaneous debris taken off site.

Gaiaxy/Spectron Remedial ActionRemoval Action Execution Plan(Draft)


A R 3 0 0 5 0 9

XV. Traffic Control Plan

CEV will initiate a Traffic Control Plan for all material and supply deliveries,equipment mobilization and demobilization and all other activities involving thesurrounding public roads to assure that safety of the nearby residents and the on-site work force are not compromised.

Material deliveries, most notably, trucks delivering stone products to the jobpresent the greatest challenge in maintaining a safe, functional work area. Themain concern is the volume of trucks which will be traveling along eitherProvidence Road or Little Elk Creek Road enroute to the site. CEV is sensitive tothe residents and cognizant of the fact there are children in the area and will takeall necessary precautions to ensure their safety.

CEV will schedule a meeting at the individual quarries supplying stone productsfor the project. The meeting(s) will be to stress the importance of safeprofessional driving by the employees of the quarries or by any of the quarriessubcontractors (independent truckers). Disciplinary actions against the driver andthe quarry will be discussed if there are any violations by the drivers. There willbe a zero tolerance for violations. If a driver does not obey the speed limit,yielding to traffic, abusive language or any other act not acceptable to CEV he orshe will be immediately removed from the site and told not to return. The quarrywill be contacted with the name of the driver, truck number and an explanation ofthe violation. The quarry will then have to supply another driver to fill the void ofthe dismissed truck.

CEV will supply a 'spotter' positioned on-site to direct the trucks to the properlocation to dump their loads. The spotter(s) is responsible to manage all truckson-site to ensure safe movement and dumping operations on-site. A site vicinitymap will be given to each supplier of material required to deliver to the site Themap will depict the truck route to be used to enter the site. The spotter will alsobe responsible to move construction traffic over the Providence Road Bridge whennecessary. CEV will take every precaution necessary to ensure the safety of theresidents and the on-site personnel during traffic movement operations.

Galaxy/Speclron Remedial ActionRemoval Action Execution Plan(Draft)


A R 3 0 0 5 I O

2CONE

EXPANSIONSHELL THRUST

'RING

R1H HOLLOW-COREf&WfSS^E^;-

PRE-STRESSABLE * POSITIVE

MEETS ASTM A-615DEFORMATION PATTERN

(Fig. A) WHIia/hs Hollaw-Cora anchorsallow for fun growl encapsulation in up anddown bolting applications and allows groutflow from the lowest gravitational poim

Through years of development Williams has produced and patented ihe Pre-stressable, Hollow-Core, Groutatjle Spin-Lock Rock Bolting Systems. The"hollow-core" allows the bolt to always be grouted from the lowest gravita-tional point (Fig. A), in an up-boning situation, the grout Is pumped In throughthe plastic grout tube and begins to fill the drill hole from the plate. The groutrises until the entire hole is filled and the grout returns through the hollow bar.In down grouting situations, the grout is pumped through the hollow bar andstarts at the bottom ot ;jie hole. It rises and returns through the de-air tubewhen the hole Is filled. Improperly or incomplete grouted bolts are subjectedto relaxation and corrosion. Pre-measured capsule systems cannot properlyaccount for u nknown fissu res and voids and often leave the bolt vulnerable todeterioration. The Williams Hollow-Core Grouting System spreads groutthrough the rock fissures creating a completely protected monolithic sectionincluding rock, grout and bolt.

Full installation procedures can be found on pagss———:————'—*• .i*ltl.;——,' . 'TV) JT7T TT".-T-———————————'———

STRUQTLJff/VL PROPERTIES ,Yield Stress Ultimate Stress . Bprtgalton in 2" Reduction of Area

70 KS! 'Vo'kSI." ' " - "

R1H WILLIAMS LOW GRADE HOLLOW-CORE PRE-STRESSABLE ROCK & CONCRETE ANCHORASTM A 615 DEFORMATION PATTERN

THREADSPERM.

(51mm)

NET

THRUTHREADS

*>.'

2.427 100,000 IDS.(444.9 WU)

Note:(1) Care should be taken to drill a slraiont Property sized hole.(2) A (unction of strata strength. Mom torau* roav be reeruirod on lono bolts or in special rock condrtioiK. Consutt your Wiffiams Representatta for more soecffic dffeBs.(3) Strew to rtcsiretf tensH? low using a hollow rim hytouflc pck. Consutt yow Wiltens Representative.(4) WILLIAMS reserves DM right to ship fufl tefigtli or coupled units ss necessary,(5) On special orders, R1H grade may be heat treated tor cold weather environment fer minimum Ctiarpy vikws ot M tl-1bs. at -20T {3CTC).(8) Ultimate simple shear strengths are appnnirmttty .751 tht uttimzte tensile strengths. Designer! should pravid* adequate safety factor* for «Ie snexr rtn;ngth$ bVed on condiGons ot

use. Inconsistencies in rock front srw to sire antj evsn from hole to hoie may affect anchor performances. Fissures, voids, seams, rock psi, drillirtQ through clay or bentonite snd directoror balding planes are all possible variables, Sieutt piodlons occur, consult VVifliams for troubleshootlno techniques.

UJILLIflfTiS

i6WEl£Ol9l 'ON ON3 SUVmiM 0311 86-1

"SPIN- LOCK"0 ROCK BOLTS

GROUTING • PERMANENT KEYHOLEPLATE

Because the "SPIN-LOCK"* head assembly provides 300°perimeter expansion anchorage (Rg. B) and develops thefull strength of the rod, the hollow-core rock bolt may be pre-stressed to the desired load and tested prior to gouting.

BOUNDRY DAM-C11 V Of SEAtTLE(Underground Powerhouse)Design - Bechtei CorpPrime Contractor • Mannix S.G.S,

(Fig. B) Williams "Spin-Lock" head assembites give a 300° perimeter expansion anchor-age. For more Information on "Spin-Lock"head assembfies, turn TO page 20.

STRUCTURAL PROPERTIESYield Stress Ultimate Stress Elongation In 2" Reduction of Area

91 KSI 124 KSI 15% 40%

R1H HIGH GRADE HOLLOW-CORE PRE-STRCSSABLE fiOCK & CONCRETE ANCHOR ASTM A 615 OEPORMATiON PATTERN

DIMTHREADSPERI*.

r-a(25mm)

•^

(51 mm)

.. NET' AREA

THRU'THREADS

IN.*

.536

1.115 '

2.427

b.fSfGN 10AT soy. bilLTMflffl

33.000 LR

69,000 LB(30G.9kli

ISO.OOQIb(6672 KN

MAXIMUM' WORKINGLllAO TO

117,000 LBS.(209,1 WJ)

-100,00'0 LfiS.C444.8KN)'

219,000 Its.(974.2 XN)

ULTIMATE'jTflEHGtti

66,OdOLBS.(233.6 ktJ)

135,000 LBS.(613-fiMI)

(1334.4 kN)

ROW TYPE,1 ' '

Hard 4M«ftifnMedium & Weak

WeaK Rock & CancnxaRack & Concrete

_Rack A CoQcrrte.'

Rocfc 4 Concrete

HOLE

l-3M"-(4

"SPIN-LOCK" ROCK BOLT INSTALLATION PROCEDURE"T^O;̂ :VV^^J.̂

STEP#1 DRILLINGUSE STANDARD ROTARY PERCUSSION EQUIPMENT

N

In down bolting situations, drillthe holes to extend 10" to 16"beyond the length of the rockbolr to allow for segmentsdropping into the bottom of thehole. Overhead rock drilling orshallow concrete applicationsrequire only minimum clear-ance, 1" to 3" of overdrlll.Care should be taken to Insurean accurate and straight hole.Anchor installation shouldoccur within 24 hours of open-ing drill hole. Before insertingrock bolt, probe hole to insure itis clear to proper depth. Use ablow pipe to remove mud, dayand debris when necessary. Ifrock ROD value is 50-70%,water testing the hole is recom-mended before proceeding(see page 32.) Install testanchors prior to drilling all ofthe rock anchor holes.

DOWNBOLTINGSITUATIONSREQUIREDRILLINGHOLES 10-70 16"BfeYONOTHE LENGTHOF THE ROOKBOLT.

CHURCHILL FALLS HYDROELECTfltC OEVEIX3PMENTOwner - Churchill Palls (Labrador) Corp.Design: Acres Canadian BeehtslContractor - Churchill Contractors

STEP #2 BOLT PLACEMENT

DRILLHOLE

." f'"*1? 'r~l£;r7v;;>L~

Place ftut, washer,and plate on rock boltand lower bolt intodrill hole with thrust-ring, malleable shelf.and cone set in position on theinner threaded portion of thebolt. If rock boll becomesstuck because of a crookedhole, lock two nuts on the endof ih« baft and tap bolt Intop(3£e with a sledge hammer orair hammer. A jumbo drillingrig can be used to push largediameter bolts Into the hole.For rock bolts longer than 20',especially In poor rock orsh«l« where drill holes rend todrift or collapse, an oversizedrill hole can be used within 4to 6 ft. of anchor area. This willexpedite installation. Careshould be used to insure cor-rect drill hole size however Inthe anchor area. Bolt shouldhang by the nut against thebearing plate until set.

WILLIAMSHEAVY DOTYHEX NUT ANDHARDENEDSTEEL WASHER

SETTING= U'TOOL

jj ' WILLIAMSKEYHOLEPLATE

ROCK BOLT BEINGINSERTED INTOHOLE

WILLIAMSHOLLOWROCKBOLT

THRUST RINGMALLEABLE

CONE

"BOUNDARY DAM" POND, OREILLE RIVERDepartment of Lighting, City of SeattleDesign; Sechtel-LeedshJfl. Prime Contractor • Mannlx s.G.S.

16

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"SPIN-LOCK" ROCK BOLT INSTALLATION PROCEDURE

STEP #3 SETTING THE ANCHORQUICK SPIN US(NQ (MPACTGUN

WILLIAMS FfTTtNG ADAPTERFOR IMPACT TOOL OR TORQUE WRENCH-'"

I" j#YT'!-K*l~'HWi- T9FIMPACT TOOL2-3" OF THREAD

TfiZ-12_^ PNEUMATIC TORQUE WRENCH5s •RECOMMENDED-

MULTIPLlE;flT8Zl3

TORQUE WHENCHTSZ

SETTING u^ ĵTOOL -^tf

«JS

;̂̂

Install setting 1661 Oh threaded end. The settingtool must be turned oh to its "full engagement (tointernal stop) prior to contacting the hex nut. Setthe expansion anchor by torquing ttte rod T6 therequired torque (see Spin-Lock Rockbott Charts).This is done by turning the setting tool in a clock-wise direction using either a pneumatic or manualtorque wrench (refer to Accessories, pg. S6), Thisaction rnigrates the cone Into shelf, thusexpanding the anchor. The bolt can be sec eitherwith or without the steel bearing plate in place,and with any desired amount 6f thread extendingbeyond the hex nut. After setting the boft removethe two piece getting tool by separating the topnut from the body.

AUBURN-WASHINGTON BRIDGEContractor: Burnham Construction

KX3.-& t̂ K1-

NOTE: When salting or t&nslcrcing rock bolts by use of an impact gun, a random check of torque usfng a calibrated handtorque wrench or hydrautfc j$ck should be done to Insure the Impact gun continues delivering (ho specified torque.

STEP #4A TESTING THE ANCHOR BOLTMETHOD A Tenstonlng with a Test Jack

Test the rock bolt by jacking the rock bolt to ihe required tension (usually Va of the ultimatestrength). Once the bolt is tested, it Is very easily pretenstoned. This pretensioning is accom-plished by using a wrench to tighten the rock bolt nut to transfer the test load from the jackto the rock bolt. The needle on the pump gauge will drop slightly to indicate less tension onthe jack and frame only. Release jack pressure and remove jack, frame extension rod andcoupling.HELPFUL HINTS:If outward migration of bolt is noticed during tensloning, check to make suffe that tension Is increasingon pump gauge.A. If tension is increasing on gauge the outward migration is indicating the anchor is further expand-

ing. If migration Is excessive, it can be minimized or avoided by applying more torque to set meanchor. (For maximum torque allowed check wfth your Williams representative.

B, if tension is not increasing on gauge this outward migration may be anchor slippage. This indicatesThat more torque is required to set rhe anchor or that a larger expansion head may be required.(Check with your Williams representarfve.)1. Make sure final torque is being applied in a continuous turn fashion using T82 or T8Z12 wrench.2. Check to see that the proper drill bit size was used in drilling the hole.

PLATE WASHERNOT,

^

.̂ HOLLOW CORE••̂ HYDRAULIC JACK

SOUP HfGH-STHENOT(EXTENSION BARHfGH-STRENGTHCOUPLINGUSE WRENCHTO TIGHTENNUT HERE WHENREQUIREDTENSION ISREACHED

inCDCDCOor

17

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"SPIN-LOCK" ROCK BOLT INSTALLATION PROCEDURE

STEP #5 GROUTING (WITH WILLIAMS HOLLOW-CORE BOLT)FttOM GROUTPUMP

GROUT TUBE

WILLIAMS GROUTTUBE ADAPTER

DE-AIRMETHOD A

Down or HorizontalGrouting

Screw grout tube adapter on to rockboft. Blow air through hollow core toassure system is clear- Pump Wil-X-Cement Grout through hollow coreof boft until a continuous flow ofgrout is seen coming out of the de;airtube. This indicates that all air hasbeen removed from drill hole and allcracks, and fissures in the rock areMl of grout. Remove grout tubeadapter. Trie drill hole has been fullygrouted and all standing water or airhas been removed. OU> HICKORY LOCK

and Contractors - U.S. Army Corps of Engineers

OR DENSEEXPANSIVEFOAM

WHEN GROUTING IN WATER USE THE SAME PROCEDURES OUTLINED ABOVE. By utilizing WilliamsPre-stressed Grourable Hollow-Core Rock Bolts, grout is forced into areas in back of the anchorage, as wellas into all porous rock-seams, fracture zones, and voids In the area of the drill-hole. Only Williams pre-stressed patented Hollow Bar Anchor Jn combination with special plates for grouting after pre-stresslng,gives external proof (return grout Wow) of a job well done.

METHOD BUp Grouting

(Using standard grout mixor Poly Grout)

For UP-GROUTING, inject grout atthe pressure required to offset statichead. Grout should be forcedthrough the short tube which will beplaced at the lower level of the holeuntil it returns through the de-airhole in the end of the bar. Dischargeof pure grout in a steady streamthrough the de-air hole Is positiveproof that the entire hole is filled andentire area of the bolt includingseams fs well grouted. Plug end ofbolt and continue pumping briefly toforce grout to end of hole. Theftblock the grout tube.

RETURN NOTE: If WihX-Cement Grout Is not used, please refer to pg. 39 for alter-nate grout specifications, pg. 12 for Poly Grout applications, or pg. 8 torthixotropic grout installation.

FROM GROUTPUMP

UJILLIflfTlS19

80 'd/.6fr6£l£0l9! 'ON

«3