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Constancia Project
Technical Specifications for Earthworks,
Geosynthetics, Pipework, and Concrete
prepared for:
Hudbay Perú S.A.C.
Av. El Derby No. 055, Torre 3, Piso 4
Distrito de Santiago de Surco
Provincia y Departamento de Lima, Perú
Telephone: 51 1 628-7272
Telefax: 51 1 628-7275
prepared by:
Knight Piésold and Co.
1999 Broadway Street, Suite 600
Denver, Colorado 80202-5706 USA
Telephone: (303) 629-8788
Facsimile: (303) 629-8789
E-mail: denver@knightpiesold.com
Table of Contents
Page
1.1 Introduction
The technical requirements in this document cover the quality of materials and workmanship for
earthworks, Geosynthetics, pipework, and concrete; as well as structural steel, valves, fittings,
coatings, controls, and instrumentation for facilities designed by Knight Piésold and Co. (Knight
Piésold) for the Constancia Project. It is understood that the Hudbay Perú S.A.C. (Hudbay) and
STRACON-GyM Alliance, with the assistance of Ausenco, has overall responsibility for construction
management of the Constancia Project. In general, this Specification is applicable to the Tailings
Management Facility (TMF), Main Sediment Pond, Cunahuiri Reservoir, Waste Rock Facility (WRF),
WRF Ponds, Landfill, Access and Haul Roads, Diversion Channels, TMF Sediment Ponds (2), and
Construction Road Sediment Ponds (2).
“Concrete Contractor” is defined as the party that has executed a contract agreement with the
Earthwork Contractor to supply concrete to applicable portions of the Work. The Concrete Contractor
is responsible for all Quality Control (QC) for all concrete supplied for the Work. Since the amount of
concrete required for the work associated with this specification is relatively small, for the remainder of
these Technical Specifications, the term Earthwork Contractor is used and is inclusive of the Concrete
Contractor. The Earthwork Contractor may perform the concrete construction without the involvement
of a specialty contractor for the concrete construction.
“Drawings” are defined as the construction drawings at Revision 0 or above that have been “Issued
for Construction” by the Engineer. The latest numbered revision of any Drawing shall be the Drawing
applicable to the Work.
“Earthwork Contractor” is defined as the party that has executed a contract agreement with the
Company to complete the Work shown on the Drawings and as specified herein. The Earthworks
Contractor may also be referred to as the Contractor. If the Earthworks Contractor elects to retain the
services of a Concrete Contractor, the Concrete Contractor shall be approved by the Company. If the
Earthworks Contractor elects to perform the concrete construction itself, the term Earthworks
Contractor shall include the Concrete Work. The Contractor for the Constancia project is Stracon-
GYM.
“Engineer” is defined as Knight Piésold or any of its authorized representatives. The Engineer is
independent from the Earthwork Contractor and is responsible for observing and documenting
activities related to Quality Assurance (QA) for earthworks, geosynthetics, and concrete.
“Modifications” are defined as changes made to the Technical Specifications or the Drawings that are
approved by the Engineer and the Company, in writing, after the Technical Specifications and
Drawings have been issued for construction. These also refer to changes to design elements in the
field to account for unforeseen conditions. Modifications may be documented by revisions to the
drawings or specifications or Addenda issued by the Engineer.
“Project” means the construction of all items necessary for the completion of the structure(s).
“Quality Assurance” is defined as the observation of the construction activities and completed Works
and review of the QC data by the Engineer to offer an opinion on the conformity of the Work to the
requirements of the drawings and specifications and intent of the design. QA is the responsibility of
the Engineer and must be carried out to meet the requirements described in these Technical
Specifications or as specified by the Engineer and/or the Company.
“Quality Control” is defined as the testing and inspection necessary to ensure that the Work is
constructed in compliance with the Technical Specifications. QC observation and/or testing is the
responsibility of the Contractor or his subcontractors.
“Reference Information” is defined as information provided to the Contractor by the Company to assist
in completing the Work. However, the Company makes no warranties or representations as to
accuracy or completeness and the Contractor shall be solely responsible for any and all conclusions
and deductions made using this information.
“Site” is defined as the Constancia site owned by Hudbay and where the Work is to be completed as
described in these Technical Specifications and detailed on the Drawings.
“Subcontractor” means a party which, with approval of the Company, has executed a subcontract with
Contractor for part of the Work.
“Technical Specifications” are defined as the Technical Specifications, Quality Assurance, and Quality
Control for Earthworks at Revision 0 or its latest revision. This title may be revised to be project
specific to the Constancia project and specific structures covered by the specification or above and
any other specifications and Addenda furnished by the Engineer and/or the Company that apply to the
Work. The latest numbered revision of any specifications shall be the document applicable to the
Work. The Technical Specifications may also be referred to as Specifications.
“Units” refer to units of measurement. In general, the Technical Specifications and the Drawings refer
to metric units, which are the standard for the project, for lineal measurements, areas, sieve sizes,
pipe diameters, etc. However, in several cases, the material purchased and/or test equipment and
results will be expressed in Imperial units, which is acceptable provided they are equivalent to the
specified metric units. Equivalent sieve sizes for metric and imperial units are provided at the end of
this section.
“Unsuitable Material” is defined as any material not meeting the technical requirements of this
Specification.
“Work” is defined as the furnishing of all Labor, Plant, Materials and Supplies, and the carrying out of
all activities in order to complete the construction as shown on the Drawings and as defined in the
Contract Documents for the Earthwork Contract, including the implementation of temporary sediment
control measures and creation and maintenance of the construction access roads that connect areas
of the Work.
Imperial Metric
18 inches 457.2 mm
12 inches 304.8 mm
9 inches 228.6 mm
6 inches 152.4 mm
4 inches 101.6 mm
3 inches 76.2 mm
2 inches 50.8 mm
1-½ inches 37.5 mm
1 inch 25.4 mm
3/4 inch 19.1 mm
1/2 inch 12.7 mm
3/8 inch 9.52 mm
No. 4 4.75 mm
No. 8 2.36 mm
No. 16 1.18 mm
No. 30 0.60 mm
No. 40 0.43 mm
No. 50 0.30 mm
No. 100 0.15 mm
No. 200 0.075 mm
M:\Denver\Projects\201\00245.41\Deliverables\Reports Specs\1700 Tech Specs\Rev0\Text_Rev0.docx
2.1 Inspection
All Work shall be subject to inspection, examination, and test by the Engineer and/or the Company at
any time during manufacture or construction and at any place where such manufacture or
construction is carried out. The Engineer and/or the Company is authorized to call the Contractor’s
attention to any failure of the Work to conform to the Specifications or other provisions of the Contract.
The Engineer and/or the Company shall also have the right to reject defective materials without
charge therefore, and the Contractor shall promptly segregate and remove such rejected material
from the premises. Any Work done beyond the lines and grades shown on the Drawings and/or
specified by the Engineer and/or the Company will be considered as unauthorized and may be
ordered removed. If any remedial construction is required to repair over-excavations or the like,
remedial construction shall be the Contractor’s responsibility and performed in keeping with the
specification requirements or Specifications, Drawings or Addenda prepared by the Engineer. Should
the Contractor’s Work fail to comply promptly with the Specification’s or Drawing’s or any subsequent
Specification of the Engineer and/or the Company made under the provisions of this paragraph, the
Engineer and/or the Company shall have the authority to cause defective materials or Work to be
remedied or removed and replaced.
The Contractor shall furnish promptly all reasonable facilities, labor, and materials necessary for
proper and convenient inspection and for any test that may be required by the Engineer or the
Company. All inspections and tests by the Engineer or the Company shall be performed in such a
manner as not to unnecessarily delay the Work. The Engineer or Company may require that the
testing be completed by the QC personnel provided by the Contractor.
Should it be considered necessary or advisable by the Engineer and/or the Company at any time
before final acceptance of the entire Work, to make examinations of Work already completed by
removing or tearing out any part or parts of the same, the Contractor shall, upon request, promptly
furnish all necessary facilities, labor, and materials.
All materials proposed to be used may be tested at any time during their preparation and use. Unless
otherwise provided in the Specifications, the sampling and testing of materials will be done in
accordance with the current methods approved by the American Society for Testing Materials
(ASTM). If after trial, it is found that sources of supply, which have been approved, do not furnish a
uniform project, or if the product from any source proves unacceptable at any time, the Contractor
shall furnish approved materials from another approved source. No material, which after approval,
has in any way become unfit for use shall be used in the Work. The Contractor shall give the
Company reasonable notice in advance of the manufacture or production of materials to be supplied
under this contract so that the Company may arrange for mill and factory (Plant) inspection and
testing of the same. No materials shipped by the Contractor from the Plant prior to having
satisfactorily passed such testing and inspection by the Company, or prior to the receipt of notice from
the Company that such testing and inspection will not be required, shall be incorporated in the Work.
The Contractor shall furnish to the Company six (6) certified copies of all required factory and mill test
reports.
The Contractor shall submit to the Engineer and/or the Company for review, copies of such drawings
as may be required by the Company and/or Engineer. Such submissions shall give complete details
and information and contain sufficient views and be to such suitable scales as will show clearly the
Work or item. Each drawing shall be carefully checked and signed by the Contractor prior to
submission. The sequence of submission of drawings shall be such that all pertinent information is
available to the Engineer and/or the Company for reviewing each drawing as it is received. Each
submission shall be made sufficiently in advance of the schedule requirements for the Work shown on
the drawings to allow for the Company’s and Engineer’s proper consideration of the drawings, and for
their revision and re-submission, if necessary, without delaying the Work. Where original design is
involved, as determined by the Engineer and/or the Company, such drawings shall bear the seal or
stamp and the signature of a professional engineer with appropriate registrations.
The Contractor shall not order any materials or perform any Work shown or required on such
drawings prior to receipt of the Company’s and/or Engineer’s review thereof and written authorization
to proceed with the Work.
The review by the Company and/or Engineer of drawings and schedules submitted by the Contractor
shall not be construed as indicating any checking of the drawings and schedules, and shall not relieve
the Contractor of his responsibility for adequacy of design and accuracy of detail of the Work shown
on such drawings and schedules or for any errors therein or of any other of the Contractor’s
responsibilities under the Contract.
Upon receipt by the Company, all project-related drawings are the property of the Company.
Facilities access and haulage must meet or exceed all applicable standards.
Construction and access roads shall be constructed to include safety berms with a minimum height of
one-half the maximum wheel diameter of the equipment that will use the road. They shall also include
drainage control to avoid uncontrolled release of water and sediment from the project site.
Haul/access roads constructed by the Contractor will not be for his exclusive use. Other contractors
working on the Site, along with the Company and the Engineer, shall be afforded the use of the roads.
The Contractor shall be responsible for traffic control on all roads under his use, whether constructed
by the Contractor or provided by the Company. For the Company’s roads such as the main Site
access road(s), the Contractor, if he elects and has approval to use these roads, will not be allowed to
significantly disrupt the normal traffic flow. Traffic stoppage or disruption shall be minimal and not
disrupt the Company’s other operations.
In general, mine haulage roads will not be available to the Contractor for use in the Work. However, if
mine haul roads are required for use in the Work and have been made available to the Contractor by
the Company, mine haulage equipment will have right-of-way, and the Contractor may at times be
subject to traffic restrictions/delays. It will be the Contractor’s responsibility to make account for and
to schedule for this.
3.1.2 Stream Diversion, Dewatering, Drainage, and Well-Point Dewatering for Cutoff Trench
Excavation
3.1.2.1 Stream Diversion, Dewatering, and Drainage
Except as otherwise specified by the Engineer and/or the Company and provided for by the Contract,
the Contractor shall investigate, design, construct, operate, maintain, and subsequently remove such
temporary cofferdams, dikes, fills, surface and subsurface dewatering, and drainage facilities as are
necessary for control and removal of all water entering the Work areas including seepage and
leakage water, precipitation and overland runoff, and water resulting from the operations of the
Contractor and others.
The Contractor shall provide, maintain, and operate any temporary diversion, drainage and/or
pumping facilities, including well-point dewatering, required to control ground and surface water in
order to keep the excavations dry and in a stable condition. The Contractor’s dewatering operations
shall be accomplished in a manner that will not adversely affect the stability of the excavated slopes
and will not cause erosion and softening of adjacent materials. Surface water accumulated in an
excavation shall be drained or pumped to a Company-approved facility. The Contractor’s dewatering
and diversion methods shall not interfere with the performance of other Work that may be ongoing
and are subject to review and approval by the Company and/or the Engineer.
The Contractor shall obtain written approval from the Company before discontinuing the operation of
any dewatering system.
Cofferdams, dikes, fills, and dewatering and drainage facilities provided by the Contractor shall be
subject to the approval of the Company and/or Engineer and shall be such as to permit the Work to
be performed in an orderly and efficient manner under dry conditions. Prior to commencement of the
Work, the Contractor shall develop and submit a Stormwater Protection and Prevention Plan
(SWPPP) for approval by the Company and/or the Engineer.
The Contractor shall submit the “As-Built” drawings for each Work segment as is completed.
3.1.5 Security
The Contractor shall assume full responsibility for the security of the Work and of the equipment,
supplies, and materials in the assigned Work areas. In the context of this Section, security shall
include the provision for the duration of the Contract, of all fencing, gates, lights, signs, guards,
flagmen, watchmen, and other measures necessary for the protection of the Work and materials
against theft, damage, and entry of unauthorized personnel.
4.1 General
The technical requirements specified in this Section shall apply to all operations related to carrying out
the Work as shown on the Drawings or as specified by the Company and/or the Engineer.
The Work to be carried out under the Contract shall consist of supplying all Labor, Plant, and
Materials necessary to construct the Work as shown on the Drawings and in accordance with these
Specifications, or as otherwise specified by the Company and/or the Engineer.
Reference Information including laboratory reports, test pit and borehole logs, and figures are
available for Contractor’s information. The conclusions, interpretations, inferences drawn, and other
statements of opinion contained in the Reference Information are based upon present knowledge. No
warranties or representations as to accuracy or completeness are made. Contractor shall examine
the Site and reference information and be solely responsible for any and all conclusions and
deductions he draws with respect to all conditions, problems, and difficulties which may be
encountered in performing the Work, and shall make such use of the Reference Information as is
necessary.
These activities are in support of the construction of the TMF, Main Sediment Pond, Cunahuiri
Reservoir, WRF, WRF Ponds, Topsoil and Unsuitable Material Stockpiles, Plant Site Earthworks,
Landfill, Access and Haul Roads, Diversion Channels, TMF sediment ponds, and Construction Road
Sediment Ponds.
The Contractor shall set out the Work efficiently and accurately by approved methods and shall be
solely responsible; therefore, he shall provide, fix, and be responsible for the maintenance of all
monuments, stakes, templates, batter boards, benchmarks, and other reference marks, and shall take
all necessary precautions to prevent their removal or disturbance and shall be responsible for the
consequences of any such removal or disturbance and for the accurate reinstatement of all such
marks. The Contractor shall provide the Company and/or the Engineer with drawings showing his
monuments and control benchmarks.
The Work shall be set out to the specified requirements in all respects, but the Engineer’s and/or the
Company’s approval thereof shall not relieve the Contractor of any of his responsibilities for the due
fulfillment of the Contract. At the request of the Engineer, the Contractor shall at all times, without
charge, provide qualified men, equipment, tools, and materials to assist the Engineer in checking the
setting out of the Work.
If at any time during the progress of the Work any error should become evident or occur in the
location, grades, dimensions, or alignment of any part of the Work, the Contractor, upon such error
occurring or becoming evident, shall forthwith inform the Engineer and/or the Company and shall
rectify such error to the intent of the designs and specification requirements.
The Contractor, in his schedule of the Work, shall allow sufficient time for the carrying out of such
surveys and for resolution of any differences to the surveys that may affect his authorization to
proceed with the Work.
The Contractor shall obtain prior acceptance from the Company and/or the Engineer for his quantity
survey methods. This acceptance may require that the Engineer to participate in, or direct, the
carrying out of the survey or measurement. The Company may conduct such checks, as he may
deem necessary, including the use of a third-party surveyor. The Contractor shall assist the Company
or third-party surveyor in completing the checks and provide, if requested, any surveyor notes or data
available.
The Contractor shall prepare all estimates of monthly and final quantities for Work performed or in
place together with supporting data and computations as are deemed necessary by the Company
and/or the Engineer to determine the accuracy of the quantities. All quantities shall be submitted in a
form acceptable to the Company.
• The upper 0.3 m of the natural ground surface shall be considered topsoil; however, localized areas
of topsoil may be significantly thinner or thicker. Topsoil will not be suitable as fill material and shall
be stripped from all working area surfaces and from the surfaces of borrow areas where present. All
topsoil removed shall be stockpiled in accordance with Section 4.4.5.
• Topsoil stripping shall be required for all new access roads and borrow areas, as well as
embankment and other fill area footprints.
• The Engineer shall inspect the area to determine whether clearing, grubbing and stripping has been
completed to meet the requirements of this Specification.
• A survey will be made by the Contractor to determine quantities.
The Contractor shall not excavate beyond the lines and grades shown on the Drawings or as required
by the Engineer, without the prior written approval of the Engineer.
Pockets of Bog Material within the limits of an excavation, as defined by the Engineer, shall be
removed and hauled to designated stockpile areas or other locations approved by the Engineer and
the Company.
When the sequence of excavation and placement of fill requires temporary stockpiling of material,
different classes of material shall be stockpiled separately and shall be placed in such a manner to
provide natural drainage and a stable embankment. Measures such as the implementation of BMPs
shall be taken by Contractor to ensure minimized erosion and maximum sediment control associated
with any temporary stockpiling of material.
The Contractor, in his scheduling of the Work, shall allow sufficient time in his construction schedule
for the carrying out of such surveys and for the Engineer’s proper consideration thereof prior to his
authorization to proceed with the Work in the area.
4.5.1 Stream Diversion, Dewatering, Drainage, and Well-Point Dewatering for Cutoff Trench
Excavation
Except as otherwise specified by the Engineer and/or the Company and provided for by the Contract,
the Contractor shall investigate, design, construct, operate, maintain, and subsequently remove such
temporary cofferdams, dikes, fills, surface and subsurface dewatering, and drainage facilities as are
necessary for control and removal of all water entering the Work areas. Cofferdams, dikes, fills, and
dewatering and drainage facilities provided by the Contractor shall be subject to the approval of the
Company and/or the Engineer and shall be such as to permit the Work to be performed in an orderly
and efficient manner under dry conditions. Prior to commencement of the Work, Contractor shall
develop and submit a SWPPP for approval by the Company.
The Contractor shall obtain written approval from the Company before discontinuing the operation of
any dewatering system.
The Contractor shall provide, maintain, and operate any temporary diversion, drainage, and/or
pumping facilities, including well-point dewatering, required to control ground and surface water in
order to keep the excavations dry and in a stable condition. The Contractor’s dewatering operations
shall be accomplished in a manner that will not adversely affect the stability of the excavated slopes
and will not cause erosion and softening of adjacent materials. Surface water accumulated in an
excavation shall be drained or pumped to a Company-approved facility for treatment prior to disposal.
The Contractor’s dewatering and diversion methods shall not interfere with the performance of other
Work that may be ongoing and are subject to review and approval by the Company and/or the
Engineer.
Light to heavy ripping may be needed as a construction expedient for excavation and rock trimming in
localized areas. If blasting is required in deeper excavations, a blasting plan must be submitted to the
Company for review and approval. Blasting may be required to construct the spillways, outlet piping
and sumps.
The Contractor shall not excavate beyond the lines and grades shown on the Drawings or specified
by the Engineer without the prior written approval of the Engineer and/or the Company. The limits of
excavation may be shallower or deeper than shown on the drawings. The Engineer will determine
where and when an acceptable surface has been exposed in the excavation for founding the
embankments and related structures.
Suitable excavated materials meeting the specification requirements may be placed in the fills as
specified by the Engineer. Unsuitable materials within the limits of an excavation shall be removed
and stockpiled as specified by the Engineer. These materials may include, but will not be limited to,
soft moist zones, highly organic or other deleterious materials, and in some cases, zones of exposed
cobbles and boulders.
The Contractor shall protect and maintain all excavations until approved by the Engineer or until such
time as the adjacent placement or overlying placement of material has been completed.
The Contractor shall be solely and completely responsible, until completion of the Work, for the safety,
stability, maintenance, support, and protection of all excavated surfaces, the excavation of which is
carried out under the Contract, and for the safety of his work force and the forces of others while they
are in the Contractor’s working areas, including areas in the immediate vicinity of the excavations.
The Contractor shall supply and install rock reinforcement and provide all temporary supports,
bulkheads, canopies, sheeting and bracing, divert surface water, remove water from the excavations,
and shall provide and maintain such drainage and pumping facilities as are necessary to control
ground and surface water in order to stabilize and protect the excavations. The Contractor’s
dewatering operations shall be accomplished in a manner that will not adversely affect the stability of
the excavated slopes and will not cause erosion and softening of adjacent materials. Except as
otherwise approved by the Engineer, such temporary support and facilities shall be removed by the
Contractor on completion of the Work.
General guidelines as to rock quality are discussed in the following sections. The bedrock surface
shown on the Drawings is intended to guide the initial excavation. Inspection and acceptance of the
bedrock surface by the Engineer may result in an excavation which varies from the limits shown. The
actual surface may be higher or lower than that shown on the Drawings.
Rock Alteration
H/E M/S
OP/OHF R1 R2
Degree of Fracturing
OMF/OPF R3 R4
CMF R5 R6
CMFI/CPFI R7 R8
Rock Alteration
H/E. Highly to extremely altered; the material is discolored and the original minerals within the rock
have been almost entirely altered to secondary minerals, even though the original rock fabric may be
intact. The rock has been weakened to such an extent that a 5-centimeter (cm) diameter core can
easily be broken by hand.
M/S. Moderately to slightly altered; the rock is discolored and noticeably weakened, but a 5-cm
diameter core cannot be broken by hand. This category also includes rock that is only slightly
discolored and that does not show a noticeable decrease in strength. Unaltered rock resides in this
category.
Degree of Fracturing
OP/OHF. Open, pulverized to highly fractured; bedding and foliation planes are not easily
distinguished or fracture density in the rock generally occurs on a frequency higher than one fracture
per 5 cm. Discontinuities are open with little or no infilling.
OMF/OPF. Open, moderately to partially fractured; fracture density in the rock generally occurs on a
frequency greater than one per 5 cm. Discontinuities are open with little or no infilling.
CMF. Closed, moderately fractured; bedding or foliation planes are not easily distinguished or
fracture density in the rock generally occurs on a frequency less than one fracture per 5 cm.
Discontinuities are closed and are neither healed nor infilled.
CMFI/CPFI. Closed, moderately to partially fractured infilled; fracture density in the rock generally
occurs on a frequency less than one per 5 cm. Discontinuities are closed and are either healed or
infilled.
The excavated foundation surface shall be cleaned of all loose and weathered rock to produce a
clean rock surface such that consists of only intact tightly wedged or otherwise anchored rock pieces.
Where seams, cracks, or fissures containing sand or clay or other soft or incompetent material occur
in the foundation, they shall be cleaned out and treated by filling with dental concrete as follows:
Openings narrower than 2 inch (5 cm) should be cleaned to a depth of three times the width of the
opening and filled with dental concrete.
Openings wider than 2 inch (5 cm) and narrower than 5 feet (1.5 m) should be cleaned to a depth of
three times the width of the opening or to a depth where the opening is 0.5 inch (12 mm) wide or less,
but not to a depth exceeding 5 feet (1.5 m) and filled with dental concrete.
Such cleaning shall be done by the use of pneumatic tools, trowels, bars, hand brooms, or other hand
equipment, and high-pressure water jets and/or air jets, or by other methods approved by the
Engineer.
The Contractor shall trim and shape the final excavation surface to achieve an intimate contact with
the various embankment zones and allow adequate compaction adjacent to the foundation. In
particular, final excavated surfaces adjacent to embankment fill zones shall have a maximum slope of
70 degrees to horizontal with maximum change in slope from a vertical plane of 20 degrees in
6 meters (m). Final excavated rock surfaces to receive slush grout shall have a maximum slope of
2H:1V and preferably 2.5H:1.0V or flatter. Rock overhangs and other surface irregularities are to be
excavated and/or in-filled with concrete as specified by the Engineer.
After completing excavation and foundation preparation of the embankment expansion foundation, a
geologist will map the geological features of the exposed surface and the Engineer will determine the
need for and extent of drilling to investigate subsurface conditions, if any. Based on the results of
geologic mapping and any additional subsurface investigation, the Engineer will specify the need for,
and the type and extent of, foundation surface treatment. Such treatment shall include any
combination of additional excavation, dental concrete, reinforced dental concrete blanket, and slush
grouting. The Engineer may specify another method of treatment such as a concrete cutoff trench
below a reinforced dental concrete blanket if deemed necessary by the Engineer.
While based on the current information available it is not believed a grout curtain will be necessary
except for the Containment pond. If rock conditions vary significantly from those used as a basis for
the design a partial or full grout curtain may be required.
4.6.4.2.1 Bentonite
The bentonite for use in the slurry wall shall be Wyo-Ben Hydrogel, or equal, as approved by the
Engineer.
The bentonite, to be delivered, shall be tested by the Manufacturer and shall meet the following
requirements as determined from a mixture of bentonite and distilled water prepared in accordance
with API Standard Specifications, 13A, latest revision, and tested in accordance with API Code RP
13B, latest revision:
Contractor must submit name of the bentonite supplier, the source of bentonite and a sample to the QA
consultant prior to construction in accordance with the specifications
4.6.4.2.2 Water
Water shall be free of excessive amounts of deleterious substances, as determined by the Engineer
that could adversely affect the properties of the slurry or backfill.
• pH 6 to 8
• Hardness <50 ppm
• Low dissolved solids to allow proper hydration of bentonite
The Contractor shall add additional bentonite to make the slurry denser or more viscous than the
limits specified above, if deemed necessary by the Engineer.
Admixtures to alter the characteristics of the slurry in the trenches, including but not limited to
softening agents, dispersants, retarders or plugging or bridging agents, shall not be permitted unless
approved by the Engineer.
4.6.4.6 Backfill
• Materials for the backfill mix shall consist of slurry, dry bentonite, if necessary excavated trench
materials, and approved off-site soil.
• Backfill shall be free of roots, organic soil, lumps, trash, and debris.
• The backfill mixture shall have the following gradation limits:
4.6.4.7 Equipment
4.6.4.7.1 Trench Excavation
Equipment for excavating the slurry trenches shall consist of a hydraulic excavator. The equipment
shall be capable of excavating the minimum required trench width of 1-meter in a single pass of the
excavating tool. The equipment shall be capable of excavating at least 3.0 m deeper than the
maximum depth shown on the drawings.
• The Contractor shall take all precautions in conduct of Work as may be necessary to avoid
disturbance or damage to existing utilities and other structures.
• The excavation equipment shall remain at least 6 m away from overhead utilities.
• The trench excavation shall be at least 1-meter wide.
• Excavation of a lead-in trench is required if placement of the initial slurry is to be accomplished
without the use of a hydraulic excavator. The lead-in trench shall commence far enough away from
the cutoff wall and ramp down to the full depth of the cutoff wall at a slope of 1.5H:1.0V to avoid
segregation of backfill particles.
• The trench excavation shall be continuous to the depths indicated on the Drawings or as specified
by the Engineer. Actual depth of the wall will be determined based on visual observation of the
trench cuttings. The wall shall be keyed into the bedrock at least 0.3 m or as specified by the
Engineer.
• The entire depth of excavation shall be carried along the trench line. Prior to backfilling any portion,
and before the excavator starts his next cut, the Contractor shall pass the excavating tool along the
completed section of the trench excavation to confirm continuity.
• The toe of the slope of the trench excavation shall not advance beyond the backfill slope by more
than 60 m and there shall be at least 10 m between the toe of the backfill and trench excavated to
its design depth.
• The excavation shall be continuous from one end to the other, unless approved by the Engineer. If
for some reason it becomes necessary for the slurry wall to be constructed in phased segments,
some re-excavation of the previously constructed phase of the slurry wall will be necessary. This re-
excavation shall consist of backfill removal and reconstruction of a minimum horizontal length of 3 m
of slurry wall over the entire depth of the wall.
• The Contractor shall maintain trench stability to its full depth at all times. Sloughs, slides, or any
instability shall be re-excavated and/or repaired as approved by the Engineer.
• Stockpiling. Material excavated from slurry trenches that is suitable for the backfill mixture may be
stockpiled adjacent to the trench for subsequent processing.
• Cobble and Boulder Removal. The Contractor shall excavate all cobbles and boulders as
necessary along the slurry wall alignment and dispose of them at an on-site location as specified by
the Engineer.
• Mixing and blending shall be performed in such a manner as to produce the required backfill as
specified in these Specifications.
• The Contractor shall make every effort to cooperate with the Engineer in developing and enacting a
mixing technique to satisfy the hydraulic conductivity criterion.
• The Contractor shall, if specified by the Engineer, employ one or more of the following techniques to
satisfy the hydraulic conductivity criterion:
− Use a higher percentage of clay and silt materials in the backfill by separating and spoiling the
excavated sandy layers.
− Add dry bentonite, up to 3.5 percent by dry weight, to the backfill. Bentonite shall be spread
over 15 to 20-cm-thick layers of soil backfill material and mixed thoroughly.
− Add more bentonite to the slurry mixture.
• The backfill mixture shall be in compliance with the backfill requirements, immediately prior to
introduction into the trench.
• The backfill shall be placed so that no pockets of slurry are present in the completed slurry wall.
The backfill shall not be deposited in any manner that will cause segregation. Dropping of backfill
material into the slurry will not be permitted.
• The Contractor shall backfill continuously in the direction of the excavation from the beginning of the
trench to the end of the trench, unless approved otherwise by the Engineer.
• If a lead-in trench is not excavated, the initial backfill shall be placed by lowering the material to the
bottom of the trench by means of a hydraulic excavator bucket or other approved equipment until
the backfill emerges from below the slurry surface and achieves its natural angle of repose from the
bottom of the trench to the surface.
• Placing operations shall proceed in such fashion that the top of the backfill below the surface of the
slurry shall follow a reasonably uniform grade and shall not have hollows that may trap pockets of
slurry during subsequent backfilling. The bulldozer operator shall pile sufficient backfill on the edge
of the existing backfill to cause the backfill to enter the trench by sliding down the forward face of the
previously placed backfill.
• The toe of the backfill slope shall not be less than 10 m following the toe of the excavation to permit
proper cleaning.
• Additional backfill material shall be placed on top of the trench to accommodate settlement.
For rock foundations beneath the cutoff trenches, the Contractor shall place dental concrete and slush
grout or other foundation preparation measures as shown on the Drawings, described in the
Specification or as otherwise specified by the Engineer. The nature and extent of slush grouting and
dental concrete placement will depend upon the nature of the rock encountered in the excavations
and the results of the bedrock cleaning operations performed by the Contractor.
For foundations bottoming on soil, foundation preparation shall include removing loose and oversized
material, and compacting, the surface as described in Section 4.7.7 and Section 4.8.
Within the footprint area of the Core, all joints, cracks, and shear zones shall be cleaned of all soil and
debris. For openings narrower than 5 cm, material filling the cracks shall be cleaned to a minimum
depth of three times the crack width at the surface or as specified by the Engineer. Beneath the Core,
for openings wider than 5 cm and narrower than 1.5 m, the opening shall be cleaned to a depth where
sound material is encountered or a minimum of three times the crack width, or as specified by the
Engineer. The amount of cleaning for surface cracks with a width wider than 1.5 m, as well as
foundation treatment will be specified by the Engineer and may include a reinforced dental concrete
blanket and/or concrete cutoff trench.
Cleaning methods to be used include air and water jets, picks, and other hand tools or brooms as
necessary to ensure a bond of the slush grout to bedrock.
The final cleaned and prepared surface shall be approved in writing by the Engineer before being
covered.
Contractor shall maintain the prepared surface prior to placement of slush grout and avoid the use of
tracked vehicles on the exposed and cleaned bedrock surface. Any vehicle traffic on the cleaned
foundation surface shall be avoided unless absolutely required.
The Contractor shall use experienced personnel for slush grouting and dental concrete placement.
The materials and equipment supplied and methods and procedures employed by the Contractor
shall be subject to the approval of the Engineer.
Dental concrete shall consist of cement, sand, and aggregate mixed in suitable proportions with water
and additives to produce a concrete having a minimum 28-day compressive strength of 2,000 psi or
13,79 MegaPascals (MPa). Maximum aggregate size shall be 4 cm. A smaller aggregate size may
be used to fill smaller discontinuities if the 4-cm size aggregate inhibits dental concrete penetration
into the discontinuities. The Contractor shall submit to the Engineer the mix design with compressive
test results of the mix design 3 weeks prior to dental concrete placement.
Depressed areas, potholes, and similar irregularities, determined by the Engineer to prohibit adequate
compaction of the fill material, shall be filled with dental concrete vibrated into place. Rock ribs or
similar irregularities shall be removed or trimmed to a suitable height, then filled with dental concrete
to produce slopes, which are no greater than 1H:1V.
Wire mesh reinforced dental concrete blankets shall be constructed to have a minimum thickness of
300 mm. If a slab is placed, all joints or cracks shall first be filled with slush grout, even when it is
decided that a slab can be placed over a large cavity or over closely spaced joints or cracks to
expedite Work. Thin areas of dental concrete over a jagged rock surface are likely places for
concrete cracking and shall be avoided by using a sufficient thickness of dental concrete or by
avoiding continuous slabs of concrete. Feathering at the ends of slabs shall be avoided. The
decision about whether to place a slab of dental concrete will be at the discretion of the Engineer.
The finished surface of the wire mesh reinforced dental concrete blankets shall have a roughened,
broomed surface to bond well to the embankment fill materials.
Dental concrete shall be cured by water or with an approved curing compound until it is covered by
earthfill. Earthfill operations shall not be permitted over dental concrete until it has reached
70 percent of its 28-day design strength. This will allow the concrete to develop sufficient strength to
withstand stresses caused by earthfill placement operations. Construction equipment shall not be
driven on exposed concrete surfaces.
The final prepared dental concrete surface shall have a relatively smooth surface against which slush
grout and soil can be placed and compacted by heavy equipment.
4.7.3 Shotcrete
4.7.3.1 General
The Engineer shall secure a competent Concrete Contractor for installing all shotcrete associated with
the completion of the Work. This contractor may be independent of the Contractor. Shotcrete may be
installed for erosion protection in conjunction with channel work and slope erosion blankets and as
shown on the Drawings.
Proposed shotcrete will be wet-hatched. If it is preferred to use a dry-batch system for producing
shotcrete, all proposed procedures and equipment shall be submitted to the Engineer for approval.
Typically, shotcrete to be placed will come from on-site volume hatching using approved materials. In
general, shotcrete work shall be conducted in accordance with:
• American Concrete Institute (ACI) 212.2, “Guide for Use of Admixtures in Concrete”
• ACI 304, “Recommended Practice for Measuring, Mixing, Transporting and Placing Concrete”
• ACI 306, “Standard on Cold Weather Concreting”
• ACI 308, “Standard Practice for Curing Concrete”
• ACI 318, “Building Code Requirements for Reinforced Concrete”
• ACI 506R, “Guide to Shotcrete”
• ACI 506.2, “Specification for Materials, Proportioning, and Application of Shotcrete”
However, some deviation from the above standards may be required for on-site volume hatching and
is subject to the Engineer’s review and approval.
Quality control of the shotcrete shall be the responsibility of the Concrete Contractor, with quality
assurance being the responsibility of the Engineer.
Certificates of inspection by the Engineer will be required for placing reinforcement and embedded
items, placing shotcrete, placing backfill, and receiving final acceptance. These certifications shall
describe in detail the work performed and shall be signed by the Concrete Contractor and Engineer.
General
Shotcrete shall be composed of, but not limited to, Portland cement, water and both fine and coarse
aggregate. Shotcrete shall be designed to give a practical combination of materials, which will
produce the required durability and strength in the hardened shotcrete.
Reinforced shotcrete to be used in the Work shall have a minimum 28-day flexural strength, according
to ASTM C 78, of 6.9 MPa. Minimum compressive strength, according to ASTM C 42, shall be
34.5 MPa. During the pre-qualification testing, a ratio of compressive to flexural strength shall be
established for quality assurance purposes. Quality assurance during actual placement of shotcrete
will be governed by compressive strength testing.
Shotcrete Workability
The slump for wet-mix shotcrete shall be near the minimum that the pump will handle with 75 mm
being the maximum slump to be used.
Trial hatching of mixture proportions or materials which have had no previous use onsite shall be
accompanied by data verifying material properties, mixture proportions, test data, and performance.
At least 30 days before start of construction, the Concrete Contractor must perform and complete trial
hatching using proposed mixes approved by the Engineer to demonstrate capability of equipment,
workmanship, and materials.
Historical data of materials and mixture proportions used previously onsite may be used in lieu of trial
hatching, subject to the approval of the Engineer and MYSRL. Historical data submitted shall include
all material data, mixture proportions, and test reports or data summaries.
The total chloride content from all sources including mixing water, cement, admixtures, and aggregate
shall not exceed 0.10 percent by mass of cement for reinforced shotcrete applications in a moist
environment exposed to chloride and 0.15 percent in a moist environment not exposed to chloride.
If there is substantial concern of the shotcrete being subjected to freezing and thawing conditions, air
entraining may be used subject to the approval of the Engineer. Typically, an air content of 8 to
12 percent in the mixture results in in-place shotcrete having a proper air void system to provide
sufficient frost resistance.
The responsibility for the design of all shotcrete mixes to be used in the Work shall rest entirely with
the Concrete Contractor. Shotcrete shall conform to all requirements of ACI 506.2, “Specification for
Material, Proportioning and Application of Shotcrete,” except as modified by the requirements of these
Specifications or as directed by the Engineer. For on site volume hatching, some deviation may be
Details of concrete mix designs and reasonable evidence demonstrating the mix proportions selected
will produce concrete complying with these Specifications, such as results of cylinder compression
tests of trial mixes, shall be submitted to the Engineer by the Concrete Contractor 30 days in advance
of commencement of any concreting operations. The Concrete Contractor shall not alter such mix
designs without the Engineer’s written approval.
The Concrete Contractor shall cooperate with and provide assistance to the Engineer in obtaining
samples of aggregates and shotcrete and in maintaining quality control of all aspects of shotcrete
production at the batch plant and at the point of placement.
4.7.3.3 Materials
Water
Water to be used for shotcrete mixing shall be for cleanup and curing of concrete as well as water
used for spraying Concrete Aggregates and shall be potable water, fresh, clean, and free from
deleterious amounts of silt, organic matter, alkali, acids, salts, and other impurities. The Concrete
Contractor shall submit water quality information to the Engineer for review prior to approval of the
water source by the Engineer and MYSRL.
Cement
Except as approved by the Engineer, Portland cement shall be Type I or Type II and shall conform to
ASTM C 150. Where the shotcrete will be exposed to soil or water high in soluble sulfates, Type II or
V shall be used.
Any request to deviate from the use of Type I, Type II, or Type V Portland cement must be submitted
in writing to the Engineer for approval. No rapid hardening (Type III) cement types will be allowed.
Admixtures
Any admixtures proposed for use by the Concrete Contractor shall be submitted to the Engineer for
approval. The Concrete Contractor must obtain written approval from the Engineer prior to use.
Aggregates
Fine aggregate shall be processed natural sand. Aggregate proposed for shotcrete purposes shall be
subject to inspection and approval by the Engineer.
All shotcrete aggregates shall be sound, free of harmful materials, and non-reactive with the alkali that
may be contained in the cement. Aggregates shall comply with the quality requirements and shall be
properly graded in accordance with ASTM C 33, C 131, and C 136. The table below shows
acceptable grading limits. Aggregate failing to comply with tills grading may be used if
pre-construction tests demonstrate that it gives good results and subject to the approval of the
Engineer; however, a uniform grading is essential. The Concrete Contractor shall be responsible for
the quality of all such materials used in the Work.
The dust content, measured as the percentage of material passing the 0.07 mm sieve, shall not
exceed 5 percent in the case of fine aggregate and 1.5 percent in the case of coarse aggregate. The
fineness modulus shall fall in the range of 1.6 to 3.5 (inclusive).
The chloride content of the aggregates shall not exceed 0.03 percent by mass, and the aggregate
shall be free of organic materials.
Soundness and durability requirements will conform to Standard ACI Specifications for structural
concrete.
4.7.3.4 Formwork
In general, formwork will not be required in shotcrete applications. If formwork is deemed necessary,
it shall meet the same requirements as for concrete installation.
The addition of water at the hatching and mixing equipment shall be solely at the Concrete
Contractor’s risk. Any materials that are hatched too wet shall be disposed of at the Concrete
Contractor’s expense.
If admixtures are to be used, dispensers shall receive special attention to ensure that the material is
dispensed within ±3 percent of the required batch quantity and is uniformly dispersed throughout the
mixture.
Earth or granular foundations shall be thoroughly compacted and be kept damp several hours prior to
application of the shotcrete. Shotcrete shall not be placed on any surface which is frozen or spongy
or where there is free water.
All rock surfaces against which shotcrete is to be placed shall be clean and sound.
Safe, adequate scaffolding shall be provided so that the nozzleman can hold the nozzle at the
optimum angle and distance from the surface for all parts of the Work. The scaffolding should also
provide easy access to the shotcrete surface for screening and finishing operations.
4.7.3.7 Reinforcement
All reinforcement shall conform to ASTM A 615, A 616, or A 617, whichever is most applicable, as
determined by the Engineer. The minimum characteristic yield strength for all reinforcement is
fy=400 MPa. Reinforcing bars used for shotcrete shall not be larger than No.5, and bar spacing shall
be limited to between 150 mm and 300 mm unless otherwise indicated on the Drawings.
Welded wire fabric (WWF) shall be galvanized flat stock and shall conform to American Association of
State Highway and Transportation Officials (AASHTO) Designation M55-89 (ASTM A 1851).
Minimum wire spacing shall be 150 mm and nominal wire diameter 6.4 mm unless otherwise indicated
on the Drawings. Fabric sheets shall be lapped one and one-half spaces in all directions and wire
tied.
Chain link fabric, when used, shall conform to AASHTO Designation M181-90 Type I (zinc-coated
steel) with 50-mm mesh and 4.0-mm-diameter wire.
Tie wires for reinforcement shall be 16-gauge wire, bent flat in the plane of the mesh. Ties for
reinforcement shall be black annealed and not less than 1.5 mm in diameter. At the time shotcrete is
placed, reinforcement shall be free from rust, scale, oil, or other coatings which will impair the ability of
shotcrete to bond with the reinforcement.
When several layers of wire fabric are required, the first layer is covered with shotcrete prior to placing
the next layer, with ties extending from the first layer to the next. At least one layer of fabric shall be
used for each 75 mm of shotcrete thickness.
Anchors to support reinforcement shall be spaced each way at a maximum of 900 mm.
The minimum shotcrete cover to any reinforcement bar shall be 75 mm and 37.5 mm to any welded
wire or chain link fabric unless indicated otherwise on the Drawings.
Within 24 hours of completing the earthworks, the Concrete Contractor shall provide the Engineer with
24 hours’ notice stating when and where shotcrete is to be placed. Final inspection for approval of
shotcrete placement will be undertaken by the Engineer only after placement of reinforcement and
embedded items and surface preparation have been completed. No shotcrete shall be placed before
the Engineer has inspected the reinforcement and embedded items and certified them in writing as
being ready for shotcrete placement. Such inspection and certification shall in no way relieve the
Concrete Contractor of any liabilities due to errors and/or omissions of any part of the construction.
After the surface has been prepared to receive shotcrete, the Concrete Contractor shall install taut
ground wires or other means such as non-corroding pins or nails to demonstrate that the required
thickness has been obtained. Install such devices on approximate 1.5 m maximum center-to-center
spacing and on all high points of the surface.
When placing shotcrete, the operator shall generally hold the nozzle at a 90-degree angle to the
surface where shotcrete is being applied. When shotcreting around reinforcement, the nozzle shall
be held at a slight angle to assure sufficient shotcrete is applied beneath said reinforcement. In the
case of wire mesh reinforcement, the nozzle should be held close enough to the surface to ensure
that shotcrete adheres to the underlying surface before building up on the reinforcement. Interior
corners shall be gunned by directing the nozzle in the plane bisecting the angle of intersection of the
In general, a distance of 1.0 m shall be maintained between the nozzle and the shotcrete surface
during application.
At all times during application of the shotcrete, a separate operator shall use an air hose or other
adequate means to clear away all rebound which may settle on the surface being treated, ahead of
the advancing shotcrete.
When a layer is to be covered by a succeeding layer, it shall first be allowed to develop its initial set.
After initial set has occurred, all loose material and rebound shall be removed by brooming, scraping,
or other means. Surface deposits, which take a final set, shall be removed by sandblasting and the
surface cleaned with an air-water jet.
All areas that may contain loose aggregate trapped between the applied shotcrete and the underlying
surface shall be cut out and repaired with shotcrete at the Concrete Contractor’s expense.
In channel lining applications and slopes, slotted weep hole pipes shall be placed through the
shotcrete bed, into the subgrade, as shown on the Drawings or at the discretion of the Engineer. The
pipe end penetrating the subgrade shall be capped. The purpose of the weep holes is to provide
ground water pressure relief below the shotcrete bed.
Rebound
Rebound is aggregate and cement paste that bounce off the surface during the application of
shotcrete because of collision with the hard surface, the reinforcement, or the aggregate particles
themselves.
Rebound shall not be worked back into the construction and shall not be salvaged for use in later
batches of shotcrete. If it does not fall clear of the Work, it must be removed before it hardens and
discarded as approved.
Measurement of rebound from test panels shall be considered before beginning the shotcrete
operation to ensure sufficient material supplies during the actual application.
Suitable headgear, protective clothing, and safety equipment shall be the sole responsibility of the
Concrete Contractor to prevent serious injury from rebound during its application.
Construction Joints
In general, a panel shall not be started unless it can be completed during the shift. However, if the
Work must be stopped or is interrupted for a period of time, joints shall be made that allow the in-
place shotcrete to set or harden. At joints, shotcrete shall be tapered from full thickness to zero over
a minimum distance of 1 m.
Prior to placing additional shotcrete, the tapered joint surface and adjacent rock shall be wet
sandblasted and washed to break the mortar surface and clean away any laitance, rebound, or other
contamination. High-pressure air/water jets may be used in lieu of wet sandblasting if satisfactory
results can be demonstrated to the Engineer.
The wet cleaned surface shall then be coated with a rich mortar paste using the shotcrete equipment.
Alternately, the surface may be coated with a cement water paste after which the shotcrete shall be
applied. The shotcrete may be applied directly to the wet, cleaned surface if rebound during the initial
application results in a rich mortar coating on the joint surface free of trapped rebound, voids, or
objectionable lamination and the Engineer approves such application.
Contraction Joints
Contraction joints shall be installed in channel lining applications, or as indicated by the Engineer or
on the Drawings, to control shrinkage cracking of the shotcrete. The joints shall be created by pre-
4.7.3.9 Finish
All shotcrete surfaces shall be left in their rough, natural gun finish.
Surfaces shall be kept continuously moist for at least seven days to allow sufficient tensile strength to
resist shrinkage strains.
Agents are not recommended. However, if the Concrete Contractor proposes to use curing agents,
approval by the Engineer is required prior to use.
Fill shall not be placed adjacent to or upon any shotcrete, which has not attained 70 percent of the
designed minimum compressive strength measured at 28 days.
All shotcrete which lacks uniformity, which exhibits segregation, honeycombing, or lamination, or
which contains any dry patches, slugs, voids, or sand pockets shall be removed and replaced with
fresh shotcrete at the Concrete Contractor’s expense.
Core holes shall not be repaired with shotcrete. Instead, they shall be filled with a tightly compacted
epoxy mortar or compound, as directed by the Engineer, that is moisture insensitive with an epoxy
binder that conforms to ASTM C 881, Type III.
Where surface crazing, shrinkage cracks, or low strengths occur, additional analysis will be required
by the Engineer to determine the effect upon the structure. In some cases, no remedial action may
be required; in others, a surface treatment with a polymer may be satisfactory. In cases where the
performance of the structure is significantly degraded, the affected shotcrete areas shall be removed
and replaced with sound shotcrete at the Concrete Contractor’s expense.
In general, repaired sections of shotcrete shall be secured through the use of keys, dovetails, or
anchors.
General
The Engineer will inspect from time to time all aspects of the Work to ensure the Work is being carried
out properly. The Concrete Contractor shall cooperate fully and provide all necessary assistance to
enable the Engineer to carry out such inspections and tests.
• Within 30 days prior to construction, provide the following in sufficient quantities to perform the test
trials:
− Shotcrete equipment and materials as approved.
− Plywood forms for use as test panels fabricated in accordance with ASTM C 1140, each 1 m
square and 100 mm deep, so constructed that the test panels do not vibrate when shotcrete is
placed. Mount test panels firmly in a sturdy timber framework so constructed that the shotcrete
nozzle is exactly 1 m away from test panels, all as observed by the Engineer.
• For each shotcrete mix, fabricate test panels for three vertical and three horizontal panels shooting
positions.
Subject to the approval of the Engineer, rock or existing concrete surfaces may be used for testing.
Where the shotcrete will contain reinforcement, this shall be duplicated in at least part of the test
panels to show whether sound shotcrete is obtained behind reinforcing bars or welded wire fabric.
Test panels shall consist of a minimum 100 mm thickness of dense, uniform shotcrete without
rebound inclusions, segregation voids, or weakness of bond between layers. For each test panel
produced, records of mix proportions and details of placement procedure such as nozzle distance,
rate, and angle of application, thickness of layers, time lapse between layers, and time lapse between
mixing and application shall be made and submitted to the Engineer.
Each panel shall be cured in a manner identical to that anticipated for curing in the field, or as directed
by the Engineer. The panels shall also be protected against being disturbed and from exposure to
extreme heat or cold during this period.
Test panels will be tested to determine conformance of the shotcrete to Specifications. If the results
are unacceptable, fabricate additional test panels using revised mix proportions, mixing and
application equipment, or application procedures until acceptance test panels are achieved.
Panels shall be cored or sawn no sooner than after 7 days of standard curing. The specimen shall be
tested in compression at 28 days to evaluate the mixture performance. Depending on the expected
strengths, testing at 7 or 14 days is adequate to determine the suitability of the nozzleman and
process. Core specimens shall be tested for compressive strength in accordance with ASTM C 42.
Beam specimens shall be tested for flexural strength in accordance with ASTM C 78. Generally, two
specimens shall be tested at 7 days and two at 28 days with an additional two specimens being
available for special testing if required.
Visual Examination
Visual examination of sawn surfaces shall be performed to determine the uniformity of the shotcrete.
Panels shall be sawn into quadrants after seven days of standard curing. The cut surfaces of the
specimens shall be carefully examined, and additional surfaces shall be exposed by sawing the panel
when this is considered necessary to check the soundness and uniformity of the material. All cut and
broken surfaces shall be dense and substantially free from laminations and sand pockets.
The maximum absorption and voids of the shotcrete in place, when tested under ASTM C 642, shall
be 7 percent for absorption and 16 percent for voids.
Pre-construction testing and evaluation shall precede the actual work by sufficient time to allow for
nozzleman certification at the start and ending with strength testing at 28 days. Construction of
shotcrete for payment shall not begin prior to nozzleman certification and 28-day strength testing
unless approved by MYSRL.
During the shotcreting operations, the Engineer will sample and test all classes of concrete in
accordance with ACI Standard 318. The Concrete Contractor shall provide such facilities as may be
necessary for procuring and handling representative test samples, including suitable devices for
obtaining representative samples of concrete for uniformity tests. All necessary tools, equipment, and
labor for obtaining and testing samples shall be furnished by the Engineer. The Engineer will carry
out continuous inspection of shotcrete quality and placement of shotcrete through the course of the
Work.
All shotcrete will be subject to inspection and testing according to applicable ASTM standards as
listed under Section 1, Volume 01.04, “Steel-Structural, Reinforcing, Pressure Vessel, Railway,” and
Section 4, Volumes 04.01, “Cement; Lime; Gypsum” and 04.02, “Concrete and Aggregates,” without
compromising the requirements of other standards detailed elsewhere herein.
The Concrete Contractor shall perform as many control tests on material as necessary to determine
suitability of borrow areas. These control tests shall be submitted to the Engineer for approval prior to
Materials
Manufacturer’s certified results for cement shall be supplied at the specified intervals and whenever a
change in the appearance or performance of the material is suspected.
The moisture content of each aggregate group shall be used to determine the amount of free water to
be added to each batch of shotcrete. Moisture contents shall be established prior to the start of each
shift and when a change is made in stockpile or borrow sources.
Shotcrete
A test panel shall be shot at least once a shift. The panel shall be shot by a nozzleman who is placing
shotcrete in the permanent work. The panel shall be at least 450 mm x 450 mm x 75 mm. Cores
shall be taken from the panel in accordance with the provisions of ASTM C 42 to verify the
compressive strength of the shotcrete.
At established intervals, and whenever deemed necessary by the Engineer, cores shall be obtained
from the in-place shotcrete to verify the strength. The samples shall be cured and tested in a manner
similar to that of test panels.
The mixture proportions of the shotcrete shall be checked regularly to verify that the original
properties are being maintained. This shall generally be accomplished by verifying that the batch
weights, especially the cementitious materials and water weights, are as required.
The wet-mix shotcrete shall have a specified air content as determined by ASTM C 231 and shall be
determined at regular intervals and at locations throughout the Work as indicated by the Engineer.
The air content shall be determined by sampling at the pump.
The in-place thickness of the shotcrete may be verified by probing the fresh shotcrete with a sharp
tool. Areas of reduced thickness shall be corrected immediately by application of additional material.
Cores of hardened shotcrete may be taken to verify areas of suspect thickness as directed by the
Engineer.
Nondestructive testing of the uniformity and quality of in-place shotcrete may be assessed through the
use of testing devices such as impact hammers or probes (ASTM C 805 and ASTM C 803), ultrasonic
equipment (ASTM C 597), and pull-out devices (ASTM C 900). The use of such devices shall be at
the direction of the Engineer and shall be used to identify areas of suspect quality and relative
strength, not for actual strength determination.
Where appropriate, complete shotcrete coatings shall be checked for complete bond to the substrate
and bond between each shotcrete layer using a small hammer on the surface. All areas of
delamination shall be removed and shotcrete reapplied at the Concrete Contractor’s expense.
The quality of the shotcrete shall be thoroughly evaluated by visual inspection. Surfaces shall be
inspected for uniformity, voids at the surface, varying finish conditions, dry conditions, seepage of
water, cracking, and damaged sections.
Shotcrete work and embedded items that exceed the specified tolerance limits shall be remedied or
removed as required by the Engineer.
When testing shotcrete cylinders, no more than one test per structure shall yield strengths less than
the specified strength, and no individual test shall yield a strength less than 10 percent below the
specified strength.
Grout for slush grouting shall consist of cement and sand thoroughly mixed in the proportions of one
part cement to two parts fine aggregate by volume (or as specified by the Engineer), with sufficient
water to produce a mixture which can be poured and broomed into cracks and fractures in the surface
of the rock to fill completely all open joints, crevices, and minor imperfections in the rock surface. The
slush grout shall have a minimum 28-day compressive strength of 2,000 psi or 13.79 MPa. The grout
shall be mixed in a mechanical mixer for at least 2 minutes and shall be applied to the surface and
broomed into cracks and fractures within 40 minutes of mixing. The Contractor shall submit details to
the Engineer of a slush grout-mix design that meets this specification. Upon approval by the Engineer
of the mix design, the Contractor shall provide a truck scale batch for testing to confirm performance
of the 28-day mix design.
After approval of all bedrock cleaning and other surface preparation by the Engineer, the bedrock
surfaces to be treated shall be moistened prior to slush grout placement. Slush grout shall then be
applied into individual cracks by funneling, troweling, pouring, or rodding, or applied over closely
Core material shall be placed on the finished surface within 30 minutes after the slush grout has been
placed and approved by the Engineer. The initial 30-cm-thick layer of Core material shall have a
moisture content 0 to 4 percent above optimum. The initial layer shall be wheel-rolled in order to
protect the foundation from damage. After the initial 30-cm-thick layer of material has been placed
with the wheel rolling procedure, normal compaction equipment as specified elsewhere herein shall
be utilized. To avoid deterioration of the slush grout and initial lift of Core material the Engineer may
specify the Contractor to place a minimum of 1 m of Low Permeability Core material (Zone A) over the
prepared foundation in accordance with the normal placement and compaction procedures described
in Section 4.8.4.1.
The surface of exposed soils shall be proof rolled by at least four passes of a Caterpillar Model 825
compactor or approved equivalent. Other compactors can be considered provided that they can be
demonstrated to obtain a compacted surface comparable to that obtained by the Caterpillar
Model 825 compactor or approved equivalent.
Any soft or loose areas that deform significantly under the weight of the roller shall be removed. This
is the minimum requirement for foundation preparation of the natural soil surface. The Contractor
shall provide any additional foundation preparation as necessary to achieve the specified compaction
requirements for compacted materials to be placed and compacted above the foundation surface.
Embankment and fill materials shall be placed to the lines and grades as shown on the Drawings. All
fill materials shall be free of vegetation, debris, organic matter, and other deleterious materials and
meet the requirements of the Specifications and designs.
No fill shall be placed within a minimum distance of 30 m on any part of the foundation until all
required foundation preparation has been completed and the foundation preparation has been
approved by the Engineer.
4.8.1.1 Deviations
The permissible maximum horizontal and vertical deviation from the finished outside slope surfaces or
zone boundaries of the embankment expansion from the lines and grades shown on the Drawings, or
specified by the Engineer, shall be in accordance with Section 4.3, and:
• The finished outside slope surfaces shall not be lower than the required lines and grades shown on
the Drawings.
• The dam crest width shall not be less than the dimensions shown on the Drawings or specified by
the Engineer.
• The Contractor shall allow for any settlement that may take place during the course of construction.
The levels on the Drawings will allow for post-construction settlement and the Contractor shall build
to and be paid for building to these levels.
Material placed on the fill that is too wet for compaction shall be removed, left to dry, or be aerated
and dried by disking or other approved means until the moisture content is uniform throughout the
layer and within the limits specified or approved by the Engineer. Material placed on the fill that is too
dry shall be moistened by sprinkling with water. The layer shall then be disked or otherwise mixed
prior to compaction until the moisture content is uniform throughout the layer and within the limits
specified or approved by the Engineer. Any section of fill containing material that is too wet or too dry
shall not be compacted until the moisture content of the material is brought within the desired limits.
Material which cannot be brought within the specified limits shall be removed and replaced with
suitable material.
The Contractor shall exercise care to avoid cross contaminating the fill materials and/or the fill zones
on embankments. Contaminated fill materials that do not meet the requirements of this Specification
shall not be used in the fill or shall be removed from the fill if already placed.
In general, the fill is to be constructed in horizontal layers with each layer being completed over the
full length and breadth of the zone as approved by the Engineer before placement of subsequent
layers. Each zone shall be constructed only with materials meeting the specified requirements and
shall be free from lenses, pockets, and layers of materials which are substantially different in
gradation from the surrounding material in the same zone, as specified by the Engineer.
Except in areas approved by the Engineer, where space is limited or as otherwise specified, fill shall
be placed and compacted by routing the hauling, spreading, processing, and compaction units
approximately parallel to the axis of the embankment. Where impractical limits exist, the hauling,
spreading, processing, and compaction units shall be so routed that they do not follow in the same
paths but spread their traveled paths evenly over the surface of the fill. Special compactors shall be
used, as specified in Section 4.8.3.5, in areas that are not accessible to large compaction equipment.
The specified moisture contents and densities are to be achieved.
If materials require moisture conditioning, the Contractor shall employ whatever method and
equipment is necessary to condition the material to meet the specified moisture content.
Should the fill surface become rutted or uneven subsequent to compaction, it shall be re-leveled and
recompacted before the next layer of fill is placed. Material which is soft and yielding as a result of the
presence of excessive water shall either be removed from the fill or allowed to dry naturally or by
scarifying, until the specified moisture content has been attained. The material shall then be
recompacted to provide a firm, unyielding surface meeting the density requirements of this
Specification.
For zoned embankments, the Contractor shall maintain a minimum slope of 0.5 percent across
constructed fill zones to promote surface drainage during construction to the upstream slope for the
core and upstream shell, and downstream slope for the drain and downstream shell.
In the case of the core, if the surface of the fill becomes too dry or hard to permit suitable bonding with
the subsequent layer, the material shall be loosened to a depth not to exceed 20 cm by scarifying or
disk harrowing and reprocessed to meet the Specification requirements before an additional lift is
placed. If the dry or hard layer is greater than 20 cm thick and is judged by the Engineer to be
detrimental to the construction it shall be removed and replaced.
The Contractor shall take every precaution, when operating equipment near existing structures, to
avoid damage to adjacent structures and disturbing the foundation system(s).
The rolling pattern along all zone boundaries or construction joints shall be such that the full number
of roller passes required shall be applied to each material on each side of the boundary. Where
materials are similar on each side of the boundary the compaction equipment can straddle the
boundary such as the boundary between the core and upstream shell where the potential to cross
contaminate materials is minimal. Where dissimilar materials are adjacent to each other, compaction
equipment shall not cross the material boundaries. For instance, where drain material is adjacent to
the core or downstream shell use of compaction across the construction boundaries shall not be
permitted since the risk of contaminating the drain material is high.
The Contractor shall do whatever is necessary to prevent surface runoff or water from any other
source from eroding fill materials placed for the Work, and shall immediately repair any damage
resulting from such erosion, using materials and methods approved by the Engineer.
The Contractor may perform a supplementary investigation for his own purposes but a copy of the
results of any such investigation shall be submitted to the Company and the Engineer. The
Contractor’s borrow area operations shall be subject to the approval of the Company and the
Engineer. The Contractor shall clear and strip the borrow area and shall as and where specified by
the Engineer, stockpile all topsoil which, in the opinion of the Company or the Engineer, can be
salvaged. The borrow areas shall be developed with due consideration for drainage and runoff from
the excavated surfaces so as not to cause erosion of the adjacent terrain. The borrow areas shall be
Except as permitted by the Company, waste material from an excavation for the Work or from a
processing operation in a borrow area shall be disposed of in a spoil area or in an approved area set-
aside for the purpose within the project site.
The Contractor’s borrow area operations shall be subject to the approval of the Company and/or the
Engineer and shall be such as to avoid waste of any suitable construction material therein. In order to
develop the borrow area, both topsoil and, in some cases, up to several meters of overburden shall
be stripped. Suitable topsoil shall be stockpiled and the remainder of the stripped material, if suitable
in accordance with this Specification, shall be used as embankment fill. Before being abandoned, the
sides of the borrow area shall be brought to stable slopes (2.5H:1.0V maximum, or as specified by the
Company and/or the Engineer), with slope intersections rounded and shaped to provide a natural
appearance. All rubbish, Contractor’s equipment, and structures shall be removed from the area.
Waste piles shall be leveled, trimmed and shaped to regular lines to prevent the occurrence of
ponding or of concentrations of surface runoff and to provide a neat appearance. All borrow areas will
be graded to provide natural drainage.
The Contractor shall clear, grub, and strip all borrow areas in accordance with the provisions of
Section 4.4.
The Contractor shall excavate any open trenches and install such other drainage facilities as are
required to divert water around and drain water from any borrow area as specified by the Engineer.
The methods and equipment used for excavation of fill materials from the borrow area shall be such
that satisfactory selection and blending is achieved to provide material suitable for the respective
zones.
Where, in a borrow area, materials are encountered which would not be acceptable as fill, they shall
be left in place or excavated separately and disposed of in accordance with Section 4.4.4.
Where, in the opinion of the Engineer, the methods of excavations and operations are unsatisfactory
in that they produce materials that are not suitable for use in the fill, such methods shall be
discontinued, and the Contractor shall adopt such revised techniques and procedures as are specified
or approved by the Engineer to obtain satisfactory materials.
The Contractor shall operate the borrow areas in an orderly manner at all times, maintain them free of
surface water runoff and leave them in a tidy, well-drained condition approved by the Company and/or
the Engineer on completion.
The Contractor’s procedures for compaction of fill shall be subject to the approval of the Engineer.
Compaction of each layer of fill or subgrade shall proceed in a systematic, orderly, and continuous
manner approved by the Engineer such as to ensure that all of each layer receives the compaction
specified. The compaction shall be carried out by routing the compaction equipment parallel to the
axis of the embankment, except that where such routing is impractical such as: in roller turning areas,
in areas adjacent to structures or at the lower elevations of the fill, in areas adjacent to pipework, and
where otherwise specified by the Engineer. The compaction equipment may be routed in any
direction approved by the Engineer. Required densities and moisture contents shall be as required
elsewhere in the same material zone.
For compaction by vibratory, pad or sheepsfoot rollers, one coverage shall consist of one pass of the
roller. A minimum overlap of 0.3 m shall be maintained between the surfaces traversed by adjacent
passes of the roller drum. The power of the motor driving the vibrator shall be sufficient to maintain
the specified frequency and centrifugal force under the most adverse conditions which may be
encountered during the compaction of the fill.
Should the surface of the fill become rutted or uneven subsequent to compaction, it shall be re-
leveled before the next layer of fill is placed and, if specified by the Engineer, recompacted at the
expense of the Contractor.
Compaction equipment shall be maintained in good working condition at all times to ensure that the
compactive effort obtained is in accordance with that specified by the manufacturer. The Contractor
shall immediately make adjustments to the equipment to achieve this when necessary.
The Contractor shall adopt special compaction measures such as hand-operated vibratory
compactors or other methods approved by the Engineer to compact fill in trenches, around structures
and in other confined areas that are not accessible to the larger vibratory roller or pneumatic-tired
roller. Such compaction shall consist of not fewer than four coverages of the compaction equipment.
Before commencing Work with the proposed compaction equipment, the Contractor shall provide the
Engineer with a list of each piece of equipment to be used, together with the Manufacturer’s
specification.
4.8.4 Materials
4.8.4.1 Core
4.8.4.1.1 Use
Core material will be used to construct low-permeability embankment zones designated as Zone A.
The purpose of Zone A is to reduce and control seepage passing through embankments. Placement
of Core material within Zone A is planned for the TMF, Main Sediment Pond, and WRF Containment
Pond.
Percent Passing
Sieve Size
(by Weight)
(Square Openings)
Maximum Minimum
6-inch (152.4 mm) 100 100
3-inch (76.2 mm) 100 89
2-inch (50.8 mm) 100 83
1-inch (25.4 mm) 100 72
No. 4 (4.75 mm) 100 46
No. 10 (2 mm) 100 41
No. 40 (0.426 mm) 100 33
No. 200 (0.075 mm) 85 25
Core material placed adjacent to and within 0.5 meters of pipe encasements and other concrete faces
shall comprise materials with maximum particle size of 76.2 mm (3 inches).
Core material shall be compacted to a minimum of 95 percent of the Modified maximum dry density
as specified by ASTM D 1557. The moisture content during compaction shall be maintained within
the limits of optimum moisture content of 2 percent below to 4 percent above optimum moisture
content as specified by ASTM D 1557. The Engineer may permit minor variations from these
moisture limits if an acceptable density and permeability is being achieved. In addition, variations in
the gradation may be allowed at the sole discretion of the Engineer if permeability tests conducted in
the laboratory on samples obtained from the proposed borrow areas demonstrate the permeability
criteria is being achieved.
Core material shall be placed in a manner which does not allow planes or construction joints between
layers. As necessary, the top surface of placed Core material shall be scarified to a maximum depth
of 5 cm, or as specified by the Engineer before placement of the next layer to facilitate bonding
between layers. At no time shall the fill be placed on in-place material that has been compacted
smooth. Any fill that has not bonded adequately with in-place fill shall be removed or reworked as
specified by the Engineer. The use of sheepsfoot or other pad-type compaction equipment, which
results in a roughened compacted surface, will be considered sufficient and scarification will not be
required.
When a vertical construction joint is formed due to an interruption in the construction of that layer, the
Contractor shall spread Core material in the new section adjacent to the existing layer, mix and
moisture-condition the material on both sides of the construction joint over a distance of at least 2 m
measured from the construction joint to blend the materials together.
A test fill shall be developed at the start of the Core placement to determine the number of passes the
compactor shall make to achieve the specified density. Once the number of passes is determined the
Contractor shall make at least that many passes to compact the fill. If the field density test results
indicate that the density achieved with ongoing fill placement is above or below that specified the test
fill shall be repeated and the number of passes revised accordingly.
Test fills may be completed as part of the ongoing fill placement operation and if it meets the
specification requirements incorporated in the fill as part of the completed works.
Where fill is placed adjacent to the concrete encasement of embankment outlet works the material
placed adjacent to or within 0.5 meters of the concrete encasement shall be placed between optimum
moisture content and 4 percent above optimum moisture content and compacted with relatively
heavy, rubber-tired compactors For the concrete encased outlet works the rubber tires equipment
shall include load haul trucks, large front end loaders with a loaded bucket, motor graders such as
Caterpillar Model 14G or larger or other rubber tired equipment approved by the Engineer. The
rubber-tired equipment shall be operated parallel to the concrete encasement. The rubber tire
adjacent to the concrete shall be operated immediately adjacent to the concrete to insure a bonding of
the fill to the concrete. Thinner lifts shall be used, if needed, to obtain the required degree of
compaction. The fill shall be brought up evenly on each side of the concrete structures. Care shall be
taken to establish a test fill and achieve proper minimum compaction while not shifting or damaging
any of the outlet works and encasement.
In areas where geomembrane liner is to be placed above Core material, particles that protrude from
the surface or are not bedded during the rolling process that are deemed by the Engineer to be
detrimental to geomembrane performance under loading shall be removed by raking, brooming, or
hand picking such that the final surface meets with the approval of the Engineer and the Installer.
The Filter/Drain material shall consist of processed sands and gravels produced by the Contractor.
The Filter/Drain material shall meet the following grading requirements as specified by ASTM D 422.
Percent Passing
Sieve Size
(by Weight)
(Square Openings)
Maximum Minimum
3-inch (76.2 mm) 100 100
1.5-inch (38.1 mm) 100 95
3/4-inch (19 mm) 100 90
3/8-inch (9.53 mm) 100 78
No. 4 (76.2 mm) 100 66
No. 10 (2 mm) 80 44
No. 30 (0.6 mm) 54 10
No. 50 (0.3 mm) 37 0
No.100 (0.15 mm) 17 0
No. 200 (0.075 mm) 5 0
Where Filter/Drain material is placed adjacent to or within 0.5 meters of concrete encasement of
embankment outlet works, the material shall be compacted with hand operated vibratory plate
compactors. Care shall be taken to establish a test fill and achieve proper minimum compaction while
not shifting or damaging any of the outlet works and encasement.
4.8.4.3 Transition
4.8.4.3.1 Use
Transition material will be used to construct embankment zones designated as Zone C. The purpose
of the Zone C is to prevent migration of finer soils from Zone B into coarser structural zones of the
project structures. The Transition will be placed in Zone C of the TMF.
Percent Passing
Sieve Size
(by Weight)
(Square Openings)
Maximum Minimum
4-inch (101.6 mm) 100 100
3/4-inch (19 mm) 100 44
3/8-inch (9.53 mm) 88 20
No. 4 (4.75 mm) 77 0
No. 200 (0.075 mm) 20 0
Transition material placed adjacent to pipe encasements and other concrete faces shall comprise
materials with maximum particle size of 76.2 mm (3 inches) within 0.5 m of the concrete.
Transition material shall be compacted to a minimum of 95 percent of the modified maximum dry
density as specified by ASTM D 1557.
All Transition material shall be placed in a manner which does not allow planes or construction joints
between layers. As necessary, Transition material shall be scarified to a maximum depth of 5 cm, or
as specified by the Engineer before placement of the next layer to facilitate bonding between layers.
At no time shall the fill be placed on in-place material that has been compacted smooth. Any fill that
has not bonded adequately with in-place fill shall be removed or reworked as specified by the
Engineer. The use of sheepsfoot or other pad-type compaction equipment, which results in a
roughened compacted surface, will be considered sufficient and scarification will not be required.
Where fill is placed adjacent to the concrete encasement of embankment outlet works the material
placed adjacent to or within 0.5 meters of the concrete encasement shall be placed between optimum
moisture content and 4 percent above optimum moisture content and compacted with relatively
heavy, rubber-tired compactors. For the concrete encased outlet works the rubber tires equipment
shall include load haul trucks, large front end loaders with a loaded bucket, motor graders such as
Caterpillar Model 14G or larger or other rubber tired equipment approved by the Engineer. The
rubber-tired equipment shall be operated parallel to the concrete encasement. The rubber tire
adjacent to the concrete shall be operated immediately adjacent to the concrete to insure a complete
bonding of the fill to the concrete. Thinner lifts shall be used, if needed, to obtain the required degree
of compaction. The fill shall be brought up evenly on each side of the concrete structures. Care shall
be taken to establish a test fill and achieve proper minimum compaction while not shifting or
damaging any of the outlet works and encasement.
Percent Passing
Sieve Size
(by Weight)
(Square Openings)
Maximum Minimum
4-inch (101.6 mm) 100 100
3/4-inch (19 mm) 100 44
3/8-inch (9.53 mm) 88 20
No. 4 (4.75 mm) 77 0
No. 200 (0.075 mm) 5 0
Coarse Transition material placed adjacent to and within 0.5 meters of pipe encasements and other
concrete faces shall comprise materials with maximum particle size of 76.2 mm (3 inches).
Where fill is placed adjacent to the concrete encasement of embankment outlet works the material
placed adjacent to or within 0.5 meters of the concrete encasement shall be placed between optimum
moisture content and 4 percent above optimum moisture content and compacted with relatively
heavy, rubber-tired compactors. For the concrete encased outlet works the rubber tires equipment
shall include load haul trucks, large front end loaders with a loaded bucket, motor graders such as
Caterpillar Model 14G or larger or other rubber tired equipment approved by the Engineer. The
rubber-tired equipment shall be operated parallel to the concrete encasement. The rubber tire
adjacent to the concrete shall be operated immediately adjacent to the concrete to insure a complete
bonding of the fill to the concrete. Thinner lifts shall be used, if needed, to obtain the required degree
of compaction. The fill shall be brought up evenly on each side of the concrete structures. Care shall
be taken to establish a test fill and achieve proper minimum compaction while not shifting or
damaging any of the outlet works and encasement.
In addition, the following materials can also be used to construct access and haul roads: Core,
Transition and Coarse Transition materials, and Structural Rockfill and Thick-Lift Structural Rockfill.
Material specifications and placement procedures associated with these materials are presented in
sections within these Specifications.
Percent Passing
Sieve Size
(by Weight)
(Square Openings)
Maximum Minimum
12-inch (304.8) 100 100
6-inch (152.4 mm) 100 74
3-inch (76.2 mm) 100 50
2-inch (50.4 mm) 92 34
3/4-inch (19 mm) 73 0
3/8-inch (9.53 mm) 60 0
No. 200 (0.075 mm) 20 0
Note:
The maximum particle size shall be no larger than two-thirds the lift thickness.
Structural Fill material placed adjacent to pipe encasements and other concrete faces shall comprise
materials with maximum particle size of 76.2 mm (3 inches).
Structural Fill material shall be compacted to a minimum of 95 percent of the maximum modified dry
density as specified by ASTM D 1557.
Structural Fill material placed in Haul and Access Roads shall be compacted with a minimum of four
passes of the fully loaded haul trucks (CAT 777 haul truck equivalent or larger). The trucks shall be
operated on the fill to provide uniform compaction of each lift. The trucks shall “split their tracks” and
not travel on the fill in a manner that concentrates traffic in a singular path but instead distributes the
compactive effort uniformly over the entire fill.
Alternatively, should the Earthworks Contractor elect to use a compactor, a test fill shall be developed
at the start of Structural Fill placement to determine the number of passes the compactor shall make
to achieve adequate compaction. The compaction shall be achieved by compaction equipment
described in Section 4.8.3. The number of passes required to achieve adequate compaction is to be
agreed upon by the Engineer and the Company. Once the number of passes is determined the
Contractor shall make at least that many pass to compact the fill. If during construction, in the
Engineer or Company’s opinion, it is noted that the ongoing fill placement is not achieving adequate
compaction, the test fill shall be repeated and the number of passes revised accordingly.
Density testing and the use of a test fill will not be required unless, in the opinion of the Engineer,
sufficient compactive effort is not being applied to the fill. If this is the case, the Engineer will design a
test fill to determine the revised lift thickness and minimum number of passes of the loaded haul
trucks to meet the shear strength and settlement criteria as the basis for design.
Where fill is placed adjacent to the concrete encasement of embankment outlet works the material
placed adjacent to or within 0.5 meters of the concrete encasement shall be placed between optimum
moisture content and 4 percent above optimum moisture content and compacted with relatively
heavy, rubber-tired compactors. For the concrete encased outlet works the rubber tires equipment
Percent Passing
Sieve Size
(by Weight)
(Square Openings)
Maximum Minimum
12-inch (304.8) 100 100
6-inch (152.4 mm) 100 74
3-inch (76.2 mm) 100 50
2-inch (50.4 mm) 92 34
3/4-inch (19 mm) 73 0
3/8-inch (9.53 mm) 60 0
No. 200 (0.075 mm) 5 0
Note:
The maximum particle size shall be no larger than two-thirds the lift thickness.
Coarse Structural Fill material placed within 0.5 m of pipe encasements and other concrete faces shall
comprise materials with maximum particle size of 76.2 mm (3 inches).
The Coarse Structural Fill shall be compacted with a minimum of four passes of the fully loaded haul
trucks (CAT 777 haul truck equivalent or larger). The trucks shall be operated on the fill to provide
uniform compaction of each lift. The trucks shall “split their tracks” and not travel on the fill in a
manner that concentrates traffic in a singular path but instead distributes the compactive effort
uniformly over the entire fill.
Where fill is placed adjacent to the concrete encasement of embankment outlet works the material
placed adjacent to or within 0.5 meters of the concrete encasement shall be placed between optimum
moisture content and 4 percent above optimum moisture content and compacted with relatively
Alternatively, should the Earthworks Contractor elect to use a compactor, a test fill shall be developed
at the start of the Coarse Structural Fill placement to determine the number of passes the compactor
shall make to achieve adequate compaction. The compaction shall be achieved by compaction
equipment described in Section 4.8.3. The number of passes required to achieve adequate
compaction is to be agreed upon by the Engineer and the Company. Once the number of passes is
determined the Contractor shall make at least that many pass to compact the fill. If during
construction, in the Engineer or Company’s opinion, it is noted that the ongoing fill placement is not
achieving adequate compaction, the test fill shall be repeated and the number of passes revised
accordingly.
Density testing and the use of a test fill will not be required unless, in the opinion of the Engineer,
sufficient compactive effort is not being applied to the fill. If this is the case, the Engineer will design a
test fill to determine the revised lift thickness and minimum number of passes of the loaded haul
trucks to meet the shear strength and settlement criteria as the basis for design.
Percent Passing
Sieve Size
(by Weight)
(Square Openings)
Maximum Minimum
24-inch (609.6 mm) 100 100
12-inch (304.8 mm) 100 74
6-inch (152.4 mm) 100 50
1-1/2-inch (38.1 mm) 78 0
No. 10 (2 mm) 30 0
No. 200 (0.075 mm) 5 0
Note:
The maximum particle size shall be no larger than two-thirds the lift thickness.
Structural Rockfill material placed within 0.5 m of concrete pipe encasements and other concrete
faces shall comprise materials with maximum particle size of 76.2 mm (3 inches).
The Structural Rockfill shall be compacted with a minimum of four passes of the fully loaded haul
trucks (CAT 777 haul truck equivalent or larger). The trucks shall be operated on the fill to provide
uniform compaction of each lift. The trucks shall “split their tracks” and not travel on the fill in a
manner that concentrates traffic in a singular path but instead distributes the compactive effort
uniformly over the entire fill.
Density testing and the use of a test fill will not be required unless, in the opinion of the Engineer,
sufficient compactive effort is not being applied to the fill. If this is the case, the Engineer will design a
test fill to determine the revised lift thickness and minimum number of passes of the loaded haul
trucks to meet the shear strength and settlement criteria as the basis for design.
Percent Passing
Sieve Size
(by Weight)
(Square Openings)
Maximum Minimum
1200 mm 100 100
1000 mm 100 90
24-inch (609.6 mm) 100 77
500 mm 100 70
12-inch (304.8 mm) 100 52
6-inch (152.4 mm) 100 26
3-inch (76.2 mm) 88 0
1-1/2-inch (38.1 mm) 78 0
No. 10 (2 mm) 30 0
No. 200 (0.075 mm) 5 0
Note:
The maximum particle size shall be no larger than two-thirds the lift thickness.
The Thick-Lift Structural Rockfill shall be compacted with a minimum of four passes of the fully loaded
haul trucks (CAT 777 haul truck equivalent or larger). The trucks shall be operated on the fill to
provide uniform compaction of each lift. The trucks shall “split their tracks” and not travel on the fill in
a manner that concentrates traffic in a singular path but instead distributes the compactive effort
uniformly over the entire fill.
4.8.4.5.5 Rockfill
4.8.4.5.5.1 Use
Rockfill will be used for the construction of the WRF Sediment Retention Structure.
Rockfill shall be compacted with a minimum of four passes of the fully loaded haul trucks. The trucks
shall be operated on the fill to provide uniform compaction of each lift. The trucks shall “split their
tracks” and not travel on the fill in a manner that concentrates traffic in a singular path but instead
distributes the compactive effort uniformly over the entire fill.
Density testing and the use of a test fill will not be required unless, in the opinion of the Engineer,
sufficient compactive effort is not being applied to the fill. If this is the case, the Engineer will design a
test fill to determine the revised lift thickness and minimum number of passes of the loaded haul
trucks to meet the shear strength and settlement criteria as the basis for design.
Embankment Fill A, placed in the modified transition zones that extend 5 meters upstream and
downstream of the Main Sediment Pond and 5 meters upstream of the WRF Containment Pond
Cores, shall be sandstone that breaks down to a soil with no visible pore spaces.
Embankment Fill B, located within the Main Sediment Pond and WRF Containment Pond shells, shall
be sandstone that is generally less than two-thirds of the compacted lift thickness. Alternatively if
alluvium is available from the required excavation in the Main Sediment Pond reservoir area it can be
used as Embankment Fill B. If alluvium is used it shall be comprised of sands and gravels with less
than 12 percent passing the number 200 sieve.
Embankment Fill C, placed within the Cunahuiri Reservoir embankment, shall be glacial till excavated
from within the limits of the Waste Rock Facility footprint.
Embankment Fill A shall be compacted to a minimum of 92 percent of the Modified maximum dry
density as specified by ASTM D 1557. The moisture content during compaction shall be maintained
within the limits of 2 percent below to 4 percent above optimum moisture content as specified by
ASTM D 1557. The Engineer may permit minor variations from these moisture limits if an acceptable
density is being achieved.
A test fill shall be developed at the start of the Embankment Fill A placement to determine the number
of passes the compactor shall make to achieve the specified density. Once the number of passes is
determined the Contractor shall make at least that many pass to compact the fill. If the field density
test results indicate that the density achieved with ongoing fill placement is above or below that
specified the test fill shall be repeated and the number of passes revised accordingly.
Test fills may be completed as part of the ongoing fill placement operation and if it meets the
specification requirements incorporated in the fill as part of the completed works.
Embankment Fill B placed in the upstream and downstream shells of the embankments shall be
sandstone from Borrow Area 6A breaks down to a soil or that does not break down to a soil. If the
material breaks down to a soil it shall be placed and compacted as described for Embankment Fill A.
If it is sandstone that does not break down to a soil it shall be placed in 50 cm lifts and compacted by
controlled routing of the hauling equipment. If it is alluvium with sufficient fines it shall be placed in
horizontal lifts not to exceed 30 cm in loose lift thickness unless otherwise approved by the Engineer.
Thinner lifts may be required to meet the compaction requirements as specified by the Engineer. The
maximum particle size shall be limited to two thirds of the compacted lift thickness. It shall be
compacted to a minimum of 92 percent of the Modified maximum dry density as specified by ASTM D
1557. The moisture content during compaction shall be maintained within the limits of 2 percent
below to 4 percent above optimum moisture content as specified by ASTM D 1557. The Engineer
may permit minor variations from these moisture limits if an acceptable density is being achieved. If
the alluvium is too coarse to be controlled by the modified proctor density test it shall be placed in
30 cm loose lifts and compacted by a minimum of four passes of the fully loaded haul trucks. The
trucks shall be operated on the fill to provide uniform compaction of each lift. The trucks shall “split
their tracks” and not travel on the fill in a manner that concentrates traffic in a singular path but
instead distributes the compactive effort uniformly over the entire fill.
Embankment Fill C shall be placed in horizontal lifts not to exceed 30 cm in loose lift thickness unless
otherwise approved by the Engineer. Thinner lifts may be required to meet the compaction
requirements as specified by the Engineer. The maximum particle size shall be limited to two thirds of
the compacted lift thickness. The compaction shall be achieved by compaction equipment described
in Section 4.8.3.
Embankment Fill C material shall be compacted to a minimum of 92 percent of the Modified maximum
dry density as specified by ASTM D 1557. The moisture content during compaction shall be
maintained within the limits of optimum moisture content of 2 percent below to 4 percent above
optimum moisture content as specified by ASTM D 1557. The Engineer may permit minor variations
from these moisture limits if an acceptable density is being achieved.
Where fill is placed adjacent to the concrete encasement of embankment outlet works the material
placed adjacent to or within 0.5 meters of the concrete encasement shall be placed between optimum
moisture content and 4 percent above optimum moisture content and compacted with relatively
The Alluvial Drain material shall consist of processed sands and gravels produced by the Contractor.
The Alluvial Drain material shall meet the following grading requirements as specified by
ASTM D 422.
Percent Passing
Sieve Size
(by Weight)
(Square Openings)
Maximum Minimum
4-inch (101.6 mm) 100 100
3/4-inch (19 mm) 100 44
3/8-inch (9.53 mm) 88 20
No. 4 (4.75 mm) 77 0
No. 200 (0.075 mm) 12 0
Where Alluvial Drain material is placed adjacent to or within 0.5 meters of concrete encasement of
embankment outlet works, the material shall be compacted with hand operated vibratory plate
compactors. The maximum particle size adjacent to concrete shall be 76.2 mm. Care shall be taken
to establish a test fill and achieve proper minimum compaction while not shifting or damaging any of
the outlet works and encasement.
Percent Passing
Sieve Size
(by Weight)
(Square Openings)
Maximum Minimum
6-inch (152.4 mm) 100 100
3/4-inch (19 mm) 100 70
3/8-inch (9.53 mm) 100 60
No. 4 (4.75 mm) 100 52
No. 10 (2 mm) 100 42
No. 200 (0.075 mm) 50 7
The Bog Embankment Fill shall be compacted to a minimum of 95 percent of the maximum modified
dry density as specified by ASTM D 1557. The moisture content during compaction shall be
maintained within the limits of optimum moisture content of 2 percent below to 4 percent above
optimum moisture content as specified by ASTM D 1557. The Engineer may permit minor variations
from these moisture limits if an acceptable density is being achieved.
All Bog Embankment Fill material shall be placed in a manner which does not allow planes or
construction joints between layers. As necessary, the Bog Embankment fill shall be scarified to a
maximum depth of 5 cm, or as specified by the Engineer before placement of the next layer to
facilitate bonding between layers. At no time shall the fill be placed on in-place material that has been
compacted smooth. Any fill that has not bonded adequately with in-place fill shall be removed or
reworked as specified by the Engineer. The use of sheepsfoot or other pad-type compaction
equipment, which results in a roughened compacted surface, will be considered sufficient and
scarification will not be required.
For the Bog Embankment fill, when a vertical construction joint is formed due to an interruption in the
construction of that layer, the Contractor shall spread the material in the new section adjacent to the
existing layer, mix and moisture-condition the material on both sides of the construction joint over a
distance of at least 2 m measured from the construction joint to blend the materials together.
A test fill shall be developed at the start of the Bog Embankment Fill placement to determine the
number of passes the compactor shall make to achieve the specified density. Once the number of
passes is determined the Contractor shall make at least that many pass to compact the fill. If the field
density test results indicate that the density achieved with ongoing fill placement is above or below
that specified the test fill shall be repeated and the number of passes revised accordingly.
Test fills may be incorporated in the embankment as long as the material placed meets this
specification requirement.
Percent Passing
Sieve Size
(by Weight)
(Square Openings)
Maximum Minimum
6-inch (152.4 mm) 100 100
3/4-inch (19 mm) 100 44
3/8-inch (9.53 mm) 100 20
No. 4 (4.75 mm) 90 0
No. 200 (0.075 mm) 50 0
When placed in larger areas as site grading fill, General Fill material shall be compacted to a
minimum of 95 percent of the maximum modified dry density as specified by ASTM D 1557.
When placed as trench backfill, General Fill material shall be placed and spread in lifts not to exceed
30 cm in loose lift thickness, and the maximum particle size shall not exceed two-thirds of the loose lift
thickness. Special compaction measures such as hand-held vibratory compactors or other methods
approved by the Engineer shall be used as described in Section 4.8.3.5.
When placed as safety berms, the General Fill material may be placed loosely unless specified
otherwise in Drawings.
Soil Liner B material shall meet the grading requirements set forth below and be obtained from borrow
areas designated on the Drawings or by the Company and approved by the Engineer. The Contractor
shall be responsible for processing the materials to obtain the required moisture content prior to
compaction regardless of the moisture condition of the materials at the source. The material shall
generally be comprised of silty or clayey sands and gravels with a minimum of 25 percent passing the
No. 200 sieve (fines) and a maximum particle size of 152.4 mm meeting the following gradation limits
in accordance with ASTM D 422.
Soil Liner material shall be compacted to a minimum of 95 percent of the maximum modified dry
density as specified by ASTM D 1557. The moisture content during compaction shall be maintained
within the limits of optimum moisture content of 2 percent below to 4 percent above optimum moisture
content as specified by ASTM D 1557. The Engineer may permit minor variations from these
moisture limits if an acceptable density and permeability is being achieved. In addition, variations in
the gradation may be allowed at the sole discretion of the Engineer if permeability tests conducted in
the laboratory on samples obtained from the proposed borrow areas demonstrate the permeability
criteria is being achieved.
Soil Liner material shall be placed in a manner which does not allow planes or construction joints
between layers. As necessary, the top surface of placed Soil Liner material shall be scarified to a
maximum depth of 5 cm, or as specified by the Engineer before placement of the next layer to
facilitate bonding between layers. At no time shall the fill be placed on in-place material that has been
compacted smooth. Any fill that has not bonded adequately with in-place fill shall be removed or
reworked as specified by the Engineer. The use of sheepsfoot or other pad-type compaction
equipment, which results in a roughened compacted surface, will be considered sufficient and
scarification will not be required.
A test fill shall be developed at the start of the Soil Liner placement to determine the number of
passes the compactor shall make to achieve the specified density. Once the number of passes is
determined the Contractor shall make at least that many pass to compact the fill. If the field density
test results indicate that the density achieved with ongoing fill placement is above or below that
specified the test fill shall be repeated and the number of passes revised accordingly.
In areas where geomembrane liner is to be placed above Soil Liner, particles that protrude from the
surface or are not bedded during the rolling process that are deemed by the Engineer to be
detrimental to geomembrane performance under loading shall be removed by raking, brooming, or
hand picking such that the final surface meets with the approval of the Engineer and the Installer. In
addition, in areas where soil liner is to be used beneath a geomembrane it shall be placed in at least
two lifts.
Percent Passing
Sieve Size
(by Weight)
(Square Openings)
Maximum Minimum
3/4-inch (19 mm) 100 100
3/8-inch (9.53 mm) 100 75
No. 4 (4.75 mm) 100 55
No. 10 (2 mm) 100 45
No. 200 (0.075 mm) 50 12
Percent Passing
Sieve Size
(by Weight)
(Square Openings)
Maximum Minimum
3/4-inch (19 mm) 100 100
3/8-inch (9.53 mm) 100 35
No. 4 (4.75 mm) 70 0
No. 200 (0.075 mm) 5 0
Percent Passing
Sieve Size
(by Weight)
(Square Openings)
Maximum Minimum
3-inch (76.2 mm) 100 100
3/4-inch (19 mm) 100 34
3/8-inch (9.53 mm) 73 0
No. 4 (4.75 mm) 50 0
No. 10 (2 mm) 20 0
No. 200 (0.075 mm) 5 0
Coarse Drainage Gravel placed over and around underdrain pipes shall be placed by mechanical or
labor-intensive methods, ensuring that the pipework remains undamaged and undisplaced after
placement. Extreme care shall be taken during backfilling operations around all connections and
fittings to ensure that these connections and fittings remain intact after aggregate placement.
Placement of the Coarse Drainage Gravel around the main collector pipes shall be conducted in a
manner such that the material fills the void beneath the haunches of the pipes. Hand placement of
the material beneath the haunches of the pipe will be required if necessary to achieve complete
bedding of the pipe.
Coarse Drainage Gravel placed within embankments and channels shall be placed and lightly
compacted with an excavator bucket in loose lifts not to exceed 30 cm in thickness unless otherwise
approved by the Engineer. Care must be taken to avoid contaminating the material, both in the
stockpile area and the in-place fill. Any contaminated material shall be removed.
Percent Passing
Sieve Size
(by Weight)
(Square Openings)
Maximum Minimum
6-inch (152.4 mm) 100 100
2-inch (50.4 mm) 100 68
3/4-inch (19 mm) 100 40
3/8-inch (9.53 mm) 100 20
No. 4 (4.75 mm) 83 0
No. 50 (0.3 mm) 17 0
No. 200 (0.075 mm) 5 0
Drainage Rock material placed within 0.5 m of pipe encasements and other concrete faces shall
comprise materials with maximum particle size of 76.2 mm (3 inches).
Drainage Rock placed over and around underdrain pipes shall be placed by mechanical or labor-
intensive methods, ensuring that the pipework remains undamaged and undisplaced after placement.
Extreme care shall be taken during backfilling operations around all connections and fittings to ensure
that these connections and fittings remain intact after aggregate placement.
Placement of the Drainage Rock around the main collector pipes shall be conducted in a manner
such that the material fills the void beneath the haunches of the pipes. Hand placement of the
material beneath the haunches of the pipe will be required if necessary to achieve complete bedding
of the pipe.
Drainage Rock shall be placed to, or slightly below, the crown of the pipe and compacted by four
passes of a vibratory plate compactor a distance of at least four pipe diameters on each side of the
pipe. Sufficient Drainage Rock shall be placed to maintain the pipes in position but not more than
needed such that there is adequate compaction of materials beneath the haunches of the pipe.
Percent Passing
Sieve Size (by Weight)
(Square Openings)
Maximum Minimum
3-inch (76.2 mm) 100 100
3/4-inch (19 mm) 100 60
3/8-inch (9.53 mm) 85 40
No. 4 (4.75 mm) 65 30
No. 10 (2 mm) 50 20
No. 40 (0.426 mm) 30 12
No. 200 (0.075 mm) 15 5
In addition, the Pipe Bedding shall be non-plastic in accordance with ASTM D 4318.
4.8.4.17 Riprap
4.8.4.17.1 Use
Riprap shall be used for erosion protection for the WRF Facility drains and channels, within spillways,
as upstream slope protection of embankments, and within the diversion channels.
The Riprap shall generally conform to the following gradation requirements in accordance with ASTM
C136:
Some minor deviation from these limits may be acceptable for specific cases, subject to the
Engineer’s approval. Processing may be required to produce the specified material.
Acceptance of the Riprap gradation will be based on visual observations made by the Engineer.
Testing may be required if specified by the Engineer.
Some minor deviation from these limits may be acceptable for specific cases, subject to the
Engineer’s approval. Processing may be required to produce the specified material.
Concrete mortar for Grouted Riprap shall consist of medium strength concrete with a 28-day strength
of 2,000 psi (13.8 MPa). Maximum aggregate size shall be 13 mm and the concrete is to have a
slump of between 125 and 200 mm. Sand mixes may be used provided sufficient cement is added to
give good strength and workability. The Engineer shall approve the concrete mortar mix prior to any
commencement of the grouting.
Acceptance of the Grouted Riprap gradation will be based on visual observations made by the
Engineer. Testing may be required if specified by the Engineer.
Providing a finished, smooth surface for the Grouted Riprap is not intended or acceptable. The grout
is intended to stabilize the Riprap in place, not provide a smooth drainage surface. The contractor
shall apply water or cover with wet burlap or polyethylene for a period of 7 days after placement.
Weep holes shall be provided in the blanket to relieve hydrostatic pressure build-up behind the grout
surface. Weeps shall extend through the grout into the underlying bedding layer or soil. Weeps shall
consist of 50 mm diameter slotted PVC pipes having a maximum horizontal spacing of 2 m. The
buried end of the weep shall be covered with an end cap or wire screen. Where a filter layer is not
placed under the Riprap blanket, the buried end of the weep shall extend a minimum 150 mm beyond
the grout and be encapsulated in a coarse geotextile fabric filled with 19 mm aggregate.
The Riprap Bedding material shall consist of processed sands and gravels. The material shall meet
the following gradation requirements as specified by ASTM D 422.
Percent Passing
Sieve Size (by Weight)
(Square Openings)
Maximum Minimum
1-1/2-inch (38.1 mm) 100 100
1-inch (25.4 mm) 100 90
3/4-inch (19 mm) 100 65
3/8-inch (9.53 mm) 80 45
No. 4 (4.75 mm) 65 30
No. 10 (2 mm) 52 22
No. 40 (0.426 mm) 35 15
No. 200 (0.075 mm) 20 5
Care must be taken to avoid contaminating the Riprap Bedding material, both in the stockpile area
and the in-place fill. Any contaminated material shall be removed.
Road Wearing Course material shall have a gradation as specified in the following table.
Percent Passing
Sieve Size (by Weight)
(Square Openings)
Maximum Minimum
1-1/2-inch (38.1 mm) 100 100
1-inch (25.4 mm) 100 80
3/4-inch (19 mm) 100 65
3/8-inch (9.53 mm) 80 45
No. 4 (4.75 mm) 65 30
No. 10 (2 mm) 52 22
No. 40 (0.426 mm) 35 12
No. 200 (0.075 mm) 20 5
The material shall be placed in loose lift thicknesses between 150 and 200 mm, and compacted to a
minimum of 92 percent of the maximum modified dry density as specified by ASTM D 1557.
4.9 Geosynthetics
The technical requirements in this document cover the quality of materials and workmanship for
Geosynthetics designed by Knight Piésold for the Constancia Project, and as detailed on the
Drawings.
4.9.1 General
The Geosynthetics Manufacturer and/or Installer shall submit the following information, where
applicable to the type of geosynthetic they are supplying and installing, in writing to the Company prior
to installation of Geomembrane material.
• The Geosynthetics Manufacturer shall confirm in writing that the guarantees covering materials and
all workmanship as well as degradation due to ultraviolet light listed in these Specifications can be
achieved prior to the award of the bid.
• Certification stating that all resin is from the same manufacturer.
• Copy of QA/QC certificates issued by Geomembrane Manufacturer, resin supplier, and third party
independent Quality Assurance tester.
• Certification that extrudate resins and/or rod is from one manufacturer, is the same resin type, and
was obtained from the same resin supplier as the resin used to manufacture the Geomembrane
rolls.
• A copy of the Installer’s QC Manual shall be submitted through the Company to the Engineer prior
to the award of the bid. If the manual has been provided for previous project Work and no changes
have been made to the manual since that submittal, then this requirement may be waived by the
Company. If there are discrepancies between these Geosynthetics Specifications and the Installer’s
QC Manual, the more stringent will apply unless approved otherwise by the Engineer.
• Weld test data for high-density polyethylene (HDPE) and linear low-density polyethylene (LLDPE)
welds (both extrusion and wedge welds) shall be supplied to the Engineer upon request prior to the
award of the bid.
• Upon award of the bid, the Geosynthetics Installer shall supply the Engineer with the proposed
panel layout. The review will be for concept only, and actual panel placement will be determined by
site conditions and will be approved at the time of installation.
Any damage by mechanical or other means such as water entering through non-welded panels or
incomplete patches, repairs, etc., shall be repaired to meet the requirements of the Geosynthetics
Specifications or as approved by the Engineer. The Installer shall promptly cover approved subgrade
to avoid damage to the approved subgrade. Damage caused by weather to approved areas not
attributed to the Installer shall be repaired to meet the Geosynthetics Specifications requirements or
as approved by the Engineer by the Contractor. Any damage to approved areas resulting from poor
surface runoff control (e.g., allowing surface runoff onto approved areas) as a result of operations of
the Installer shall be repaired to meet the Specifications requirements or as approved by the Engineer
and the Company.
After installation of the Geomembrane Liner and final QC measures are completed by the Installer
and approved by the Engineer, areas receiving a cover material shall be clearly identified, and the
Engineer and the Company shall be notified for Geomembrane inspection. Upon signed acceptance
by the Installer, Earthwork Contractor, Engineer, and the Company that the Geomembrane has been
installed in accordance with the Geosynthetics Specifications, it will be available to the Earthwork
Contractor, as applicable, for placing cover material. At that time, the Earthwork Contractor will
assume responsibility for maintaining the condition of that portion of the Geomembrane until it is
covered.
Any damage to accepted Geomembrane Liner as a result of the Earthwork Contractor’s operation will
be repaired to meet the Geosynthetics Specifications requirements or as approved by the Engineer
and the Company.
All resin shall consist of all virgin material from the same manufacturer, shall not be intermixed (third
party to confirm), and no reclaimed polymer may be added to the resin. The manufacturing process
shall not use more than 10 percent rework. If rework is used, it must be similar HDPE to the parent
material.
The Geomembrane shall be HDPE material manufactured of new, first-quality products designed and
manufactured specifically for the purpose of liquid containment in hydraulic structures. The finished
material shall be free of holes, blisters, undispersed raw materials, or any sign of contamination by
foreign matter.
Geomembrane material is to be supplied in roll form. Each roll is to be identified with labels indicating
the manufacturer’s name, product identification, thickness, length, width, and roll number.
The Geosynthetics Manufacturer must be ISO 9000-certified, and the manufacturer’s laboratory must
be certified by GAI/LAP for the tests being performed and shall have a third-party in-plant
independent QA Program. The proposed third-party company must be submitted to the Company
and approved by the Company prior to manufacture of the Geomembrane. The third-party shall
The HDPE Geomembrane material shall be certified in writing by the manufacturer to meet the
following minimum criteria. One such certificate shall accompany each batch delivery of HDPE to
site.
Dispersion only applies to near spherical agglomerates. Nine of ten views shall be Category 1 or 2. No more than one view
from Category 3.
Properties from GSE specifiers guide handbook
Dispersion only applies to near spherical agglomerates. Nine of ten views shall be Category 1 or 2. No more than one view
from Category 3.
Properties from GSE specifiers guide handbook
4.9.5 Installation
4.9.5.1 General
The Geomembrane shall be installed into the Geomembrane Liner on the area shown on the
Drawings or as specified by the Company or the Engineer.
Prior to deployment of Geomembrane, the Installer shall inspect, certify, and accept with the,
Engineer, Earthwork Contractor, Geosynthetics Contractor, and the Company all surfaces on which
the Geomembrane is to be placed to ensure conformance with the Earthwork Specifications.
Surfaces not in compliance with the Earthwork Specifications shall be rectified by the Contractor.
The amount of Geomembrane deployed without final QC and final repairs being completed shall not
exceed 25,000 m2 without the written approval of the Engineer and the Company. In addition, no
seams shall be left unwelded, and no openings in the liner shall be left at the end of a shift without the
Installer notifying the Engineer and obtaining the Engineer’s approval.
The Geomembrane shall be placed over the prepared surface using methods and procedures that
ensure a minimum of handling and do not damage the Geomembrane or the underlying surface. The
Installer shall provide adequate temporary anchoring and ballast devices (commonly sandbags),
which will not damage the Geomembrane, to prevent uplift and damage due to winds. Ballasting by
means of placing loose piles of material shall not be used unless expressly approved by the
Company. The Installer is solely responsible for the safety of his operation including decisions
regarding Geomembrane deployment in adverse weather conditions and the amount of temporary
anchoring and ballasting required.
Handling and storage of Geomembrane shall be in accordance with the Geosynthetics Manufacturer’s
printed instructions. Personnel walking or working on the Geomembrane shall not engage in activities
or wear shoes that could damage the Geomembrane. Smoking is not permitted on the
Geomembrane or in Geomembrane storage areas.
The Geomembrane shall be installed in a relaxed condition and shall be free of tension or stress upon
completion of the installation. All necessary precautions, including provisions for installing extra
material, shall be taken to avoid trampolining of Geomembrane, which will remain exposed (i.e., pad
and pond slope breaks and corners, solution channels, etc.).
If wrinkles develop in the Geomembrane that result in folding that does not disappear in the cooler
times of the day when the Geomembrane lies relatively flat, then some of the excess Geomembrane
may need to be removed. Prior to any corrective action, problem areas should be monitored over a
two- to three-day period during the cooler and hotter times of the day to determine whether the
wrinkles are a problem and the extent of excess Geomembrane to be removed. Problem areas
should be brought to the attention of the Engineer who then, with the Installer, will specify the
corrective action to be taken.
To the maximum extent possible, panels shall be oriented such that seams are parallel to the line of
the slope.
Horizontal field seams on slopes should be kept to a minimum. Seams shall be made by lapping the
uphill material over the downhill material with sufficient overlap. Three feet are to be allowed from the
toe or the top of the slope to any horizontal seam on flat areas. Also, horizontal seams of adjacent
panels shall, in general, be separated by a minimum 1 m. A sequential seam numbering system
compatible with the panel numbering system shall be used to identify seams.
Installation shall be performed under the direction of a superintendent who has installed a minimum of
2
one million m of HDPE or other flexible lining material. The superintendent shall be provided by the
Installer and shall be in charge of the installation.
The welding equipment used shall be capable of continuously monitoring and controlling the speed
and the temperatures in the zone of contact where the machine is actually fusing the lining material to
ensure that changes in weather conditions will not affect the integrity of the weld. The welding
machine manufacturer’s published data for ranges of temperature and speed in conjunction with the
Geosynthetics Manufacturer’s recommendations shall be followed.
An adequate amount of handling equipment, welding apparatuses, and test equipment shall be
maintained onsite to avoid delays due to problems with equipment failures. The Engineer shall, at the
start of the project and periodically during the project, review the Installer’s available equipment and
its performance and shall make recommendations to the Company if he considers that the equipment
is inadequate to perform the work without delays.
No “fish mouths” shall be allowed within the seam area. Where “fish mouths” occur, the material shall
be cut, overlapped, and extrusion welded. All welds on completion of the Work shall be tightly
bonded. Any membrane area showing distress due to excessive scuffing or puncture from any cause
shall be replaced or repaired by the Installer.
The Installer shall take into account that rapid weather changes are very possible, resulting in delays
in construction of field seams. Jointing of panels and repairs shall only be completed under weather
conditions allowing such work within the warranty limits imposed by the Geosynthetics Manufacturer.
No seams shall be welded unless the ambient air temperature is above 0°C, unless approved by the
engineer in advance. If approved more frequent weld testing may be required to evaluate the integrity
of the cold temperature welding. In addition other cold weather welding techniques may be required.
• No welding equipment or operator shall be allowed to perform production welds until equipment and
operators have successfully completed a trial weld.
• A minimum of two trial welds per day per welding apparatus are to be completed, one made prior to
the start of work and one at midday. Notwithstanding the above, trial welds shall be completed, at a
minimum, for every 4 hours of seaming operation or as specified by the Engineer.
• Trial welds shall be completed after repairs have been made to equipment.
• Each technician using the equipment shall complete a trial weld.
• Trial welds shall be made under the same surface and environmental conditions as the production
welds, i.e., in contact with subgrade and similar ambient temperatures and using similar materials
and pre-seaming and seaming techniques as will be used for production welds.
• Trial weld samples shall be a minimum of 900 mm long by 300 mm wide, marked with the date,
technician’s name, ambient temperature, and welding machine number and temperature.
• Four 25 mm wide-by 150 mm long test strips shall be cut from the trial weld. These strips shall be
tested for peel adhesion and bonded seam strength.
• A trial weld specimen shall pass when the values specified in these Specifications are achieved in
both peel and shear tests. The minimum values specified for peal and shear are presented in the
following Geosynthetic Research Institute (GRI) Test Method GM19, Revision 4: November 15,
2010, titled Seam Strength and Related Properties or Thermally Bonded Polyolefin Geomembranes.
• The trial weld is to be repeated in its entirety when any of the trial weld samples fail in either peel or
shear.
A QC technician shall inspect each seam, marking his initials and the date inspected at the end of
each panel. Any area showing a defect shall be marked and repaired in accordance with HDPE repair
procedures.
All field inspection, sampling, and testing shall be done by the Installer in accordance with these
Geosynthetics Specifications and be approved by the Engineer.
The field installation-testing program shall consist of periodic visual observations and continuity and
strength tests. These inspections and tests are to be made routinely and are automatic regardless of
other types of testing required. The program shall include the following non-destructive and
destructive testing inspections and repair procedures as described below.
• Visual observations are to be made routinely and shall include the following:
− Visually check field seams for squeeze out, footprint, melt, and overlap.
− Check machines for cleanliness, temperature, and related items.
− Examine all seams and non-seam areas of the Geomembrane for defects, holes, blisters,
undispersed raw materials, and any sign of contamination by foreign matter.
• Continuity testing is required for all field seams and repaired areas. Inter-seam pressure or “air
testing” and testing using a vacuum box are considered acceptable methods for continuity testing.
Inter-seam testing shall be used as the primary method for continuity testing, and other methods
shall be used in places not practical for inter-seam testing. The test procedure for inter-seam
pressure or air testing is the following:
− Seal both ends of the seam to be tested by applying heat to the end of the seam until flow
temperature is achieved. Clamp off the ends and let cool.
− Insert a pressure gauge/needle assembly into the end of the seam and seal.
− Apply air pressure to the void between the two seams according to the following schedule:
• The initial start pressure is read after a 2-minute relaxing period, which allows the air to reach
ambient liner temperature; the ending pressure is read after 5 minutes.
• The results of the leak test shall be marked at the test location and shall be recorded by the
Installer. If the test fails, the location of the leak shall be found and repaired, or the entire seam shall
be repaired and retested.
• After the test is complete, the air is to be released from the opposite end of the seam from where
the air is applied.
• Repair the area where the pressure gauge/needle assembly was installed, and the air was released.
• Observation for melt- or burn-through shall be conducted on all wedge welds in addition to air
pressure testing of the seam.
• Destructive samples may be obtained from field seams or repaired areas by cutting perpendicular to
the seams. The sample should be approximately 600 mm long by 300 mm wide. This sample shall
be cut into two samples of 300 mm by 300 mm and labeled with the welder identification, date, and
location. One of the samples will be retained by the Company, and one of the samples will be
tested by the Installer in accordance with the applicable ASTM or GRI standards as appropriate.
• The frequency for obtaining destructive test samples shall be not less than one sample per 150 m of
field seam. Coupons (five per series of tests 25 × 200 mm) from the destructive sample shall be
The agreement upon the appropriate repair method shall be decided between the Installer and the
Engineer. Procedures available include the following:
• Surfaces of the polyethylene that are to be repaired by extrusion welds shall be lightly abraded to
ensure cleanliness.
• All Geomembrane shall be clean and dry at the time of repair.
• Extend patches or caps at 150 mm for extrusion weld and 100 mm for wedge weld beyond the edge
of the defect, and round corner of patch material. The edges of all patches are to be beveled.
• All patches and caps shall be surveyed and displayed on Record of Construction Drawings.
All resin shall consist of all virgin material from the same manufacturer, shall not be intermixed (third
party to confirm), and no reclaimed polymer may be added to the resin. The manufacturing process
shall not use more than 10 percent rework. If rework is used, it must be similar LLDPE to the parent
material.
The Geomembrane shall be LLDPE material manufactured of new, first-quality products designed and
manufactured specifically for the purpose of liquid containment in hydraulic structures. The finished
material shall be free of holes, blisters, undispersed raw materials, or any sign of contamination by
foreign matter.
Geomembrane material is to be supplied in roll form. Each roll is to be identified with labels indicating
the manufacturer’s name, product identification, thickness, length, width, and roll number.
The Geosynthetics Manufacturer must be ISO 9000-certified, and the manufacturer’s laboratory must
be certified by GAI/LAP for the tests being performed and shall have a third-party in-plant
independent QA Program. The proposed third-party company must be submitted to the Client and
approved by the Client prior to manufacture of the Geomembrane. The third party shall perform the
tests required at the required frequency as stated in these Geosynthetics Specifications. The third
party shall inform the Geosynthetics Manufacturer, Company, and the Engineer of any discrepancies
or non-conformance test results that occur. Material produced by the Geosynthetics Manufacturer
that does not conform to the third-party test results or meet the standards specified herein shall not be
shipped to site. All test results (the Geosynthetics Manufacturer’s and third party) shall be supplied
through Company to the Engineer, and the rolls of material shall be clearly identified and correlate to
the test results provided. The Engineer shall not approve the material that has arrived at site prior to
reviewing the third party and the Geosynthetics Manufacturer’s test results and confirming the results
of each laboratory (i.e., meet minimum values stated in these Geosynthetics Specifications).
Extrudate resins and/or rods shall be from the same manufacturer as the Geomembrane rolls and of
the same resin type.
The material shall be warranted against manufacturer’s defects as well as degradation due to
ultraviolet light for exposed areas for a minimum of 20 years from the date of installation or as
mutually agreed prior to award of the Contract for Geosynthetics supply between the Client and the
Geosynthetics Manufacturer. This warranty shall, except as agreed otherwise by the Client or the
Carbon black dispersion (only near spherical agglomerates) for 10 different views: 9 in Categories 1 or 2 and 1 in Category 3.
(2)
Not recommended since the high temperature of the Std-OIT test produces an unrealistic result for some of the antioxidants in
the UV exposed samples.
Carbon black dispersion (only near spherical agglomerates) for 10 different views: 9 in Categories 1 or 2 and 1 in Category 3.
(2)
Not recommended since the high temperature of the Std-OIT test produces an unrealistic result for some of the antioxidants in
the UV exposed samples.
Extrudate resins and/or rods shall be from the same manufacturer as the Geomembrane rolls and of
the same resin type.
4.9.6.3 Installation
4.9.6.3.1 General
The Geomembrane shall be installed into the Geomembrane Liner on the area shown on the
Drawings or as specified by the Client or the Engineer.
Prior to deployment of Geomembrane, the Installer shall inspect, certify, and accept with the,
Engineer, Earthwork Contractor, Geosynthetics Contractor, and the Client all surfaces on which the
Geomembrane is to be placed to ensure conformance with the Earthwork Specifications. Surfaces
not in compliance with the Earthwork Specifications shall be rectified by the Contractor.
The amount of Geomembrane deployed without final QC and final repairs being completed shall not
exceed 250,000 square feet without the written approval of the Engineer and the Client. In addition,
The Geomembrane shall be placed over the prepared surface using methods and procedures that
ensure a minimum of handling and do not damage the Geomembrane or the underlying surface. The
Installer shall provide adequate temporary anchoring and ballast devices (commonly sandbags),
which will not damage the Geomembrane, to prevent uplift and damage due to winds. Ballasting by
means of placing loose piles of material shall not be used unless expressly approved by the Client.
The Installer is solely responsible for the safety of his operation including decisions regarding
Geomembrane deployment in adverse weather conditions and the amount of temporary anchoring
and ballasting required.
Handling and storage of Geomembrane shall be in accordance with the Geosynthetics Manufacturer’s
printed instructions. Personnel walking or working on the Geomembrane shall not engage in activities
or wear shoes that could damage the Geomembrane. Smoking is not permitted on the
Geomembrane or in Geomembrane storage areas.
The Geomembrane shall be installed in a relaxed condition and shall be free of tension or stress upon
completion of the installation. All necessary precautions, including provisions for installing extra
material, shall be taken to avoid trampolining of Geomembrane, which will remain exposed (i.e., pad
and pond slope breaks and corners, solution channels, etc.).
If wrinkles develop in the Geomembrane that result in folding that does not disappear in the cooler
times of the day when the Geomembrane lies relatively flat, then some of the excess Geomembrane
may need to be removed. Prior to any corrective action, problem areas should be monitored over a
two to three day period during the cooler and hotter times of the day to determine whether the
wrinkles are a problem and the extent of excess Geomembrane to be removed. Problem areas
should be brought to the attention of the Engineer who then, with the Installer, will specify the
corrective action to be taken.
To the maximum extent possible, panels shall be oriented such that seams are parallel to the line of
the slope.
Horizontal field seams on slopes should be kept to a minimum. Seams shall be made by lapping the
uphill material over the downhill material with sufficient overlap. Three feet are to be allowed from the
toe or the top of the slope to any horizontal seam on flat areas. Also, horizontal seams of adjacent
panels shall, in general, be separated by a minimum 3 feet (ft). A sequential seam numbering system
compatible with the panel numbering system shall be used to identify seams.
Installation shall be performed under the direction of a superintendent who has installed a minimum of
10 million square feet of LLDPE or other flexible lining material. The superintendent shall be provided
by the Installer and shall be in charge of the installation.
Extreme care shall be taken by the Installer in the preparation of the areas to be welded. The seam
area shall be cleaned and prepared according to the approved procedures in the Installer’s QC
Manual, and all sheeting shall be welded together by thermal methods.
The welding equipment used shall be capable of continuously monitoring and controlling the speed
and the temperatures in the zone of contact where the machine is actually fusing the lining material to
ensure that changes in weather conditions will not affect the integrity of the weld. The welding
machine manufacturer’s published data for ranges of temperature and speed in conjunction with the
Geosynthetics Manufacturer’s recommendations shall be followed.
An adequate amount of handling equipment, welding apparatuses, and test equipment shall be
maintained onsite to avoid delays due to problems with equipment failures. The Engineer shall, at the
start of the project and periodically during the project, review the Installer’s available equipment and
its performance and shall make recommendations to Company if he considers that the equipment is
inadequate to perform the work without delays.
The Installer shall take into account that rapid weather changes are very possible, resulting in delays
in construction of field seams. Jointing of panels and repairs shall only be completed under weather
conditions allowing such work within the warranty limits imposed by the Geosynthetics Manufacturer.
No seams shall be welded unless the ambient air temperature is above 32°F, unless approved by the
Engineer in advance. If approved more frequent weld testing may be required to evaluate the
integrity of the cold temperature welding. In addition other cold weather welding techniques may be
required.
• No welding equipment or operator shall be allowed to perform production welds until equipment and
operators have successfully completed a trial weld.
• A minimum of two trial welds per day per welding apparatus are to be completed, one made prior to
the start of work and one at midday. Notwithstanding the above, trial welds shall be completed, at a
minimum, for every 5 hours of seaming operation or as specified by the Engineer.
• Trial welds shall be completed after repairs have been made to equipment.
• Each technician using the equipment shall complete a trial weld.
• Trial welds shall be made under the same surface and environmental conditions as the production
welds, i.e., in contact with subgrade and similar ambient temperatures and using similar materials
and pre-seaming and seaming techniques as will be used for production welds.
• Trial weld samples shall be a minimum of 3 ft long by 1 ft wide, marked with the date, technician’s
name, ambient temperature, and welding machine number and temperature.
• Four 1-inch-wide by 6-inch-long test strips shall be cut from the trial weld. These strips shall be
tested for peel adhesion and bonded seam strength.
• A trial weld specimen shall pass when the values specified in these Specifications are achieved in
both peel and shear tests.
• The trial weld is to be repeated in its entirety when any of the trial weld samples fail in either peel or
shear.
A QC technician shall inspect each seam, marking his initials and the date inspected at the end of
each panel. Any area showing a defect shall be marked and repaired in accordance with LLDPE
repair procedures.
All field inspection, sampling, and testing shall be done by the Installer in accordance with these
Geosynthetics Specifications and be approved by the Engineer.
The field installation testing program shall consist of periodic visual observations and continuity and
strength tests. These inspections and tests are to be made routinely and are automatic regardless of
other types of testing required. The program shall include the following non-destructive and
destructive testing inspections and repair procedures as described below.
• Visual observations are to be made routinely and shall include the following:
• Visually check field seams for squeeze out, footprint, melt, and overlap.
• Check machines for cleanliness, temperature, and related items.
• Examine all seams and non-seam areas of the Geomembrane for defects, holes, blisters,
undispersed raw materials, and any sign of contamination by foreign matter.
• Continuity testing is required for all field seams and repaired areas. Inter-seam pressure or “air
testing” and testing using a vacuum box are considered acceptable methods for continuity testing.
Inter-seam testing shall be used as the primary method for continuity testing, and other methods
shall be used in places not practical for inter-seam testing. The test procedure for inter-seam
pressure or air testing is the following:
• Seal both ends of the seam to be tested by applying heat to the end of the seam until flow
temperature is achieved. Clamp off the ends and let cool.
• Insert a pressure gauge/needle assembly into the end of the seam and seal.
• Apply air pressure to the void between the two seams according to the following schedule:
• The initial start pressure is read after a 2-minute relaxing period, which allows the air to reach
ambient liner temperature; the ending pressure is read after 5 minutes.
• The results of the leak test shall be marked at the test location and shall be recorded by the
Installer. If the test fails, the location of the leak shall be found and repaired, or the entire seam shall
be repaired and retested.
• After the test is complete, the air is to be released from the opposite end of the seam from where
the air is applied.
• Repair the area where the pressure gauge/needle assembly was installed, and the air was released.
• Observation for melt- or burn-through shall be conducted on all wedge welds in addition to air
pressure testing of the seam.
• Destructive samples may be obtained from field seams or repaired areas by cutting perpendicular to
the seams. The sample should be approximately 2 ft long by 1 ft wide. This sample shall be cut
into two samples of 1 ft by 1 ft and labeled with the welder identification, date, and location. One of
the samples will be retained by the Client, and one of the samples will be tested by the Installer
using a calibrated tensiometer in accordance with the applicable ASTM standards as appropriate.
• The frequency for obtaining destructive test samples shall be not less than one sample per 500 ft of
field seam. Coupons (five per series of tests 1.0 × 8.0-inch) from the destructive sample shall be
tested for peel and bonded-seam strength as well as for thickness in accordance with the applicable
ASTM standards. All shear and peel test results shall meet or exceed the project requirements. If
one or more of the coupons fails, the sample will be considered a failure.
• In the event of a failing test result, the following procedure shall be used:
• The Installer shall follow one of two options:
• Reconstruct the seam between the two passed test locations on either side of the failed test
location, or
• Trace the failed weld by a series of tests to delineate the length of the failed weld. New coupons
shall be cut within 10 feet in both directions of the failed sample and testing. This process is
repeated until a zone is established defining the seam to be repaired.
• If any sample fails, the process shall be repeated until passing tests are achieved to establish the
zone in which the seam shall be reconstructed or capped. Acceptable seams shall be bounded by
two locations from which samples have passed destructive tests.
The agreement upon the appropriate repair method shall be decided between the Installer and the
Engineer. Procedures available include the following:
• Surfaces of the polyethylene that are to be repaired by extrusion welds shall be lightly abraded to
ensure cleanliness.
• All Geomembrane shall be clean and dry at the time of repair.
• Extend patches or caps at least 6-inches for extrusion weld and 4-inches for wedge weld beyond
the edge of the defect, and round corner of patch material. The edges of all patches are to be
beveled.
• All patches and caps shall be surveyed and displayed on Record of Construction Drawings.
4.9.7 Geotextile
4.9.7.1 General
These Specifications cover the requirements for the geotextile to be incorporated into the Work,
specifically for spillway and channel construction.
4.9.7.2 Scope
Contractor shall furnish all geotextile, labor, incidental materials, tools, supervision, transportation,
and installation equipment necessary for the installation of geotextile, as specified herein, and as
shown on the drawings.
• ASTM D 5261, Standard Test Method for Measuring Mass per Unit Area of Geotextiles
• ASTM D 4632, Standard Test Method for Grab Breaking Load and Elongation of Geotextiles
• ASTM D 4533, Standard Test Method for Index Trapezoidal Tearing Strength of Geotextiles
• ASTM D 4833, Standard Test Method for Index Puncture Resistance of Geotextiles,
Geomembranes and Related Products
• ASTM D 4491, Standard Test Method for Water Permeability of Geotextiles by Permittivity
• ASTM D 4751, Standard Test Method for Determining Apparent Opening Size of a Geotextile
• ASTM D 4354, Standard Practice for Sampling of Geosynthetics for Testing
• ASTM D 4759, Standard Practice for Determining the Specifications Conformance of Geosynthetics
4.9.7.4 Submittals
Prior to material delivery to project site, the Contractor shall provide the Engineer with a written
certification or manufacturer’s quality control data sheet that displays that the geotextile meets or
exceeds minimum average roll values (MARV) specified herein.
The Contractor shall submit, if required by the Engineer, the manufacturer’s quality control manual for
the geotextile to be delivered to the site.
The geotextile shall be able to withstand direct exposure to ultraviolet radiation from the sun for up to
30 days without any noticeable effect on index or performance properties.
The geotextile shall meet or exceed all of the following material properties:
Test
Tested Property Frequency NW4 NW6 NW8 NW10 NW12 NW16
Method
AASHTO M288
3 2 1 >1 >>1 >>>1
Class
Mass per Unit Area, ASTM D 4 6 8 10 12 16
8,500m2
oz/yd2 (g/m2) 5261 (135) (200) (270) (335) (405) (540)
Grab Tensile ASTM D 120 170 220 260 320 390
8,500m2
Strength, lb (N) 4632 (530) (755) (975) (1,155) (1,420) (1,735)
ASTM D
Grab Elongation, % 8,500m2 50 50 50 50 50 50
4632
Puncture Strength, ASTM D 60 90 120 165 190 240
8,500m2
lb (N) 4833 (265) (395) (525) (725) (835) (1,055)
Trapezoidal Tear ASTM D 50 70 95 100 125 150
8,500m2
Strength, lb (N) 4533 (220) (310) (420) (445) (555) (665)
Apparent Opening
ASTM D 70 70 80 100 100 100
Size, Sieve No. 50,000m2
4751 (0.212) (0.212) (0.180) (0.150) (0.150) (0.150)
(mm)
ASTM D
Permittivity, sec-1 50,000m2 1/50 1.50 1.50 1.20 0.80 0.70
4491
Permeability, ASTM D
50,000m2 0.22 0.30 0.30 0.30 0.29 0.27
cm/sec 4491
Water Flow Rate, ASTM D 120 110 110 85 60 50
50,000m2
gpm/ft2 (l/min/m2) 4491 (4,885) (4,480) (4,480) (3,460) (2,440) (2,035)
UV Resistance
ASTM D per
(% Retained after 70 70 70 70 70 70
4355 formulation
500 hours)
Roll Length(1), 600 600 600 300 300 300
ft (m) (182) (182) (182) (91) (91) (91)
15 15 15 15 15 15
Roll Width(1), (m)
(4.6) (4.6) (4.6) (4.6) (4.6) (4.6)
9,000 9,000 9,000 4,500 4,500 4,500
Roll Area, ft2, (m2)
(836) (836) (836) (418) (418) (418)
Notes:
The property values listed are in weaker principal direction. All values listed are MARV except apparent opening size in mm
and UV resistance. Apparent opening size (mm) is a Maximum Average Roll Value. UV is a typical value.
(1)
Roll lengths and widths have a tolerance of +/- 1 percent.
4.9.7.6 Manufacture
All rolls of the geotextile shall be identified with permanent marking on the roll or packaging, with the
manufacturer’s name, product identification, roll number, and roll dimensions.
4.9.7.7 Transport
Transportation of the geotextile shall be the responsibility of the Contractor.
During shipment, the geotextile shall be protected from ultraviolet light exposure, precipitation, mud,
dirt, dust, puncture, or other damaging or deleterious conditions.
Upon delivery at the Site, the Contractor shall ensure that the geotextile rolls are handled and stored
in accordance with the manufacturer’s instructions to prevent damage.
The pass or fail of the conformance test results shall be determined according to ASTM Practice D
4759.
4.9.7.9 Installation
The geotextile shall be handled in such a manner as to ensure that it is not damaged in any way.
Should the Contractor damage the geotextile to the extent that it is no longer usable as determined by
these Specifications or by the Engineer, the Contractor shall replace the geotextile.
The geotextile shall be installed to the lines and grades as shown on the Drawings and as described
herein.
The geotextile shall be rolled down the slope in such a manner as to continuously keep the geotextile
in tension by self-weight. The geotextile shall not be dragged across rough surfaces to avoid
“combing” or damaging the geotextile.
The geotextile shall be securely anchored where applicable. In the presence of wind, all geotextiles
shall be weighted by sandbags or approved equivalent. Such anchors shall be installed during
placement and shall remain in place until replaced with cover material.
The Contractor shall take necessary precautions to prevent damage to adjacent or underlying
materials during placement of the geotextile. Should damage to such material occur due to the fault
of the Contractor, the latter shall repair the damaged materials as specified by the Engineer.
During placement of the geotextile, care shall be taken not to entrap soil, stones, or excessive
moisture that could hamper subsequent seaming of the geotextile as judged by the Engineer.
The geotextile shall not be exposed to precipitation prior to being installed and shall not be exposed to
direct sun light for more than 15 days after installation.
The geotextile shall be seamed using heat seaming or stitching methods as recommended by the
manufacturer and approved by the Engineer. Sewn seams shall be made using polymeric thread with
chemical resistance equal to or exceeding that of the geotextile. All sewn seams shall be continuous.
Seams shall be oriented down slopes perpendicular to grading contours unless otherwise specified.
For heat seaming, fusion-welding techniques recommended by the manufacturer shall be used.
The Contractor shall not use heavy equipment to traffic above the geotextile without approved
protection.
The geotextile shall be covered as soon as possible after installation and approval.
Material overlying the geotextile shall be carefully placed to avoid wrinkling or damage to the
geotextile.
• D 1505-98 Standard Test Method for Density of Plastics by the Density-Gradient Technique
• D 1603-94 Standard Test Method for Carbon Black in Olefin Plastics
• D 4355-02 Standard Test Method for Deterioration of Geotextiles by Exposure to Light, Moisture
and Heat in a Xenon Arc Type Apparatus
• D 4491-99 Standard Test Method for Water Permeability of Geotextiles by Permittivity
• D 4716-00 Standard Test Method for Determining the (In-Plane) Flow Rate Per Unit Width and
Hydraulic Transmissivity of a Geosynthetic Using a Constant Head
• D 4751-99 Standard Test Method for Determining Apparent Opening Size of a Geotextile
• D 4833-88 (1996) Standard Test Method for Index Puncture Resistance of Geotextiles,
Geomembranes and Related Products
• D 5035-95 Standard Test Method for Breaking Force and Elongation of Textile Fabrics (Strip
Method)
• D 5199-99 Standard Test Method for Measuring Nominal Thickness of Geotextiles and
Geomembranes
• D 5261-92 (1996) Standard Test Method for Measuring the Mass Per Unit Area of Geotextiles
• D70005-03 Determining the Bond Strength (Ply-Adhesion) of Geocomposites
• Daniel, D.E. and R.M. Koerner, (1993), Technical Guidance Document: Quality Assurance and
Quality Control for Waste Containment Facilities, EPA/600/R-93/182.
• The drainage geocomposite shall be manufactured by extruding two crossing strands to form a
bi-planar or tri-planar drainage net structure (geonet) with a 6 ounces per square yard (oz/yd2)
non-woven geotextile bonded to both sides.
• The drainage geocomposite specified shall have properties that meet or exceed the values listed in
the following table.
Test
Tested Property Frequency Average Value
Method
2
Geocomposite 6 oz/yd 8 oz/yd2 10 oz/yd2
Product Code FR82060060T FR82080080T FR82100100T
Transmissivity(a),gal/min/ft (m2/sec) ASTM D 4716 1/540,000ft2 4.8 (1x10-3) 4.8 (1x10-3) 4.8 (1x10-3)
Ply Adhesion, lb/in (g/cm) ASTM D 7005 1/50,000 ft2 1.0 (178) 1.0 (178) 1.0 (178)
Roll Width(b), ft (m) 15 (4.5) 15 (4.5) 15 (4.5)
Roll Length(b), ft (m) 150 (45) 140 (42) 130 (39)
Roll Area, ft2 (m2) 2,250 (202) 2,100 (189) 1,950 (175)
Geonet Properties Average Value
Transmissivity(c), gal/min/ft (m2/sec) ASTM D 4716 24 (5x10-3)
Compression Strength, lb/ft2 (kPa) ASTM D 1621 1/540,000ft2 50,000 (2,390)
once per
Creep Reduction Factor 1.3 @ 25,000 psf
formulation
2 2
Mass, lb/ft (g/m ) ASTM D 5261 1/50,000 ft2 0.43 (2,100)
Density, g/cm3 ASTM D 1505 1/50,000 ft2 0.94
Tensile Strength (MD), lb/in (N/mm) ASTM D 5035 1/50,000 ft2 100 (17)
ASTM D 1603
Carbon Black Content, % 1/50,000 ft2 2.0
(modified)
Geotextile Properties
Mass, oz/yd2 (g/m2) ASTM D 5261 1/90,000 ft2 6 (200) 8 (270) 10 (335)
Grab Tensile, lb (N) ASTM D 4632 1/90,000 ft2 170 (755) 220 (975) 260 (1,155)
Puncture Strength, lb (N) ASTM D 4833 1/90,000 ft2 90 (395) 120 (525) 165 (725)
AOS, US Sieve (mm) ASTM D 4751 1/540,000 ft2 70 (.21) 80 (0.180) 100 (0.150)
Permittivity, (sec-1) ASTM D 4491 1/540,000 ft2 1.5 1.5 1.2
Flow Rate, gpm/ft2 (lpm/m2) ASTM D 4491 1/540,000 ft2 110 (4,480) 110 (4,480) 85 (3,460)
ASTM D 4355 once per
UV Resistance, % Retained 70 70 70
(after 500 hrs) formulation
Notes:
(a) This is an index transmissivity value measured at stress = 25,000 psf; gradient = 0.1; time = 15 minutes; boundary
conditions = plate/geocomposite/plate.
(b) Roll widths and lengths have a tolerance of ±1%.
(c) This is an index transmissivity value measured at stress = 25,000 psf; gradient = 0.1; time = 15 minutes; boundary
conditions = plate/geonet/plate.
(d) All geotextile properties are minimum average values except AOS (in mm) which is a maximum value and UV resistance
which is a typical value.
• Resin
− Resin shall be new, first quality compounded polyethylene resin.
− Natural resin (without carbon black) shall meet the following additional minimum requirements:
Sample Table
Property Test Method (1) Value
Density (g/cm3) ASTM D 1505 >0.94
Melt Flow Index (g/10 min) ASTM D 1238 <1.0
The drainage geocomposite shall be tested according to the test methods and frequencies listed
below:
4.9.8.4 Qualifications
• Geocomposite Manufacturer
• Geocomposite Manufacturer shall have manufactured a minimum of 10 million ft2 of polyethylene
geocomposite material during the last year.
• Installer
• Installer shall have installed a minimum of 1 million ft2 of geocomposite in the last five years.
• Installer shall have worked in a similar capacity on at least three projects similar in complexity to the
project described in the contract documents.
• The Installation Supervisor shall have worked in a similar capacity on projects similar in size and
complexity to the project described in the Contract Documents.
• Labeling – Each roll delivered to the site shall be wrapped and labeled by the Geosynthetics
Manufacturer. The label will identify:
• Manufacturer’s name
• Product identification
• Length
• Width
• Roll number
• Delivery – Rolls will be prepared to ship by appropriate means to prevent damage to the material
and to facilitate off-loading.
4.9.8.6 Execution
4.9.8.6.1 Familiarization
Prior to installing any of the geocomposite in the Work, the installer shall carefully inspect the installed
Work of all other sections and verify that all Work is complete to the point where the installation of the
section may properly commence without adverse impact.
If the installer has any concerns regarding the installed Work of other sections, he shall notify the
Engineer.
The geocomposite shall be installed over some long, steep slopes, and special care shall be taken so
that only full-length rolls are used at the top of the slope.
In the presence of wind, all geocomposites shall be weighted down with sandbags or the equivalent.
Such sandbags shall be used during placement and remain until replaced with the covering
Geomembrane.
Each roll of geocomposite on a slope shall be properly anchored in the anchor trench at the top of the
slope to resist sliding. Anchor trench compacting equipment shall not come into direct contact with
the geocomposite.
In applying fill material or an overlying Geomembrane, no equipment shall drive directly across the
geocomposite. The specified fill material shall be placed and spread utilizing vehicles with a low
ground pressure.
The cover soil shall be placed on the geocomposite in a manner that prevents damage to the
geocomposite. Placement of the cover soil shall proceed immediately following the placement and
inspection of the geocomposite.
The overlaps shall be joined by tying the geonet structure with cable ties. These ties shall be spaced
every 5 feet along the roll length.
Adjoining geocomposite rolls (end to end) across the roll width should be shingled down in the
direction of the slope with the upslope geonet overlapping the downslope geonet a minimum of
12 inches across the roll width.
4.9.8.6.4 Repair
Prior to covering the deployed geocomposite, each roll shall be inspected for damage resulting from
construction.
Any rips, tears, or damaged areas on the deployed geocomposite shall be removed and patched.
The patch shall be secured to the original geonet by tying every 6 inches with the approved tying
devices. If the area to be repaired is more than 50 percent of the width of the panel, the damaged
area shall be cut out, the two portions of the geonet shall be cut out, and the two portions of the
geonet shall be joined in accordance with the previous section
4.9.8.7 Warranty
• Material shall be warranted, against defects for a period of 20 years from the date of the
geocomposite installation.
• Installation shall be warranted against defects in workmanship for a period of 20 years from the date
of geocomposite completion.
4.11 Pipework
The pipework requirements outlined herein and as shown on the Drawings include furnishing all labor,
materials, construction equipment, and services for installation and/or relocation of certain pipes as
outlined in these Specifications and as shown on the Drawings.
Any contradictions between standards shall be submitted to the Engineer for decision.
The pipe shall have a minimum pipe stiffness of 5 percent deflection when tested in accordance with
ASTM D 2412, as follows:
Internal Diameter
Pipe Stiffness
(mm)
100-300 345 kPa
375 290 kPa
450 275 kPa
600 235 kPa
750 195 kPa
900 150 kPa
1,050 140 kPa
1,200 125 kPa
1,500 95 kPa
Where perforations are specified, they shall conform to the requirements as follows:
Couplings shall be corrugated to match the pipe corrugations and shall provide sufficient longitudinal
strength to preserve pipe alignment and prevent separation at the joints. Couplings, unless watertight
connections are specified, shall be split collar and shall engage at least two full corrugations on each
pipe section.
HDPE pipe lengths shall be joined by thermal butt fusion in strict accordance with the pipe
manufacturer’s recommendations unless flanged end pipes are specified on the Drawings. The butt
Stub ends and pipe fittings for butt fusion shall be of at least the same wall thickness and pressure
rating and the same resin type, grade, and cell classification and manufacture as the pipe to be joined
unless otherwise recommended by the manufacturer. Thermal butt fusion of HDPE shall be carried
out by qualified technicians.
Backup rings for flanged joints shall be the convoluted type of ductile iron material (ASTM 536-80
Grade Range from 60/40/18 to 64/45/12), drilled to ANSI bolt circles, and have a pressure rating of
1,034 kPa unless otherwise specified. Backup flanges and bolts shall be as approved or supplied by
the pipe manufacturer.
Slotting of HDPE pipe shall be equally spaced around the pipe circumference and spaced on 10 mm
centers down the axis of the pipe. Each slot shall be nominally 30 mm in length and 0.5 mm in width.
The Contractor shall install all piping required to complete the piping installation in accordance with
good piping practices whether such piping is specifically detailed on the Drawings or not. The general
layout as shown on the Drawings shall be maintained. Where interference is encountered during
installation or relocation of pipelines is deemed necessary, the Contractor shall notify the Engineer,
who will specify and approve any changes that are made.
All pipelines shall be erected to preserve accurate alignment. Care shall be taken in the installation of
pipeline runs where drainage is required to ensure that the pipeline has a continuous slope to the
point of drainage.
Prior to installation, each segment of pipe and all fittings shall be inspected for defects and/or
damage. Care shall be taken to prevent foreign material from entering the pipe while it is being
installed. Any foreign material entering the pipe shall be removed by the Contractor at his expense.
Open ends of the pipe shall be covered by temporary end caps or other approved means when
installation is not in progress. The Contractor shall be fully responsible for repairing any damage to
the pipes that occur as a result of not placing the temporary end caps.
Pipe bends to form curves either in the horizontal or vertical plane shall not exceed that
recommended by the manufacturer or approved by the Engineer. The cutting of pipe for inserting
fittings or closure pieces shall be done in a neat and workmanship like manner without damage to the
pipe and so as to leave a smooth end at right angles to the axis of the pipe.
Couplings for CPT shall be tied with plastic zip locks or wire approved by the Engineer. Where
applicable, the cut ends of the wire or protrusions of the zip lock or wire tie shall be placed so as not
to be in contact with underlying or overlying geomembrane liner.
Backfill and cover materials shall be as indicated on the Drawings and as described within these
Specifications.
All pipes and fittings shall be carefully lowered into trenches. Under no circumstances shall they be
dropped into trenches.
Backfill and cover materials shall be as indicated on the Drawings and within these Specifications.
All HDPE pipe shall be pressure tested according to the procedure described in Section 6.2.1.
4.12 Instrumentation
4.12.1 Vibrating Wire Piezometers General
Vibrating wire piezometers complete with piezometers cables and cable protection, Ottawa Sand,
readout box, installation, piezometer calibration, and survey monuments for each structure shall be
provided and installed by the Contractor. The Contractor shall notify the Engineer when piezometers
are to be calibrated and after successful calibration and installation, the Contractor, the Engineer, and
the Company shall sign off on the completed installation.
Each cable shall be attached to the appropriate piezometer and permanently marked with the number
of the instrument to which it is attached. This marking shall be every 3 m over the length of the cable
and shall be provided by the instrument manufacturer prior to shipment to the construction site. Each
cable shall be mounted on a reel and mechanically protected to prevent damage during shipping.
Each reel shall be stenciled or labeled with the name of the instrument, and all wire ends shall be
capped on the open end of the wire on the reel. The electrical cables shall be Geokon Model No. 02-
500PE-1 or equivalent.
All piezometer leads shall terminate in the Outlet Works Control House located as shown on the
Drawings and shall be mounted on a panel or panels for accessibility and to prevent damage of the
cables. All leads shall be clearly marked with each instrument number on the terminal panels.
A lockable, waterproof, and dust-resistant steel box is required to house the terminal panel. The
Geokon Terminal Box Model No. 4999, or equivalent, can handle up to 16 four-conductor sensors
(e.g., 16 vibrating wire gages with their thermistors) and fits these requirements.
Calibration data are supplied with each piezometer. A zero reading taken at a specific temperature
and barometric pressure is included. Zero readings at the site should coincide with the factory
readings within a few digits after barometric and temperature corrections are made. According to
Geokon, Inc., the factory elevation is ±175 m. At altitudes below about 1,500 m, the barometric
pressure decreases as elevation increases at a rate of approximately 3.4 kPa per 300 m.
It is important that the temperature of the piezometer be uniform and held constant. Otherwise,
variations in temperature across the body of the piezometer will give rise to temperature transients
and spurious readings. These are particularly noticeable if the piezometer is gripped momentarily in
the hand.
Specification Name
®
8” Faircloth Skimmer Surface Drain – Instructions for Assembly, Use and Maintenance
Butterfly Valve Specification
Flowmeter Specification
HDPE Pipe Specification
Sediment Pond Turbidity Meter Specification
5.1 General
It will be the responsibility of the Contractor to provide independent Quality Control (QC) for the Work
carried out by the Contractor relative to the Work meeting the requirements of the Specifications and
as shown on the Drawings.
It will be the responsibility of the Engineer to provide QA for the Work carried out by the Contractor
relative to the Work meeting the requirements of the Specifications and as shown on the Drawings.
This shall not however, relieve the Contractor of the sole responsibility for completion of the work in
conformance with the requirements of the Drawings and Specifications.
The Engineer will be responsible during construction for, but not necessarily be limited to, the
following:
• Evaluating materials and procedures for compliance with the requirements of the Drawings and
Specifications.
• Observing the QC Work to offer an opinion that it is being performed in accordance with the
requirements of the Specifications.
• Assessing the Work and results of the QC testing to provide an opinion that conformance with the
intent of the design and the requirements of the Drawings and Specifications are achieved.
The Engineer, QC Contractor, QA Contractor, and/or the Company is authorized to call the
Contractor’s attention to any failure of the Work to conform to the Specifications or other provisions of
the Contract. The Engineer will work with the QA Contractor to review the inspections performed by
QC Contractor to prepare reports as described in Section 7, below.
5.2 Earthwork
5.2.1 Foundations
In general, the foundation must be of material having density and strength parameters sufficient for
the support of the proposed construction. The Engineer and Contractor must sign the Work Activity
Inspection Form indicating approval of the foundation prior to the placement of overlying material or
ongoing construction.
Inspections required:
• Check for correct and complete stripping of topsoil, organic material, and unsuitable materials
• Check for preparation and compaction of foundation surface
• Check for location of porous zones
• Check for location of encased pipes
• Check for compliance with the intent of the Design, Drawings and Specifications
All Core material shall be accepted by the QC Contractor on the Work Activity Inspection Form.
Inspections required:
• Check for compliance with Earthwork Specifications regarding material gradation, moisture
conditioning, spreading, layer thickness, surface finish, and compaction
• Check for prevention of desiccation
• Check for avoidance of damage to finished surfaces
• Check for compliance with the intent of the Design and Drawings
5.2.3 Filter/Drain, Bog Embankment Fill, Alluvial Drain, Fine & Coarse Drainage Gravel
All fill shall be accepted by the QC Contractor on the Work Activity Inspection Form.
Inspections required:
• Check for compliance with Earthwork Specifications regarding spreading, layer thickness,
compaction if required, and material gradation
• Check for avoidance of damage to the related construction
• Check for avoidance of damage to piping, Geosynthetics, or Geomembranes
• Check for maintenance of consistent and uniform drainage characteristics
• Check for avoidance of damage to completed Work and surfaces
• Check for compliance with the intent of the Designs and Drawings
Inspection required:
• Check for compliance with Specifications regarding moisture, spreading, layer thickness, surface
finish, and compaction.
• Check for compliance with the lines and grades shown on the Drawings
• Check for compliance with the intent of the Design
• Check for the presence of organic material
• Check for control on maximum particle size
• Check for regular, consistent mixing of particles to eliminate segregation of coarse particles and
formation of seepage paths
5.2.5 Structural Fill, Coarse Structural Fill, Structural Rockfill and Thick-Lift Structural Rockfill
All fill shall be accepted by the QC Contractor on the Work Activity Inspection Form. Inspections
required:
• Check for compliance with Earthwork Specifications regarding moisture, spreading, layer thickness,
surface finish, and compaction
• Check for uniform distribution of haul truck traffic and\or compactor passes over the entire fill.
5.2.6 Embankment Fill A, Embankment Fill B, Embankment Fill C, and General Fill
All fill shall be accepted by the QC Contractor on the Work Activity Inspection Form. Inspections
required:
• Check for compliance with Earthwork Specifications regarding moisture, spreading, layer thickness,
surface finish, and compaction.
• Check for uniform distribution of haul truck traffic and\or compactor passes over the entire fill.
• Check for the presence of organic material.
• Check for control on maximum particle size.
• Check for regular, consistent mixing of particles to eliminate segregation or nesting of fine particles
that would block or adversely retard seepage paths.
• Check for compliance with the intent of the Design, Drawings and Specifications.
• Check for compliance with Earthwork Specifications regarding material gradation, moisture
conditioning, spreading, layer thickness, surface finish, and compaction.
• Check for prevention of desiccation.
• Check for avoidance of damage to finished surfaces.
• Check to see that the finished surface is compatible with serving as a foundation for the
Geomembrane in accordance with the Earthwork Geosynthetics Specifications.
• Check for compliance with the intent of the Design and Drawings.
• Check for compliance with Earthwork Specifications regarding material gradation, moisture
conditioning, spreading, layer thickness, surface finish, and compaction.
• Check for prevention of desiccation.
• Check for avoidance of damage to finished surfaces.
• Check to see that the finished surface is compatible with serving as a foundation for the
Geomembrane in accordance with the Earthwork Geosynthetics Specifications.
• Check for compliance with the intent of the Design and Drawings.
• Check for compliance with Earthwork Specifications regarding moisture, spreading, layer thickness,
surface finish, and compaction.
• Check for uniform compaction over the entire fill.
• Check for the presence of organic material.
• Check for control on maximum particle size.
• Check for regular, consistent mixing of particles to eliminate segregation or nesting of fine particles
that would block or adversely retard seepage paths.
• Check to be sure the compaction equipment does not contact or otherwise damage the pipe.
• Check for compliance with the intent of the Design.
Inspections required:
• Check for compliance with the Earthwork Specifications regarding layer thickness.
• Check for hardness and durability.
• Check for correct placement and distribution of the particles in a uniform manner without nesting of
particles of the same size, avoiding damage to underlying materials.
• Check for grout penetration to subgrade soils and that smooth finished surfaces are avoided (in
Grouted Riprap applications).
• Final acceptance may be based on visual observation.
• Check gradation.
• Check for compliance with Earthwork Specifications regarding layer thickness and compaction.
• Check for correct placement.
• Check for compliance with Earthwork Specifications regarding spreading, layer thickness, and
material gradation.
• Check for oversize material.
• Check for avoidance of damage to the piezometer tip and cables.
• Check for avoidance of damage to piping, Geosynthetics, or Geomembranes.
• Check for avoidance of damage to completed Work and surfaces.
• Check for compliance with the intent of the Design.
• Check for compliance with Earthwork Specifications regarding moisture, spreading, layer thickness,
surface finish, and compaction.
• Check for uniform distribution of haul truck traffic over the entire fill.
• Check for the presence of organic material.
• Check for control on maximum particle size.
• Check for regular, consistent mixing of particles to eliminate segregation or nesting of fine particles
that would block or adversely retard seepage paths.
• Check for compliance with the intent of the Design.
• Check for compliance with Earthwork Specifications regarding moisture, spreading, layer thickness,
surface finish, and compaction.
• Check for uniform distribution of compaction effort over the entire fill.
• Check for the presence of organic material.
• Check for control on maximum particle size.
• Check for regular, consistent mixing of particles to eliminate segregation or nesting of fine particles
that would block or adversely retard seepage paths.
• Check to be sure compaction equipment does not damage the Geomembranes.
• Check for compliance with the intent of the Design.
5.2.16.6 Equipment
The Contractor shall furnish and maintain the following minimum equipment (one-half of the amount of
each type of equipment is for exclusive use by the Company or Engineer). The equipment shall be in
accordance with applicable API Standard Specifications. All equipment used by the Company or
Engineer shall be returned to the Contractor upon completion of the slurry trench Work.
The Contractor shall also furnish a measuring devise with 0.1-meter incremental markings, or
approved equivalent, for determining the depth of trench and sediment accumulations.
Inspections required:
• Prior to delivery, check material certifications for compliance with the Earthwork Specifications.
• On delivery, check that the material delivered is that matching the material certifications.
• Check for damage to pipe and culvert materials prior to installation.
• After installation, check for damage and conformance with Earthwork Specifications and Drawings.
• Check for compliance of installation with manufacturer’s recommendations.
• Check for compliance with the intent of the Design.
5.4 Concrete
The requirements for concrete and reinforced concrete materials, mixing, and placement for such
items as, but not limited to, outlet works concrete, energy dissipater structures, and spillway concrete
paving are detailed in Ausenco’s concrete specification “Constancia Project Concrete Construction
Engineering Specification, Rev 1” and dated 15 March 2012, or the most recent version thereof. The
specification is included herein by reference.
All concrete shall be accepted by the QC Contractor on the Work Activity Inspection Form. The QC
Contractor will perform three inspections:
Inspections required:
• Check for compliance with the Earthwork and Concrete Specifications regarding materials and
methods
• Check for compliance with the Drawings for line, grade, and method
• Check for reinforcing size, spacing, and alignment
• Check for form dimensions
• Check for casting surface cleanliness
• Check for vibration
• Check for surface finish
• Check for curing
• One set of tests shall be performed to check slump, total entrained air and compressive strength
• The origin (name and production plant), identification (brand name, number), production date, and
batch (or rail car number) of the resin
• A copy of the quality control certificates issued by the resin manufacturer with results of the density
and melt index tests
• A copy of the quality control test results issued by the Geomembrane manufacturer verifying the
quality of the resin used to manufacture the Geomembrane
• Thickness
• Carbon black
• Density or specific gravity
• Tensile properties
• Tensile strength at break
• Tensile strength at yield
• Elongation at break
• Elongation at yield
• Tear resistance
• Puncture resistance
• Testing methods employed and results of testing
The QC Contractor shall verify that the property values supplied by the resin and Geomembrane
manufacturers meet all the Specifications, that the measurements of the properties by the
Geomembrane manufacturer are properly documented, and that the test methods employed meet the
Geosynthetics Specifications.
A sample of each batch type shall be taken at this time. These samples shall be a minimum of
600 mm by 900 mm and cut from an undamaged area of the end of a roll. These samples shall be
used for verification of properties as listed in Section 4.9, if required, by the Contractor, the
Construction Manager, or the Company. Samples shall be submitted to the Construction Manager for
retention onsite for a minimum of one year.
5.5.1.4 Subgrade
5.5.1.4.1 Subgrade Inspection
The QC Contractor shall inspect and accept on the Work Activity Inspection Form the subgrade prior
to submittal of an area to the Contractor via the Construction Manager for his acceptance. The
subgrade is the upper surface of the Prepared Subbase. Inspections required:
This acceptance shall be recorded on the Work Activity Inspection Form. If any damage has occurred
since acceptance, the QC Contractor shall obtain reacceptance of any area that has been damaged
and repaired prior to installation of Geomembrane materials. The Geosynthetics Contractor is
responsible for maintaining the condition of the accepted area(s) until it is accepted by others for later
stages of Work.
The QC Contractor shall record any remarks concerning deployment along with the time and weather
in the Geosynthetics Panel Deployment Log.
The QC Contractor shall re-inspect any subgrade that may have been damaged after deployment has
taken place to ensure that the subgrade still meets the Specifications. This may include removal of
deployed panels. Re-inspection will be recorded on the Work Activity Inspection Form.
This code shall be marked on each panel with a non-toxic, indelible material and be clearly visible.
These data will be recorded by the QC Contractor in the Geosynthetics Panel Deployment Log.
All defects or damaged areas that require repair shall be identified by the QC Contractor by circling
the defect or area. Excessively defective panels shall be removed.
The Construction Manager shall check these daily reports against his own records to ensure
completeness. The exact location of each panel deployed shall be surveyed for the as-built records.
• At the beginning of seaming operations or the beginning of each shift and following breaks for
meals.
• After every four hours of seaming machine operation.
• After repairs have been made to the seaming equipment.
• By each operator using the seaming equipment (an operator must be qualified for each separate
piece of seaming equipment used).
• Under the same environmental conditions and with the same materials and pre-seaming and
seaming techniques as the field seams are to be fabricated.
• At the sole discretion of the QC Contractor.
All trial seam data is to be recorded in the Geosynthetics Start-Up Trial Weld/Seam Log. Trial seams
shall meet the following the Geosynthetics Specifications:
The Geosynthetics Contractor shall complete destructive testing, which shall be witnessed by the QC
Contractor, on a calibrated tensiometer. The Geosynthetics Contractor shall provide a copy of the
calibration certificate to the QC Contractor via the Construction Manager. Calibration of the
tensiometer shall be completed before the start of the project. Results of the tests shall be recorded
by the QC Contractor in the Geosynthetics Start-Up Trial Weld/Seam Log.
For trial seams, if one or more of either of the five shear strength or five peel strength test is non-
passing, an additional trial seam will be welded. If testing of the new trial seam results in any coupon
failures, neither the individual nor the welding machine will be allowed to weld production welds until
two consecutive trial seams are produced and all five shear and five peel tests from each trial weld
have passing results.
The QC Contractor may also reject any portion of a seam for any additional reason that may cause
the seam to not meet the Geosynthetics Specifications.
The Geomembrane field seamer shall mark next to each seam his or her initials, the date of the
seaming, the time, machine number, welding temperatures, and, if applicable, preheat and machine
speed and indicate with arrows the start and finish points of the seaming.
The QC Contractor shall record all seaming information as required in the Geosynthetics Field
Seaming Log.
• B = Bead
• P = Patch
• Leak = Leak
• O = Insufficient Overlap
• Bridge = Bridge
• DS = Destructive Sample
Further markings shall be used to identify the repair or destructive sample number. Bead repairs do
not need to be recorded. Insufficient overlaps shall be patched, and bridges shall be cut and patched
as required. All holes, leaks, and areas where destructive samples have been taken shall be
patched. Patching materials shall be of the same material type and thickness as the material being
repaired. A patch shall be a minimum of 150 mm larger in all directions than the area requiring repair
and shall have rounded corners. All intersections of channels created in double-wedge seaming shall
be properly prepared and seamed to eliminate leaks at the seam terminations. All repairs shall be
logged as required in the Geosynthetics Field QC Log.
Capping shall be used in the repair of fusion welds and areas of excessive overgrind. However,
extrusion over a fusion weld and excessive overgrind should be minimized. Any material on the
support layer which may cause damage shall be removed and the area repaired.
All repairs shall be non-destructively tested. Repairs shall also be inspected by the QC Contractor for
deficiencies prior to panel acceptance and seam acceptance. The QC Contractor shall record the
non-destructive test results of the seams in the Geosynthetics Field QC Log.
Geotextile:
• Material type
• Fabrication method
• Weight
• Thickness
• Grab strength
• Grab elongation
• Puncture strength
• Mullen burst strength
• Apparent opening size
• Trapezoidal tear strength
The QC Contractor shall verify that the property values supplied by the geotextile manufacturer and/or
supplier meet all Specifications, that the measurements of the properties by the geotextile supplier are
properly documented, and that the test methods employed meet the Specifications.
Any discrepancies shall be brought to the immediate attention of the Construction Manager. The
materials at this time shall be inspected for any visible damage. All geotextile materials delivered
shall be protected from ultraviolet light using a watertight protective wrapping.
The QC Contractor shall also make an independent inspection of the surfaces on which the geotextile
is to be deployed.
Standard testing forms developed by the QC Contractor shall be used for the tests described in this
section. When reference is made to an external test procedure, e.g., ASTM, the relevant test
procedure documentation is considered to be an integral part of this manual. If these external test
procedures reference or require other additional external procedures, they also are considered to be
an integral part of this document.
• Control tests
• Record tests
Control tests are used to determine that materials comply with the Earthwork Specifications prior to
placement and to determine other parameters such as optimum moisture content and maximum dry
density so that the requirements of the Earthwork Specifications are achieved. The frequency of
control tests can be reduced when material characteristics are relatively constant and consistent.
Record tests are performed, usually after placement of the materials, to determine that the in-place
materials meet the requirements as set forth in the Specifications and/or are in accordance with the
Design intent.
Tests are performed by the methods indicated and at the frequencies shown in the tables. The tests
will be performed at least the minimum number of times indicated. The Engineer may increase the
number of tests required.
6.1 Earthwork
Testing of all fill materials shall be completed in accordance with the procedures and at the
frequencies detailed in tables included in Section 7.
If the layer thickness for fill exceeds the test equipment working depth, compaction through the layer
must be verified at the commencement of fill placement. This is done by excavating a pit. Thereafter,
the compaction profile is established by testing the top of the layer. Periodic testing using pits may
then be used to confirm continued acceptable compaction throughout the layer.
Acceptance of Riprap shall be based on the visual observation of the placed Riprap by the QC
Contractor. If the QC Contractor deems it necessary, field measurements to determine the particle
size distribution of the Riprap shall be undertaken and other test work undertaken to determine its
suitability and compliance with the requirements of the Specifications.
• Visual inspection of all non-welded joints connected by “snap-fittings” or the like including a wire tie.
• Visual inspection of all welds, particularly butt-welded HDPE pipe.
The following tests are required after backfill placement and compaction around the pipes.
All inspections and test results are to be recorded on the Work Activity Inspection Form.
Prior to hydro-testing, each line will have the following items completed:
• The line will be inspected for defects and checked by ultrasound to verify wall thickness of the pipe.
• The pipe to be tested will be blind flanged on the dam with a vent valve and gauge installed to check
pressures and to relieve air during initial line charge and during the test. The gauge will be
calibrated before the test.
• A tee will be installed in the line, with a 12-inch air actuated valve on the drain side to facilitate pipe
draining in case of a line failure during testing. The drain valve will have an air supply line hooked to
it during testing. A test gauge will also be installed to check pressure. The gauge will be calibrated
before the test.
• The 4-inch JC fresh water line will be used for the initial charging of the line to be tested.
• Before the line is charged with water, spotters will be staged at regular intervals along the pipe to
check for leakage during the test. A minimum of three spotters will be used along the containment
ditch. Also, during the entire test, there will be a person at the vent valve on the dam and at the
fill/drain line at the pump house.
• Each spotter and those at each end of the line will have a radio tuned to a predetermined frequency
to communicate during the testing procedure.
• A guzzler truck, a loader, and a track hoe will be on stand-by to respond to any leaks.
• Ensure that all personnel are in place and that communications are operational.
• Commence the initial charging of the line with the 4-inch JC line. While charging the line, the vent
valve will be open.
• The line will be charged for the full length. Once it is full, it will be drained to flush the line.
• The line will then been charged for the test.
• Once the line is charged, the line will set 15 minutes to allow the air to migrate to the vent valve.
Then the air will be bled off and the line charged again.
• Once the line has been charged the 4-inch JC line will be disconnected from the line.
• The test pump will then be started and the line will be pressured. The test parameters set forth in
the specified guidelines will be used to do the test.
• The pressure will be recorded every 5 minutes during the entire test.
• If at any time a leak is spotted in the line, all personnel will be notified, the drain valve at the pump
house will be opened and the line drained. The standby equipment will be directed to the leak area
and containment efforts will commence.
The test is considered a success if the pressure does by less than 5 percent over the duration of the
test. If the pressure drops by more than 5 percent, reasons for this must be investigated and
corrected before the test is repeated.
• The line will be drained. The line will then be connected to the operating system.
• Spotter procedures will be the same as with the test procedures.
6.3 Concrete
Unless otherwise noted on construction drawings, the requirements for concrete and reinforced
concrete materials, grades and mix designs, placement and sampling/testing for such items as, but
not limited to, outlet works concrete, energy dissipater structures, and spillway concrete paving shall
conform with Ausenco’s concrete specifications “Constancia Project Concrete Construction
Engineering Specification, Rev 1” dated 15 March, 2012, or the most recent version thereof. The
Ausenco specification is included herein by reference.
Inspections required are detailed in the most recent version of Ausenco’s Concrete Specification. Any
testing deemed necessary will be performed at the discretion of the Engineer. All concrete shall be
accepted by the QC Contractor on the Work Activity Inspection Form.
Destructive shear and peel tests shall be performed on field seams at a minimum frequency of one
test per 150 lineal m of field seam. The following procedure is to be used for taking samples of field
seams:
The Installer shall be responsible for the actual cutting and testing of the sample coupons. Using a
calibrated tensiometer, five coupons shall be tested for peel strength, and five coupons shall be tested
for shear strength. Coupons must be cut with a die to ensure uniformity. Before testing, the top and
bottom of each coupon shall be measured for thickness with a zero-to-25 mm micrometer. The
micrometer should be checked prior to use for a correct zero reading.
The QC Contractor shall record the results of the seam destructive tests along with all other required
information on the Geomembrane Destructive Sample Test Data Sheet. Each coupon tested shall be
described in the log. Tested coupons as well as a 300 mm by 300 mm sample shall be provided to
In the event of a failing test result, the following procedure shall be used:
The QC Contractor shall not accept any seam until the destructive test results are deemed to have
passed. In the event that the Geosynthetics Contractor wishes to proceed prior to receiving the test
results, the Construction Manager shall obtain a statement in writing from the Installer that all liability
and cost incurred in the event of a failing test is the responsibility of the Geosynthetics Contractor.
For trial seams, if one or more of either the five shear or the five peel coupon tests result in a non-
passing test, an additional trial seam will be welded. If testing of the new trial seam results in any
coupon failures, the individual will be required to complete seaming operations until two consecutive
trial seams are produced and all five shear and five peel tests from each trial seam have passing
results.
Values measured for shear and peel are required to meet the requirements for field seams in GRI
Test Method GM 19.
The results of all tests are to be recorded in the Geosynthetics Field QC Log.
• The air pump shall be capable of pressurizing a seam to between 172 and 207 kPa.
• If needles are used, all needles shall be accounted for. Broken needles in a seam shall be removed
and discarded properly.
• If loss of pressure exceeds 20 kPa in a 5-minute time period, the Installer must locate and define the
extent of the leak.
• The QC Contractor shall inspect the air pressure gauge to ensure that it is working properly.
The density of soil and soil-aggregate materials is determined using the methods and equipment
according to ASTM Test Method D 2922. Nuclear methods are useful as rapid, non-destructive
techniques for the in-place determination of soil and soil aggregate at or near the surface. This
equipment must only be used, calibrated, and maintained by those staff specifically trained and
designated for this work.
• ASTM D 5030:
− Minimum test pit volume: 28 to 56 liters.
− Maximum particle size: 75 to 125 mm.
• ASTM D 1556 or D 2167:
− Minimum test pit volume: 1.5 to 3.0 liters.
− Minimum particle size: 12.5 to 50 mm.
The material being tested must be sufficiently cohesive to maintain stable sides during testing. It must
not deform or slough while digging the hole or pouring the sand. In general, these test methods are
limited to materials in an unsaturated condition and are not recommended for soft, friable, or seeping
materials.
The calibration, maintenance, and operating procedures for all instruments, equipment, and sampling
tools are based on or are the actual manufacturer’s instructions, specifications, and criteria for
calibration, maintenance, and operation.
Each piece of equipment used in activities affecting data quality shall be calibrated at a frequency
specified by the manufacturer.
Each piece of equipment used in activities affecting data quality shall be maintained. Following
maintenance, instruments will be calibrated according to the manufacturer’s specifications to ensure
proper completion of the maintenance procedure.
The QA Contractor will review the QC Contractor’s daily report and prepare a daily report
summarizing the work observed and provide a technical and professional opinion on the conformance
of the QC services to the design intent.
Daily reports should be submitted to the Engineer and Hudbay Minerals, Inc. no later than noon the
day following the report subject date.
The QC Contractor will work with the QA Contractor to develop summary and detail report formats to
be incorporated into comprehensive Construction Report as described in Section 7.3, below.
The QC Contractor may include such other items as Drawings, figures, and tables as are necessary
to clearly present the work performed and planned.
The QA Contractor will review the QC Contractor’s monthly report and prepare a monthly report
summarizing the conformance (or otherwise) to the Engineer’s design intent.
th
Monthly reports should be submitted to the Engineer and Hudbay Minerals, Inc. no later than the 10
calendar day following the report subject month.
Following is a summary of the test methods and frequencies for earthworks testing. Testing methods
and frequencies for other materials are presented in their respective sections.
Test Method
Type of Test
(ASTM)
Atterberg Limits D 4318
Moisture Content
a) Laboratory D 2216
b) In-Place D 3017
Particle-Size Analysis of Soils D 422
Sieve Analysis of Fine and Coarse Aggregates D 422/C136
Moisture-Density Relationship (Modified Proctor) D 1557
Field Density
a) Nuclear Method D 2922
b) Sand Cone Method D 1556
Slake Durability D 4644
Freeze/Thaw Durability AASHTO T103
Los Angeles Abrasion ASTM C131/C535
(No testing
required where
foundation is
bedrock.)
°C degrees Celcius
°F degrees Fahrenheit
AASHTO American Association of State Highway and Transportation Officials
ACI American Concrete Institute
ANSI American National Standard Institute
ASTM American Society for Testing and Materials
AWWA American Water Works Association
AASHTO American Association of State Highway and Transportation Officials
BMP Best Management Practice
cm centimeter(s)
CQA Construction Quality Assurance
EMP Environmental Management Plan
ft2 cubic foot(feet)
g/cm3 grams/cubic centimeter
H:V horizontal to vertical
Hudbay Hudbay Perú S.A.C.
Knight Piésold Knight Piésold and Co.
kPa kiloPascal(s)
lb pound(s)
LID length-to-diameter ratio
m meter(s)
m2 square meter(s)
m3 cubic meter(s)
mm millimeter(s)
MPa megapascal(s)
NRCS Natural Resources Conservation Service
PAG Potentially Acid Generating
PI Plasticity Index
PPI Plastics Pipe Institute
ppm parts per million
QA quality assurance
QC quality control
SOP standard operating procedure(s)
SPI Society of the Plastics Industry, Inc.
SWPPP Storm Water Pollution Prevention Plan
TMF Tailings Management Facility
WRF Waste Rock Facility
WWF welded wire fabric