CONTRACTOR'S INQUIRY RESPONSES NO. 2

NOVEMBER 15, 1997

BID SUMMARY RESULTS
MORRISON KNUDSEN TRAYLOR BROS $ 102,436,598.00, AWARDED NOV. 13, 1997
TUTOR SALIBA KOCH DUTRA JV $ 113,497,508.00
FCI CONSTRUCTION INTERBETON JV $ 138,497,508.00


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CALTRANS TOLL BRIDGE RETROFIT PROGRAM ADDRESS

The Caltrans District 4 Office is located at 111 Grand Avenue, Oakland, CA 94612. The mailing address is P.O. Box 23660, Oakland, CA 94623-0660. The Toll Bridge Retrofit Duty Senior telephone number is (510) 286-5549, and the fax number for Contractor's inquiries submittals is (510) 286-4563

REFERENCE DRAWING 160 OF 308, SOFFIT ACCESS OPENINGS OCCUR AT THE HINGE RETROFIT LONGITUDINAL RESTRAINER LOCATIONS AND ARE SHOWN ON THE SUSPENDED SPAN SIDE OF THE JOINT. WILL THE CONTRACTOR BE PERMITTED TO ADD AN ADDITIONAL SIMILAR OPENING ON THE ANCHOR SPAN SIDE OF THE JOINT TO FACILITATE REACTION BEAM INSTALLATION ? SIMILARLY, WILL SPANDREL BEAM OPENINGS, OTHER THAN WHAT IS SHOWN ON DRAWING 150 OF 308, BE PERMITTED?

Openings are to be minimized. Additional openings for improving the Contractors access may be considered subject to the approval of the Engineer.

OUR SHOP IS LOCATED 395 AIR MILES FROM SACRAMENTO, THEREFORE WE ARE REQUIRED TO PAY COSTS FOR CALTRANS INSPECTION OF STRUCTURAL STEEL PER SECTION 55-4.02 OF THE STANDARD SPECIFICATIONS AND SECTION 10-1.33 (PG.108) OF THE SPECIAL PROVISIONS. BOTH OF THESE SECTIONS USE THE TERM "WELDED STRUCTURAL STEEL" TO DEFINE THAT PORTION WHICH IS ASSESSED THIS INSPECTION FEE. IT IS OUR UNDERSTANDING THAT STRUCTURAL STEEL WHICH REQUIRES NO SHOP-WELDING IS NOT ASSESSED INSPECTION FEES. PLEASE VERIFY.

When welding is not being done, no inspection fees will be required.

COLUMN CASINGS, SECTION 10-1.35 (PG.111) OF THE SPECIAL PROVISIONS DOES NOT MENTION CALTRANS FEES FOR SHOP INSPECTION NOR DOES IT REFERENCE OTHER SPECIFICATIONS THAT DO SO; THEREFORE WE UNDERSTAND THAT NO FEES WILL BE ASSESSED FOR INSPECTION OF COLUMN CASINGS. PLEASE VERIFY.

The first paragraph of the column casing spec says that they will conform to Section 55, "Structural Steel" of the Standard Specifications. Section 55 has clauses that may require that fees be assessed for inspection. See inquiry above.

OUR FINAL QUESTION INFERENCE TO CALTRANS INSPECTION FEES IS THIS: SINCE WE ARE JUST OVER THE 300 AIR LINE MILE LIMIT AS SET IN THE CALTRANS SPECIFICATIONS, WE THINK CALTRANS SHOULD CONSIDER REDUCING OR ELIMINATING THE FEE IN ORDER TO GET A MORE EVEN PLAYING FIELD FOR THE PROSPECTIVE BIDDERS. THE STRUCTURAL STEEL AND OTHER FABRICATED METAL GOODS FOR THIS PROJECT ARE A SUBSTANTIAL PERT OF THE ENTIRE BID. YOU MIGHT CONSIDER THAT ENCOURAGING OUT-OF-STATE BIDDERS FOR THIS WORK AND GETTING MORE COMPETITIVE BIDS MAY BE MORE BENEFICIAL TO THE STATE OF CALIFORNIA. SOME OUT-OF-STATE STEEL FABRICATORS, INCLUDING OURSELVES, ARE SKEPTICAL OF OUR CHANCES TO BE SUCCESSFUL WHEN PENALIZED $0.02 PER POUND BY THIS CALTRANS REQUIREMENT. PLEASE CONSIDER THIS REQUEST AND ADVISE.

For this project, the specs say there will be extra costs to cover the travel expenses for inspection if over 300 air miles away. This can only be changed by addendum. We are not pursuing an addendum to change this for the following reason: We do not agree that we should consider reducing or eliminating the fees just because the fabrication plant is only a short distance past the 300 mile number. It is the fabricator's choice to bid or not to bid, but we should not change our requirements to accommodate distant fabricators. This is a major project and we need to have a means to travel in order to inspect the items.

SECTION 10-1.33 (PG. 104) OF THE SPECIAL PROVISIONS TABLES SPECIFICATIONS FOR HIGH STRENGTH STEEL FASTENERS AND (PG. 105 COL. 2) STIPULATES THAT THEY SHALL BE GALVANIZED. THE DRAWING (SHT. 20 OF 229) NOTES THAT HS BOLTS SHALL BE A325 TYPE 3 (WHICH IS THE WEATHERING STEEL TYPE AND NOT NORMALLY GALVANIZED ACCORDING TO OUR BOLT SUPPLIERS). QUESTION: ARE ANY OF THE OTHER HS RODS, THRUST RODS, AND ANCHOR BOLTS GALVANIZED? SOME OF THEM ARE EITHER A709-50W (WEATHERING STEEL) AND A354 GR BC OR BD ALLOY STEEL - WHICH SHOULD NOT BE GALVANIZED. PLEASE ADVISE.

Bolts are to be galvanized as specified in the special provisions.

FOR THE STRUCTURAL STEEL, DOES THE 300 AIR LINE MILES APPLY ONLY TO THE WELDED PORTIONS OF THE STRUCTURAL STEEL?

That is Caltrans interpretation of the special provisions. Also, this requirement applies to check samples.

WHAT IS THE DATUM FOR ELEVATIONS SHOWN ON PLANS? FOUNDATION PLANS NOTE A DATUM OF "NGVD" IN THE TITLE BLOCK. WHAT DOES THIS MEAN?

National Geodetic Vertical Datum. Year 1929.

SHEET 87 SHOWS THE EXISTING SEAL LIMITS TO BE 2"-0" OUTSIDE OF THE EXISTING FOOTING. IS THERE ANY AS-BUILT INFORMATION ON OVER BREAK CONCRETE? IS 2"0" THE MAXIMUM OR MINIMUM?

Based on the as-built plans, the existing seal limits is 2'-0". No additional info is available regarding as-builts. This must be verified in the field.

ON PAGE 63 OF THE SPECIALS (10-1.16K 9TH PARAGRAPH), REMOVED CONCRETE ON SPANDREL BEAMS IS REPLACED WITH EITHER ENCASEMENT CONCRETE OR RAPID SET CONC., DEPENDING ON IF THEY GET ENCASED. ON SHEET 121, ON CONTRACT PLANS, NOTE 1, UPPER SPANDREL VOIDS REPLACED WITH STRUCTURAL CONCRETE,...AND ALL OTHER VOIDS REPLACED WITH RAPID-SET CONCRETE. HOW ARE THE LOWER SPANDRELS TO BE TREATED?

The note appears to indicate that the voids at the lower spandrel will be filled with rapid set concrete.

WHAT IS THE DIAMETER OF THE STRAND WIRES FOR THE PRESTRESSING OF THE PRECAST FOUNDATIONS?

The anchorage systems (and thus the strand diameters) are preapproved systems. Read Section 50 "Prestressing" of the standard specifications.

IS THERE LEAD PAINT PRESENT ON THE EXISTING STRUCTURE, IF SO WHERE AND TO WHAT EXTENT?

Read "Existing Highway Facilities" starting on page 56 of the special provisions.

Do we need to paint the holes that we drill in the existing steel.

There does not appear to be any requirement to paint the holes that are to be drilled in the existing structural steel.

What, if any, is the design load capacity of the CISS and CIDH piling?

There is no design load capacity. Pile loading is lateral only.

Are the piling designed to solely resist lateral loads? If so, what is the purpose of the soil plug shown in the drawings?

Yes, piles are for lateral loads. The geotech evaluated the CISS piles including the soil plugs and concrete. Another reason is to reduce the amount of concrete required to fill the pile.

The specification permits jetting in most cases. We would expect the jetting to remove some or all of the soil plug. What would the contractor be required to do in these circumstances?

See the second paragraph of "Driving Steel Shells" on page 83 of the special provisions which says "Drilling or jetting shall not be used within the minimum soil plug to remain at the bottom of the pile, as shown on the plans".

Would Caltrans consider revising the specifications on the reinforcing steel to permit the application of the epoxy coating prior to fabrication?

No.

Please identify the construction access method, envisioned by Caltrans and the design engineer, for constructing this project within the guidelines set forth by the local permitting agencies; i.e., BCDC, CG, USACOE, etc.

Primarily barges, some resting on the bottom at low tide (in one location for maximum of 180 days).

Is there a suggested construction sequence available for this project?

In order not to restrict the Contractor in the construction method and to prevent problems for Caltrans if a flawed sequence were presented, a construction sequence was not shown on the plans. Caltrans is expecting the Contractor to assume some risk and come up with innovative solutions.

The contract documents do not identify allowable construction loads which may be imposed on the existing structure during the retrofit project. Please identify these with specific emphasis on the existing footings, box girders and deck.

The Contractor may use the existing footings, box girders and deck but must provide working drawings and engineering calculations showing that the foundation, superstructure, and deck will not be damaged or over stressed. The Contractor must perform the analysis for his own system. Approval of your plan will come from the resident engineer.

Please identify the types of existing coatings on the concrete piers.

Bitumastic Super Service Black, modified was used initially. However a CCO requested by the Contractor permitted use of Bitumastic Super Tank Solution. The two coat application was to result in a minimum dry film thickness of 9 mils.

Reference Spec. Provisions Section 10-1.19 Piling, Page 73 left column, paragraphs 7 and 8. These two paragraphs state that should a pile conflict occur the contractor shall show his proposed method to avoid such conflict. Further, these paragraphs state that acceptable methods may include battering steel shells! Based on this do we, the contractor, include in our bid leads and templates to account for possible battering required on 8', 10', 12' diameter piles? (What batter did Caltrans envision?)

A very minimum batter was envisioned, or removal of the interfering H pile.

Please clarify the datum elevation on Sheet 46 of the contract drawings, namely"-75.00" and its correlation to M.L.L.W. and M.S.L.

This is simply a reference line at elevation -75 and corresponds to other elevation references.

Please identify the construction tolerance for the foundation frame/CISS pile connection.

A tolerance of 12" is specified on page 80 "Installation of Permanent Steel Casing" and 83 "Driving Steel Shell" of the special provisions.

Can the "wings" on the foundation frame sections vary 150-200 from that which is shown to account for out of position CISS piles due to the conflicts with existing bridge piling? (Is this adjustment a changed condition?)

It is intended that the piles will be placed accurately and that changes to the layout of the foundation frames will not be necessary. Variations would have to be checked for possible increased loadings, if lengthened or moved outward. The Engineer would be required to review and approve drawings. If the Contractor inaccurately installs a pile/piles, adjustments to the foundation frame may be the appropriate solution but this will have to be decided between the Contractor and the Engineer.

Reference Sheet 76 of 229, Note 8. Where (how) do you intend for the contractor to inject the grout after the bars are post-tensioned?

Normal grouting procedures to be used. Assume grout tubes and vents along the tube will be used.

Caltrans states that jetting for CISS and CIDH piles will be allowed with restrictions. However, we cannot find any reference to jetting restrictions on page 79 of the Special Provisions. The only mention of jetting is on page 83 which refers to internal jetting during pile driving.

Halfway down the second column on page 79 states: "Care shall be taken during excavation to prevent disturbing the foundation material surrounding the pile. Equipment or methods used for excavating holes shall n ot cause quick soil conditions or cause scouring or caving of the hole. etc...." The original question referenced the restrictions on page 83 which states "Drilling or jetting shall not be used within the minimum soil plug to remain at the bottom of the pile, as shown on the plans".

Is the Contractor allowed to drive and splice piles in less than full length and if so are there any special requirements for the splices?

The requirements for splicing are included in "Steel Pipe Piling," begining on page 73.

Is it possible to use the land bounded by State Highway 92, the bay and Beach Blvd. as a laydown area?

No, this area is identified as "ESA".

When are you going to remove the no dredging restriction so that access is attainable for Bents 2-12?

Access dredging will not be permitted.

Due to the magnitude of the special equipment necessary to build this project, and the initial outlay of funds to procure steel piling, this project has the potential of a negative $ 15,000,000 cash flow. Would you consider raising the allowable amount for mobilization and/or paying for materials on hand outside the State of California, an exception to Section 9-1.06 of the standard specifications?

Payment for Mobilization will not be changed. However, payment for materials on hand outside of the State of California or the United States is addressed by addendum number 4.

Can water from dredging operations be returned to the bay if dredged materials have been removed by filtering or centrifuging?

Dewatering process shall be submitted to the Engineer for approvalby the BCDC, in accordance to Section 10-1.03, "Non-Storm Water Discharges."

Does your pile restriction times of 7:00 PM to 8:00 AM apply to sheet pile cofferdams if the noise generated is less than 86DBA?

Sheet pile cofferdams maybe permitted by the Engineers within these hours, if they the noise generated is less than the 86DBA.

Will the contractor be permitted to conduct a barge pre-grounding survey to determine if obstructions are present (and subsequent removal thereof in the areas adjacent to the bridge where grounding will occur?

The Contractor can survey any areas he needs for his work.

Can dredging be performed between December 1 and March 1 of any year within the confines of a cofferdam and immediately adjacent thereto?

See Addendum No. 8.

Can probing/locating existing bridge piling be performed between December 1 and March 1 of any year?

See Addendum No.8.

REFERENCE TO ADDENDUM #1, GENERAL CONSTRUCTION CONDITIONS. "WORK DURING RESTRICTED VISIBILITY: NO WORK FROM WATERBORNE EQUIPMENT WILL BE PERMITTED WHEN VISIBILITY AT THE WORK SITE IS LESS THAN 1,000 YARDS". IS THIS RESTRICTION ONLY APPLICABLE TO WORK IN THE NAVIGATION CHANNEL?

In order to determine the extent this constraint applies to a particular bridge, the contractor must provide a mooring plan to the Marine Safety Office (MSO) in sufficient time as addressed elsewhere in Addendum 1 for the Coast Guard to answer related contractor questions, and ultimately approve the mooring plan.

REFERENCE TO ADDENDUM #1, GENERAL CONSTRUCTION CONDITIONS. "ANCHORING OUTSIDE DESIGNATED ANCHORAGE AREAS". IS THIS RESTRICTION ALSO APPLICABLE TO CONTRACTOR'S DESIGNATED WORKING AREA ALONGSIDE THE BRIDGE?

Same as previous question

Is the property/parking area at the west abutment (both north and south) available to the contractor for use as a staging area?

No.

Reference Spec. Provision Section 10-1.17 Earthwork, page 66, paragraph "Overflow". Please clarify the parameters under which overflow is limited to 15 minutes.

Overflow is allowed under "Accidental/Incidental" circumstances. Contractor has 15 minutes to correct the problem.

Will Caltrans identify by addendum the dates in which the contractor can or can not work on the seismic retrofit project due to environmental/wildlife restrictions implied in the attachments to the contract documents?

Please refered to contract permits.

REFERENCE TO PLAN SHEET 97 OF 308 - PIN HOLDER ELEVATION. THE DIMENSIONS ON THE DRAWING INDICATE THAT THE PIN HOLDER IS TO BE 24" OD WITH 19" ID. THE NOTE TO THE RIGHT OF THE DETAIL STATES THAT THE PIN HOLDER IS TO BE 24" ID WITH 2 1/2" WALLS. PLEASE CLARIFY.

Delete "inside" from note on right of detail drawing. See Addendum No. 6

ON PLAN SHEETS 69 OF 308 THE STATIONING ALONG THE BRIDGE APPEARS TO BE INCORRECT

Add 5 to the stations on the marks shown. See Addendum No. 6

REFERENCE TO PLAN SHEET 97 OF 308 - PIN HOLDER ELEVATION. THE DIMENSIONS ON THE DRAWING INDICATE THAT THE PIN HOLDER IS TO BE 24" OD WITH 19" ID. THE NOTE TO THE RIGHT OF THE DETAIL STATES THAT THE PIN HOLDER IS TO BE 24" ID WITH 2 1/2" WALLS. PLEASE CLARIFY.

Delete "inside" from note on right of detail drawing. See Addendum No. 6

PLEASE REFER TO CONTRACT PLAN SHEET 129, NOTE 13. WHERE ARE AND WHAT SIZE ARE THE EXISTING WELDS THAT ARE TO BE "GROUND SMOOTH"?

The table on the previous plan sheet regarding area to be painted should give a rough idea of the area to be ground. Shop drawings are available but should be field verified. See Addendum No. 6

REFERENCE SHEETS 108 AND 112 OF 308. WHAT IS THE LENGTH OF THE REINFORCED CONCRETE IN THE CISS PILES AT PIERS 38 AND 38 A?

See Addendum No 6.

IS CAST-IN-PLACE CONCRETE ALLOWED FOR THE FOUNDATION FRAMES?

See Addendum No.6

REFERENCE GENERAL NOTES, SHEET 65 OF 308 CALLS FOR THE TRANSFER BEAM IN THE FOUNDATION FRAMES TO BE ASTM A709 GR50 FY=50,000 PSI. SHEET 99 OF 308, FOUNDATION MISCELLANEOUS DETAILS NO. 4 TRANSFER BEAM - ELEVATION VIEW CALLS FOR ASTM A572 GR50. WHICH IS CORRECT?

See Addendum No. 6

Sheet number 100 (of 308) in the bid documents shows a section of the CISS pile. On this section the minimum lengths shown are confusing. Are we to assume that there will typically be a void space between the soil plug and the concrete plug?

See Addendum No. 6

Can the C.I.P. closure pours in the foundation frames be increased in length from that which is shown? What type of mechanical reinforcing steel coupler is envisioned for this impossible rebar connection?

Mechanical couplers will be standard couplers approved by Caltrans. It would be difficult to make the splice length longer without hurting the integrity of the precast frame segments.

Plan Sheet 118/308 - Table of Bottom of Casing Elevations. Table does not account for 2 foot concrete column stubs to be placed at these bents. Should all elevations be raised 2 feet?

See Addendum No. 6

Plan Sheet 121/308 - Table of unsound concrete removal Note #1, states to fill voids with grout at concrete towers and shafts. There is no casing planned on concrete shafts at bents #12 - 29. How is grout to be retained at these locations.

See Addendum No. 6

Plan sheet 121 of 308, Note 1 states the procedure to repair unsound concrete and required Rapid Set Concrete Patch at "all other locations" Per Note 1, lower spandrel beam unsound concrete repairs will require the use of Rapid Set Concrete Patch material. Is rapid Set required for unsound concrete repairs on lower spandrel beams which are retrofitted with cast-in-place concrete and post tensioning elements?

Bid it according to the plans and specifications.

Spec. Section 10-1.17 Earthwork, Page 70, seal course concrete, requires that "all seal course concrete placed by the contractor......which extends more that 3'-0" beyond the limits of the existing pile cap.....shall be removed, when no longer required by the contractor."

The weight of the added new seal course must be kept to a minimum to minimize seismic movements of the foundation. Limits are measured from the outside limit of the pile cap, not the existing seal.

Is this supposed to mean 3'-0" outside the existing seal? Since pay limits for structure excavation ty. "D" are 2'-0" outside the existing seal, to use 3'-0" outside the cap for seal course concrete removal would cut the new seal in half and be difficult and costly to remove.

Limits of type D excavation are for payment only. More or less may be excavated depending on the Contractor's decision for the size of the seal, but any portion of the seal concrete outside the 3 foot limit (or 1 foot limit for the bell foundations) must be removed.

For the large diameter piling, do the field weld requirements apply to any splices made at an off-site location (such as a water side staging area)?

Welding at off-site location will be considered field welding if not done in an approved steel fabrication shop.

Specification Section 10-1.31 Epoxy-Coated Reinforcement requires coated bar reinforcement shall conform to the provisions of ASTM Designation A934/A934M. Question: Will Cal-trans also allow the current standard rebar coating which is ASTM D-3963 to be used? Only one firm in California is licensed to coat with material which conforms to ASTM A934/A934M. This eliminates other coaters from bidding this project.

A934 epoxy coated reinforcement is used for marine environments. Caltrans management has directed that it be used within the splash zone on all of the Toll Bridge retrofit projects. There may be firms outside of California that can coat with this material.

In reference to Specials Section 10-1.35, Column Casings: After removal of plants, marine growth, and other materials, is there additional surface preparation required on the existing columns prior to concrete encasement?

All materials other than concrete shall be removed. Removal of spalled or loose concrete is covered in Section 10-1.16 K, "Remove Unsound Concrete (4" Depth)," of the special provisions.

Referencing Spec. 10-1.36 regarding cleaning underwater foundation concrete. Does 100% of marine growth need to be removed from concrete surface? Is leaving of basil plates acceptable?

Yes! All materials other than concrete shall be removed. 100% of "plants, marine growth and other materials" needs to be removed from concrete surface!

Will Caltrans send a diving team into the bay under the bridge to establish the existing conditions? It is necessary to know the amount and consistency of the silt that has drifted next to the belled piers and the quantity and location of the existing old piles that where abandoned when the old bridge was removed. All the existing elevations next to the piers seem to have come from the as-built drawings. Do you really think these elevations have not changed in thirty years? The piles from the old bridge should be directly south from the new structure and could severely damage a barge during tidal fluctuations. If these items are not cleared up prior to bid time, Caltrans could be opening themselves up for a very large differing site condition claim if the existing conditions are substantially different.

Caltrans Office Of Structures Maintenance and Investigations keeps records of Pier soundings which are updated every 4 to 5 years. These should be available for viewing with the other as-built information in the District. The contours shown on the contract plans are based on an investigation, not on the as-built plans.

Sheet 100 of 408 & 99 of 408 shows a rebar cage assembly at top of piles. 1) What item is this cage paid under? 2) It show the #14 as hoops & #8 as verticals, should this be reversed? #8 as hoops & #14 as verticals.

1) Section 10-1.22- Next to the last paragraph- "Pin reinforcement will be paid for as bar reinforcing steel (Epoxy Coated) (Bridge)"

2) Page 99 Section A-A shows #14 hoops and #8 vertical bars. This is correct.

Please confirm that if a contractor or fabricator establishes a facility at a staging area for the manufacture or assembly of the piling or casing, prevailing wages apply to the work performed at that facility.

Prevailing wages shall apply to any location or facility that is established solely or primary for the purpose of contributing to any project under the administration of the awarding contractor.

Section 10-1.16I ACCESS OPENING, DECK and Section 10-1.16J ACCESS OPENING, SOFFIT of the Specifications indicate that flame cutting of existing girder members will not be allowed.

No. The Plasma Arc Method and Carbon Arc Gouging Method are too hot. The intended methods are mechanical or water cutting.

According to page 220/229 of the San Mateo-Hayward Bridge Improvements Foundation Explorations, there is no bedrock near the west end of the bridge, in the vicinity of piers 2 and 3, which is the location of the test borings. Do you anticipate hitting bedrock in the test borings? If so, at what elevation?

There is bedrock at Piers 2 & 3. CIDH piles are used there to allow coring into the bedrock and an extended reinforcing cage is required. See page 21 of 229 for elevations and requirement for test borings at the pile locations. See present borings for best information.

The SP's state that 10 water samples will be collected prior to start of work, and 30 water samples shall be collected at various times during the contract. Are you talking about a total of 40 sample events here? In other words, when we come out to collect will we be taking one sample at a time, or several?

Sampling could occur on as many as 40 seperate days. The Engineer shall determine when and where the sampling occurs based on when and where the Contractor is disturbing the existing paint system in order to determine if the limits are being exceeded and to monitor water quality.

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