CONTRACTOR'S INQUIRY RESPONSES NO. 3

NOVEMBER 15, 1997,


BID SUMMARY RESULTS
MORRISON KNUDSEN TRAYLOR BROS $ 102,436,598.00, AWARDED NOV. 15, 1997
TUTOR SALIBA KOCH DUTRA JV $ 113,497,508.00
FCI CONSTRUCTION INTERBETON JV $ 138,497,508.00

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

Air monitoring is to be performed "at least once a week during progress of work that disturbs the existing paint system." How many weeks will the work last? If we get results above the PELs, will we go to monitoring every day, and how do you want us to treat this contingency in the bid price?

The duration of work that disturbs the paint system will be determined by the Contractor so direct your question there. If limits are exceeded, the Contractor is responsible to get quality back to normal (the Contractor will have to do additional testing at his expense to show he has accomplished this).

Bid Item 69 - Install Seismic Monitoring Casing

1. a) Is the 50 foot deep hole shown on the plans (Sheet 616) supposed to be Item one of 10-1.34, which is to drill a 3-inch diamber hole?

b) Or, how deep is the 3-inch test hole supposed to be?

c) At what depth do you anticipate bedrock?

d) What is the bedrock (greenstone, graywacke, melange, serpentine, etc.)?

1a &1b) No! The items in 10-1.34 are listed to generally explain the order of work. Requirements for the work follows general explaination. See Borings on page 109, especially para.3, 6 & 7 .

1c&1d) Review the LOTBs and as-built information.

2. Item two of 10-1.34 states that State forces will perform P-S suspension logging. This boring will most like cave without casing unless the logging is done immediately after drilling. Are we to provide casing during drilling?

2) A casing does not appear to be required by the plans or specs. If the engineer determines that a casing will be needed for the 3" hole, a CCO will need to be written.

3. Is the 130-foot-deep hole on the plans (Sheet 616) supposed to be item three of 10-1.34.

3) See 1a &1b) above.

Please verify if the 2" deck plates which are included in the expansion joints are to be galvanized.

That is what the specifications read.

Reference: Special Provisions Section 10-1.29, Paragraph 6, "All metal parts of the joint seal assembly shall conform to ..."Miscellaneous Bridge Metal" of the Standard Specifications."

That is what the specifications read. Reading this specification will help you with question 1) above.

Bid Item 10-1.34 calls for the installation of "seismic monitoring equipment at downhole locations shown on the plans in the vicinity of Pier 18." Pier 18 is in the San Francisco Bay. The plans show the location to be on land along the northwest side of Highway 92 along the access road that runs under the western bridge approach. Is the location on the plans correct, or is this location in the bay?

All of the details shown on the plans work for the casings located near Abutment 1. See Addendum No. 8 for additional information.

On Bid Item 10-1.34, do you want cores to be handled in the same way that is required in the test borings section (Bid Item 10-1.1B)?

Test borings are required, but handling of the cores is different. Unless the special provisions for "Install Seismic Monitoring Casing" refer to "Test Borings", "Test Boring" requirements would not apply.

Again, on Bid Item 10-1.34, what is the surface elevation of the location for the seismic equipment installation? At what elevation do you expect to hit bedrock?

Assuming the plans are correct regarding location of the casings, the elevation can be ascertained by a site visit or by studying as-built plans. Use the new and as-built Log Of Test Borings and materials information to estimate bedrock elevation.

Ref. Addendum #6, Dwgs # 84 & 85 of 229 The notations in the transverse elevation views that reference note 14 on dwg. #84 and note 16 on dwg. #85 are not clear. The bottoms of the spandrels have completely different patterns and angle stiffener layouts than the towers. Bolt details are not shown separately. Also what is the configuration and length of the plates under the spandrels? Are these spandrel bottom plates to be welded or attached to the tower plates on the inside of the arch?

Assume Contractor's reference to page 85 is really to page 89. There is no "Spandrel Bottom Plate". The notations in the transverse elevation views and the notes refer to tower plates. The top of the tower plate is to be placed 1" below the soffit of the spandrel and the bolt details are similar to the bolt details for the outside tower plates.

Please comment on the following: 1) Find only 120" dia piles @ Pier 38 [which] have full length (less 50ft) rebar cages.

1) At Pier 38A there are such piles. Pier 38 has 60" dia piles.

2) Also only piles to [be] painted are the 120" dia piles at Pier 38. Upper 15 ft.

2) See "Open ended Cast-In-Steel Shell Concrete Piling" on page 83. Pier 38A is painted for the top 15' of shell.

The special provisions state that Non-Destructive testing of all welding is the responsibility of the Contractor. AWS D1.5-95, Section 6.7 states that radiograph testing is required for all full penetration butt welds in main members subject to calculated tension or reversal of stress. For the purpose of applying Section 5.7 of AWS D1.5-95, are the column casing butt welds considered to be "main members subject to calculated tension or reversal of stress" and therefore required to be radiograph tested?

See "Welding" on page 107 of the special provisions and Addendum #6.

Refer to Sheet 98 of 308 and various references on other sheets to the grout bags in the corners of the new footing build-ups. Do the corners of the footings get blockouts to install the grout bag assemblies after placement of the footing concrete or do the grout bag assemblies get cast in place with the footing? If the intent is to blockout the concrete in the corners, what are the dimensions of this area?

See "Concrete Corner Detail" in upper left hand corner of sheet 98 of 308. Details and dimensions are shown and location of grout bag is given.

Please provide an analysis of the existing paint on the bridge. We need to know the levels of the metals present in the paint to be able to determine the appropriate safety plan for handling and disposing of it.

This information is included in the materials information handout for this project.

Reference Special Provisions Section 10-1.39 (Clean and Paint Existing Structural Steel). The spec states that the steel is to be cleaned by a fresh water pressure wash and then a blast cleaning. We believe the blast cleaning will sufficiently clean the surface of the structural steel and the fresh water pressure wash is unnecessary. Please advise.

The pressure wash is to remove salts. Bid it according to the plans and specifications.

The epoxy coated bar specified for the reinforcing steel supply can only be obtained from one source.

A934 epoxy coated reinforcement is used for marine environments. Caltrans has determined 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.

Is it possible to substitute reinf. steel coated with epoxy prior to fabrication for the rebar coated after fabrication as specified?

The epoxy coating shall be applied after the bar is fabricated to its final shape. After the epoxy coating is applied, no further bending or fabrication will be allowed

Are the # 14 hoops and #8 verticals shown on the pin diagram on page 99 of 308 correct?

Yes

"Measurement and Payment" for steel pipe piling for CISS, CIDH shall not conform to the provisions in Sections 55-4.02 "Payment" for steel structures of the Standard Specifications as specified below. Please confirm. See revisions to 10-1.33, "Steel Structures" Subsection, Measurement and Payment in addendum #6.

Is there any reference to Section 55, "Steel Stuctures" in Section 49, "Piling"? I do not see one! It is up to the Contractor to confirm this.

Please clarify if the Department will retain care and custody of the bridge for the duration of the project and, as such, maintain in place insurance policies sufficient to cover damages, including both direct and consequential claims made by the public, that may arise from any incident/accident, however caused, which may occur during the project. If so, please provide details of any policies.

Please refer your attention to standard specifications Sections 7-1.08, "Public Convenience," 7-1.09, "Public Safety," and 7-1.12, "Responsibility for Damage."

Please clarify if it is the Department's intent that liquidated damages set out in Section 10-1.11, Maintaining Traffic, relate solely to the Contractor's failure to close and/or re-open lanes in conformance with the "Lane Closure Charts" and which would typically take place at "one end or the other" of a scheduled lane closure. (i.e. for reasons which are within the control of the Contractor such as poor planning, or poor execution of the work).

Liquidated Damages for Maintaining Traffic will apply due to poor planning or poor execution of the the work by the Contractor.

Please clarify if it is the intent of the Department to globally assess liquidated damages set out in Section 10-1.11, 'Maintaining Traffic," should an accident/incident take place which closes any-or all the traffic lanes for reasons which are beyond the Contractor's control. (i.e. traffic accident, insurable construction accident such as crane boom falling accross the bridge deck, etc.).

Liquidated Damages for Maintaining Traffic will apply in accordance to standard specifications Sections 7-1.08, "Public Convenience," 7-1.09, "Public Safety," and 7-1.12, "Responsibility for Damage."

REFERENCE SHEET 96 OF 308 - PIN HOLDER ELEVATION. THE DIMENSIONS ON THE DRAWING INDICATE THAT THE PIN HOLDER IS TO BE 24" OD PIPE 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.

See Addendum No.6

There seems to be a conflict in elevations for the larger column casings (piers #6 -11, 30-33). Using pier #6 as an example; Top of footing el. -11.00 plus 3'-0" footing buildup sect d-d el. -8.00 plus 2'-0" concrete stub sect d-d el. -6.00 plus 2" gap to bottom of casing el. -5.83 (see page 67, 85, and 118) whereas the table on sheet 118 gives the bottom of casing to be -7.83. This conflict is repeated on all the above mentioned piers. Please clarify.

See Addendum No. 6.

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?

See Addendum No. 6.

Does Section D-D for Piers 12-13 on Sheet 93 of 308 show the correct number of #11 reinforcing bars? If it is correct, where do the bars showing in C-C end?

See Addendum No.6.

Numerous details show holes to be cored through existing steel plates and into concrete. Is the hole through the steel plate to be measured and included in the concrete coring item for pay? Or is the hole in the steel plate to be paid as part of the Bridge Demolition item?

See Addendum No.8.

In special provisions page 97, 10-1.30 under "General" it refers to anchor bolts. Is this paid for under rebar?

See Addendum No. 8.

Reference Special Provisions Section 10-1.40 Miscellaneous Metal (Bridge) 1) Please furnish details and quantities of metal railings, as listed in third item list of requirements, but not shown on expansion joint assembly drawings per note 2 on sheets 222 and 226.

There does not appear to be metal railing on these sheets.

2) Please clarify: all miscellaneous metal items are hot-dip-galvanized, except, "metal railing, curb, and sidewalk (plates)", per special provisions; are "sidewalk plates" the 2" deck plates, as shown on sheets 219 and 223? If so, these plates are to receive a non-skid surface, and according to non-skid surface requirements they are to be "galvanized" prior to application of non-skid surface. If not, where are sidewalk plates on drawings?

The standard specs require galvanizing of items not otherwise noted in the specials. The flat, horizontal, curb plates (1/2" x 35" x 6'-0") are to receive non-skid surface and must be galvanized prior to its application. The vertical curb closure plate (1/2" x 8" x 1'-11") and railing closure plate (3/8" x 18" x 2'-4") are to be painted and hence are not galvanized. The 2" deck plate is included in the Expansion Joint.

Regarding the Pin Holder and bering Plate/Sleeve Assembly shown on drawing Sheet 52 of 229: A. What are the roundness and straightness tolerances? B. Who makes these pins and sleeves? C. If splicing or other weld joints (long seam) are required, can back-up bars be used? What NDE would be required? Can we leave the weld reinforcement?

A) See ASTM A519 Standard for Seamless Tubing (Ref General Note on page 65 of 308). B) Many specialty steel companies can provide this type of pipe and assemble the holder and pin. C) Field welding is not allowed. NDT will be required. Backup bars must be removed and welds ground flush on inside of retainer and outside of pin.

Please confirm existing bolts are 1" diameter @ steel tower column and spandrel splices.

See as-built plans and shop drawings.

Reference Special Provision Section 10-1.33: Is vibration stress relief of weld assemblies thermal [thermal] stress relief specified?

See Addendum No. 8

Ref. Sheet no 109 of 308, Section H-H: What bid item is to include key plate assemblies?

"Key plates"are listed in "Structural Steel Materials", in Table on page 105 of the special provisions. Bid items are 59 & 60.

Special Provisions prohibit removal of portions of steel girders by flame cutting. Is flame cutting acceptable for removing portions of steel towers? (i.e. spandrel access openings at sht. No.150 of 308).

No. Flame cutting of girders is not allowed.

Ref. Sht. No.148 of 308 "Anchor Bolt Assembly Detail": Please confirm field drilled holes through existing base plates are required for new anchor bolts and provide hole diameter.

It would be difficult to place the anchor bolts without coring a hole through the base plate. Diameter is 4 1/2".

Ref. Sht. No. 237 of 308: Please confirm field drilled holes through existing base plates are required for new anchor bolts and provide hole diameter.

It would be difficult to place the anchor bolts without coring a hole through the base plate. Diameter is 2".

Ref Sht. No. 128 of 308: please confirm table 2 - "Approximate Area of Clean and Paint Structural Steel" represents 17,300 lf of 6" wide clean and paint. This relates to Caltrans response to Karl Koch question #2 of Inquiries Responses (Fax #1) dated 8/14/97.

See revisions to plan sheet 128 in addendum #6.

Bid Item 64 "Clean and Paint Structural Steel (Existing Bridge)" covers cleaning and painting for tower retrofit per table 2, Sht. No. 128 of 308. What bid item covers cleaning and painting at hinge retrofit per note 2, Sht. No. 157 of 308?

Bid item #64 covers Clean and Paint Structural Steel (Existing Bridge) for entire structure. However, note that the superstructure surface areas requiring Clean and Paint Structural Steel (Existing Bridge) should be a very small percentage of the total.

Special Provisions section 10-1.33 specifies hanger rods to be ASTM A709 Grade 70 "as shown on the plans". Plans do not indicate grade for hanger rods (Shts. No. 158-178 of 308.)

See Addendum No. 8.

In reference to San Mateo-Hayward Bridge; Contract No. 04-0436v4 Special provisions; page 107, Welding : All welded assemblies shall be furnace stress relived after welding and prior to finishing (see attached page 107). Please clarify or define all welded assemblies that will be subject to furnace stress relive process. * Column tower plate base & anchor assembly? * Shear pin pipe sleeve? * Tower ladders and platform? * Hinge Retrofit Shear Lock Top & Bottom Assembly? * Hanger Rod brackets? * All restrainer reaction beams? * Connection beams (HP) for Longitudinal restrainer? * Key plate, Transverse & Longitudinal Brackets (Pier 38A)? * Bearing Retrofit brackets? * Other items (Please define)?

See Addendum No. 8.

Plan Drawing 173 (titled: Deck Access Opening Details), calls for four (4) deck openings at the Type F hinge near Pier 19, and four (4) deck openings at the Type E hinge near Pier 20. Plan Drawings 227 thru 234 (titled: Pier 38A - Box Girder Strengthening Details), call for eight (8) deck openings at Pier 38A. There appears to be a total of sixteen (16) deck openings.

See Addendum No. 8.

Bid Item 16 - Access Opening, Deck and Section 10-1.16I of the Special Provisions seem to relate to all of the above locations, but the bid item quantity is eight (8). Please clarify which of the sixteen (16) access deck openings are intended for Bid Item 16.

See Addendum No. 8.

Bid Item 43- Close Access, Deck and Section 10-1.26 of the Special Provisions also seem to consider all of the above mentioned locations, but the bid item quantity is eight (8). Please clarify which of the sixteen (16) access locations in the deck are closed in Bid Item 43.

See Addendum No. 8.

Addendum No. 6, changed the soil plug on the CISS piles (Sheet 100 of 308) from 30' minimum plug to 30' plug. Is it Caltrans intent to fill all the piles except the bottom 30' with concrete thus adding 15,600 additional CY of concrete to the project?

See Addendum No. 8.

Ref Plan Sheet 65 of 308. General Notes: For anchor bolts at Tower Base Anchorage Assemblies, the ASTM Grade 75 material specified is not available. Please advise.

ASTM specified material should be available. Suggest contacting a high strength bar supplier.

Ref Plan Sheet 128 of 308, Table 2: Can the "Approximate Surface Area of Welds to be Ground Smooth" data be equated to lineal feet of weld to be ground smooth? Data in this form would be much more meaningful in the preparation of our cost estimate.

See Addendum No. 8.

Ref Plan Sheet 129 of 308, Note 1: If optional tower plate splices are not used, tower plates will require splicing in the fabrication shop. Please provide welded shop splice detail.

See Addendum No.8.

Ref Plan Sheet 129 of 308, Note 14: Are bolt details for the top of Inside Transverse Face Tower Plates to be per Column Top Transverse Face Detail on Plan Sheet 133 of 309? (Similiar question at Piers 18 & 21)

See Addendum No. 8.

At bottom of page 58 on the left side of the Special Provisions, it states that air samples will be performed for "other metals." Typical other metals in lead paints are arsenic, cadmium and zink (and possibly copper). What other metals do you want to look for? Do you want tests for air borne silica? My CIH tells me that it is often cheaper to run an ICAP scan which gives you CAM-17 metals plus other metals (silica?). Is this acceptable?

See page 57, second paragraph for all different type of detectable metals. Work area Monitoring on page 58 goes on to say, "Air samples for other metals shall be collected and analysed in accordance with NIOSH Method 7300...". Alternative methods .....with equivalent limits of detection, may be used.....

The SPıs 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.

Air monitoring is to be performed ³at least once a week during progress of work that disturbs the existing paint system.² How many weeks will the work last? If we get results above the PELs, will we go to monitoring every day, and how do you want us to treat this contingency in the bid price?

The duration of work that disturbs the paint system will be determined by the Contractor so direct your question there. If limits are exceeded, the Contractor is responsible to get quality back to normal (the Contractor will have to do additional testing at his expense to show he has accomplished this).

The BCDC permit Number M97-6 states all dredging must be complete in 30 months after the permit was issued. Permit was issued on 27 March 1997. Therefore, dredging must be complete by 27 September 1999. Addendum No. 4 changed completion date from 450 working days, approximately 92 weeks or approximately 15 July 1999 to 760 working/calendars days, approximately 108 weeks or approximately 8 November 1999. If the dredging permit is not extended to allow dredging to the end of the 760-day period, the extension of time granted by Addendum No. 4 is compromised. We request that dredging permit be extended to match the life of the job.

Dredging operations shall not last the life of the project. See addendum No. 8 for additional information.

Addendum No. 8 now requires transportation for the engineer. One of the requirements is "The boat operator and crew shall be furnished for 10 hours each working day as defined by Section 4 of the specifications which include "Saturdays, Sundays and Legal Holidays?"

The Contractor shall provide the boat operator and crew for everyday that the Contractor is scheduled to work including Saturdays, Sundays and Legal Holidays.

Item No. 10 of Section 5-1.22, "Relations with U.S. Army Corps of Engineers," page 23 of Addendum No. 8 of the specifications for the subject reads: "All debris generated by construction activities, which falls into the Bay and is larger than 24" in diameter shall be removed by the Contractor." Does this infer that temporary tremie concrete used to seal off the cofferdams, if broken into pieces smaller than 24" in diameter, does not have to be removed?

No. The Contractor must contain and collect all construction debris generated by the work. This provision is to prevent the Contractor from having to removed the small debris which may accidentally & inadvertently fall into the Bay. It is not intended to allow the Contractor to pulverize materials and leave them in the Bay.

What area is included in the 5,000 square feet maximum of temporary fill to provide construction access to the bridge, as defined in Addendum No. 8, page 25, Section 5-1.25, "Relations with Bay Conservation and Development Commision?"

All new structures that extend over new areas of the Bay which have not been previously shaded by any existing structure, including new deck, piles, etc..

What hours of the day can the PG&E transmission lines be deactivated?

" The Contractor shall make all necessary arrangements with PG&E and any California Independent System Operator (ISO), who may be responsible for transmission system operation after January 1, 1998, at least 30 days prior to any proposed de-energizing to obtain a clearance from the utility company. The designated contact person at PG&E for requesting such clearances is Alain Billot, who can be reached at (415) 973-5401 or by e-mail at "ajbl@pge.com."


For comments or suggestions regarding the Toll Bridge Web Site,
Email: Bernie_Edrada@dot.ca.gov