Dutra Dredging Company
1000 Point San Pedro Road
San Rafael, CA 94901
415 721 2131





November 22, 1996                                       Serial Letter No. 0194


Department of the Army
San Francisco District, Corps of Engineers
333 Market Street
San Francisco, CA  94105-2197

Attention: Leonard SooHoo, Administrative Contracting Officer

Reference: Contract No. DACW 07-95-C-0003

Subject:  Navy Sewer Line Crossing, Information sent to Union Pacific Railroad


Dear Mr. SooHoo:
Attached please find copies of the information provided the Union Pacific Railroad regarding the Sewer line Crossing and our shoring design.

Beside the information attached we sent the Union Pacific Railroad a set of the plans.

If there is more information we can provide, please contact us.

Sincerely,

DUTRA DREDGING COMPANY



Robert D. Johnston
President

RDJ/lgd




-42' NAVIGATION IMPROVEMENTS, OAKLAND INNER/OUTER HARBOR
INSTALLATION OF 20" DIP SEWER LINE
PERMIT TO CONSTRUCT, UNION PACIFIC RAILROAD YARD
CONSTRUCTION DOCUMENTS

TABLE OF CONTENTS


Executive Summary.......................................................... i

Operation Plan............................................................. 1

Bore/Jack Pit Sheet Pile Wall Design Calculations.......................... 8

Braced Cut Shoring Design Calculations.................................... 23

H-PileJPlate Shoring Design Calculations.................................. 28

Soil Data from Previous BoringslTest Pits................................. 40

Appendix: Contract Specifications......................................... A-1







-42' NAVIGATION IMPROVEMENTS, OAKLAND INNER/OUTER HARBOR
RELOCATION OF NAVY SEWER LINE
PERMIT TO CONSTRUCT DOCUMENTATION
FOR
UNION PACIFIC RAILROAD
Prepared By:
DEBRA DREDGING COMPANY

EXECUTIVE SUMMARY

As part of the Oakland Harbor Deepening Project, Dutra Dredging Company must relocate and install a new 20" DIP sewer force main. The sewer line work consists of installing the new main from a valve box on the Alameda Bank, across the Oakland Estuary, beneath a rail line in the UPRR Oakland Intermodal Yard, and to an existing valve box on that property. The new line will replace the existing 16" line currently in use.

Work that will occur on UPRR's property includes:

The project is expected to begin in late June/early July and complete in late August, with work in the UPRR yard occurring intermittently during that time.

Work on UPRR property will be contained within a 40' wide (North-South) by 140' long (east- west) area as shown on the attached Figure 1. A cross section of the work is shown on Figure 2. Within this area, the sequence of work will be as follows:


   1. Installation of PZ 27 sheet piles (26' long) for jacking pit with W 14 x
      89 bracing: Area of 10' X25'
   2. Installation of W36 X 150 piles and 11i2" steel plate for waterside track support
   3. Excavation of jacking pit (9' deep excavation)
   4. Bore and jack 42" X 'a" thick seamless steel casing under track
   5. Install PZ 27 sheet piles for braced cut
   6. Excavate, install wales (W 18 X 40) and struts (6 X 12 Doug Fir) for
      braced cut
   7. Install pre-cast valve box
   8. Install new 20" DIP; pressure test pipe


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9. Make new connections 10. Backfill and compact over excavations, remove sheet piling & shoring. 11. Repair of any damage to asphalt, etc.
Work mill progress more or less continuously during the time frames mentioned above, with days of inactivity interspersed based on the schedule. We intend to work Monday through Friday, 0700 hrs to 1500 furs. The new connection must be done in a three hour period on a Friday evening after midnight. At this writing, the new connection will occur on 16 August 1996. This date could change either way based on the schedule.

We expect to have the following equipment on site at different times during construction:

The points of contact with the UPRR will be Mr. Jeffrey McWilliams, Project Superintendent, and Mr. Jack Fink, Project Engineer. We will set up a pre-construction meeting with UPRR site personnel to discuss the project, logistics, schedule, and communication procedures.

This submittal encompasses all of the information and documentation we feel the UPRR needs in order to complete the permit to construct. Attached are the following documents:


   1.  Complete set of bid plans and specifications
   2.  AutoCAD drawing of the pipeline route
   3.  Design calculations for the shoring
   4.  Soil boring results
   5.  Other soil data for the area
Should any more information be required, please contact Mr. McWilliams at (510) 444-8496 or Mr. Fink at (510) 444-8538. The fax number at our office trailer is (510) 444-8527.

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Figure 1 Oakland Bank NOTE: FOR A MORE DETAILED PLAN SEE SHEET 9 [This document is a plan drawing of the Navy Sewer Line crossing under the Union Pacific Railroad track. It identifies sections AA and BB along the sewer line, and it shows secton EE as a cross section approximately perpendicular to the railroad line.] [It has the following additional notes:] PILE/PLATE SUPPORT [This note is near the South East corner of the work.] (MINIMUM 10' RAIL) NO [This note is on the North side of the RR SHEETPILE NEEDED HERE track] (MINIMUM 10' RAIL)
Figure 2 Oakland Bank Profile Section E-E [This document is a cross section drawing of the Navy Sewer Line crossing under the Union Pacific Railroad track. It appears to be the section EE on Figure 1 that is running approximately perpendicular to the railroad line.]
Union Pacific Railroad Co. General Shoring Requirements [This document appears to contain information that must be supplied showing compliance with the railroad's shoring requirements, called out on sheet 8 of 20 in the contract plans for the Oakland Harbor Project, requiring the contractor to obtain a permit from UPRR. This document has the following note:] Plans of shoring to be submitted to General Director-Design for approval prior to excavating. For excavations which encroach into railroad live load surcharge zone, shoring plans to be accompanied by a copy of the design calculations, and both to be stamped by a registered professional engineer. Shoring is subject to approval of General Director-Design who reserves the option of imposing more stringent requiremetns as conditions warrant. All dimentions measured at right angle to track. [There is a cross-hatched symbol that shows slope material adjacent to the railroad and this symbol is identified as follows:] Shoring for excavation to be designed for railroad live load surcharge in addition to soil pressure.
OPERATION PLAN
OAKLAND -42' NAVIGATIONAL IMPROVEMENTS INSTALLATION OF 20" DUCTILE IRON PIPE SEWER LINE The following is a description of the procedures involved with the installation of the new 20" diameter sewer line, required testing, connection of the new sewer line, the disconnection of the existing 16" line, and the removal and disposal of the existing 16" sewer line to the extent shown on the plans and stated in the specifications. Railroad Crossing The railroad tracks in the Union Pacific Intermodal Yard on the Oakland Bank, in the vicinity of the new sewer line location (E 1,476,755.961, N 476,656.096), will be protected on both sides as required. On the north side of the tracks, a sheet pile wall will be driven at least 10 feet off the tracks to protect and support the railroad tracks from the trenching that will be required in that area. On the south side of the railroad tracks a H-pile and steel sheet lagging wall will be installed as necessary, at least 10 feet off the railroad tracks to protect the tracks from any jetty rock removal and trenching that is needed to install the new sewer line. The design and shop drawings for the sheet pile wall and H-pile walls are attached. A complete and thorough check for any and all utilities that are in the work area will be accomplished prior to any work being performed. All utility companies involved will be notified and informed as to the limits of the work area. The first phase of work will be to install the sheet piles and H-piles. To accomplish this a truck crane or crawler crane of adequate size will be brought in along with the appropriate impact hammer, piledriving leads, driving head, and any material for a driving template that is required. The 1
asphalt concrete in the area of the sheet pile wall and also any areas that require trenching, will be saw cut and removed. The work area on the Oakland Bank is approximately 140' by 75', and 250' by 135' on the Alameda Bank. Work will commence on the Oakland Bank first. After the pile locations have been surveyed in, the H-piles will then be driven first. After completion of the H-pile driving, the sheet piles on the north side of the tracks will then be driven to the required depth. At the completion of the pile driving, the boring and jacking subcontractor will come in and open up the jacking trench. After the trench is opened up, the jacking subcontractor will install the 42" steel casing under the railroad tracks. At this point, Dutra Dredging Co. will begin work on both banks, opening up the required trenching for the installation of the new 20" sewer line, and associative valve boxes and required thrust blocks. The landside piping and all new valve boxes, thrust blocks, and valves will be installed to the extent possible at this time. Underwater Trench Concurrent with the landside work, The Derrick Barge #24, or other available dredge, will begin dredging the underwater portion of the pipeline. The trench for the new 20" sewer line is at a 50' offset to the east of the existing 16" line. The landside limits of the existing 16" line will be marked prior to excavation of the new trench. The location of the existing 16" line and the limits of the new trench will be plotted into the Hypack Positioning system on the dredge to show the dredging template for the trench while also maintaining a safe distance from the existing sewer line. The dredging will commence on or about the 4th of June so that approximately four loads of material will go to the ocean disposal site for the plankton study. The remaining sand removed from the trench excavation will be stockpiled, space permitting, for backfill after the pipe is installed. The trench will be excavated from elevation -38 to elevation -57, within the limits of the channel boundaries, with side slopes large enough to maintain the integrity of the trench. Once the channel limits of the trench have been excavated, the slopes up to the Jetty limits will be excavated. On both banks, the 2
landside equipment will begin to remove the rock from the jetty and begin excavating the trench down the slope to the approximate elevation of -10 MLLW. During the dredging phase, the trench will be surveyed on a daily basis to ensure that the trench is remaining open and staying true to grade. The new 20" pipe is scheduled to be delivered to Alameda the week of July 1 st. The pipe will be delivered to the construction area on the Alameda Bank, off loaded with a crane, and stockpiled in the construction area. When the trench excavation is nearing completion, the pipe will then be assembled on rollers, on the Alameda Bank. There are two methods of installation under consideration at this point. The first and most common method of installation for this type of pipe is to pull the pipe. Once the trench has been completed, a final survey will be performed to check the trench for both alignment and grade. A factory supplied pulling head will then be attached to the pipe. A winch, stationed on the Oakland side of the estuary, will then run its wire through the trench to the Oakland Bank and be secured to the pulling head. The pipe will then be pulled from the Alameda bank, into the trench, and will end up at the toe of both jetties. At this point the pulling head will be removed. The trench will then be surveyed again, over its entire length, to ensure that the pipe is in the proper location and at the proper elevation. A Notice to Mariners will be issued prior to the pipe being pulled across the estuary. The estuary will be off limits to vessel traffic during the pulling operation until the pipe is securely in place on the bottom. The pulling operation will take place at off peak hours so as to minimize any effect on vessel traffic through the area. The pipe running down the slopes through the 42" pipe casings will then be installed from land with a crane. The final connections at the toes of the jetty will be made underwater with the use of divers. 3
A second method of installation under consideration will be to lay the pipe off a barge from one bank to the other. The pipe would be assembled on the deck of the barge, set in the water and sloped down to the trench as the barge moved from the Oakland Bank to the Alameda Bank. This method of installation would be a continuous process until all the pipe had been installed. The final connections at the toes of the slope would again be made with divers. After all the pipe has been installed, joints completed, and the thrust blocks have been in place for at least five days, the pipe will be prepared for the pressure test. The pipe will be filled with water to expel all the air and tested to 150 percent of the working pressure for a period of one hour. The hydrostatic pressure and leakage tests will be performed by an independent testing laboratory familiar with this type of test. The Contracting Officer will be informed prior to the test so that he may witness the tests if so desired. Complete test results will be forwarded to the Contracting Officer upon receipt from the testing laboratory. Only water from the top portions of the pipe will be drained out after the tests. The water will remain in the lower limits of the pipe until after its hookup with the system. Backfilling Trench After completion of a successful pressure and leakage tests, the pipeline will be backfilled, starting with the underwater portion first. The Derrick Barge #24, or other available derrick barge, will begin filling in the trench with the dredged material, or new sand as required, up to elevation -52.5 MLLW (+4", -0"). Once the sand level elevation has been verified by a hydrographic survey, the derrick barge will begin setting the bedding stone. Both the bedding stone and the armor stone will be purchased from the San Rafael Rock Quarry and delivered to the job site via barges. The bedding stone will be placed either by tremie or by a chute to minimize segregation. The bedding stone will be placed to its full layer thickness (elevation -52.5 MLLW to -51.5 MLLW, +6", -3") in one operation. The final elevation of the bedding stone will again be verified by a hydrographic survey. Finally, the armor stone will be set by the derrick barge using a clamshell bucket or skip 4
box. The final elevation of the armor stone will be elevation -49 MLLW (+/- 6") and will also be verified by a hydrographic survey. This will complete the backfilling of the underwater portion of the pipeline. Prior to any backfilling on land, plastic marking tape will be installed on all pipe that is on land and on the side slopes of the channel down to the toe of the jetties. The tape will be installed directly above the pipe at a depth of 18" below finished grade in all areas where it is practible to do so. The bedding stone will have been placed in the bottom of the trenches prior to any pipe installation on land. The sand layer will then be placed on top of the pipe and compacted with a vibratory smooth-wheel drum or base plate compactor. A one foot layer of bedding stone will be placed on top of the sand. A second layer of sand (1'-6") will then be placed on top of the bedding stone and again will be compacted. A final layer of earth backfill will be placed on top and compacted by hand operated machines to at least 90% maximum dry density. In areas where any blacktop or gravel was removed, it will be replaced in kind. Where the pipe casing runs through the jetty, the casing will be set on a sand base for leveling, and sand will also be put inside the casing to fill in around the 20" pipe. The jetty stones will be replaced where they were removed for the work. Final Connection of Sewer Line With the sewer line completely in place, including all new valve boxes, gate valves, etc., the line will be ready for a hookup to the existing 16" line on both banks. Prior to disconnecting the existing 16" line, the sewer line will need to be adequately flushed. This action will be coordinated between the Government and the U.S. Navy. The trench in the areas of the existing valve box tie-ins on both banks will be lined with plastic. This will contain any water that leaks out during disconnection of the existing pipe from draining into the soil. A pump truck 5
will also be in the immediate vicinity during the disconnection to immediately remove any water that does leak out of the existing 16" pipe. According to the specifications, there will be a three-hour time period in which to connect both ends of the new line into the system. The time will commence at midnight on Friday and end at 3:00 A.M. on Saturday with the new 22" sewer line being operational. Crews will be working on both banks to make the connections into the existing system. Communication with the respective sewer treatment facilities affected by the connection process, would be maintained at all times throughout the project. If for some reason the connection cannot be made in time, the old system will be hooked back up until the problem can be solved. If the connection can be made, but more time is needed, pump trucks will be called in or other arrangements will be made according to the affected treatment plants requirements. Once the final connections have been made and the new line is operational, the final backfilling in the areas of the connections to the existing system will be accomplished. The sheet piles and H-piles will then be removed and the areas on both banks will be cleaned up. Removal of Existing 16'l Line The existing 16" sewer line will be removed to the extent shown on the plans. The material will be dredged from on top of the line to the limits of the channel as shown on the plans. The pipeline will then be jetted by divers and the line will be disconnected from the portion that remains. The pipe that remains will be capped off and filled with concrete as required. The pipe that is to be removed will be jetted off by divers and pulled out in sections. 6