Dam Pier Concrete Repairs, Montgomery Locks and Dam, Monaca, Beaver County, Pennsylvania

The U.S. Army Corps of Engineers, Pittsburgh District, has a requirement for a project at the Montgomery Locks and Dam which comprises eleven (11) concrete dam piers, each measuring approximately 15’-9 ¼” wide by 87’-0” long by 58’-6” high, with an elevation of 664.5’ above the normal lower pool level. These piers were originally constructed in the 1930s and are currently exhibiting an overall fair to poor condition. Common deficiencies observed in the piers include delamination, spalls with exposed reinforcement, failed patched areas, and significant cracks in multiple locations.

Of particular concern are the pier noses, which are in poor condition, characterized by heavy efflorescence build-up, spalls with exposed reinforcement, unsound patched areas, and cracks up to 1” in width. To mitigate these issues and enhance the structural integrity of the piers, the selected contractor will undertake a series of maintenance efforts, focusing on concrete repair and epoxy grouting of cracks.

Scope of Work:

The dam pier concrete repairs involve the following key activities:

1. Survey and Assessment: Conduct a comprehensive survey of the concrete surfaces to assess the extent of damage and identify specific areas that require repair.

2. Concrete Repair: Remove and replace spalled and/or unsound concrete in the piers to restore their original strength and integrity.

3. Crack Grouting: Utilize epoxy grouting techniques to address and stabilize cracks in the concrete surfaces, preventing further degradation.

4. Installation of Government Furnished Flashboard: To facilitate repairs to the piers immediately adjacent to the fixed crest weirs, the Contractor shall install and remove the Government Furnished Flashboards in order to reduce the river flow overtop of the weirs. Only one set of flashboards is provided sufficient to close off the river flow in one of the two fixed crest weirs sections at a time. This flashboard system shall be returned to the Government at the conclusion of the contract.

The Contractor may utilize commercially available ready mix concrete deliveries for the concrete repairs as specified in the package. Deliveries of the concrete materials may be provided at lock wall adjacent to the land chamber and shall be coordinated with the Contracting Officer and Lock Master in advance prior to delivery.

Only one lift gate maybe closed at one point in time and the adjacent two lift gate on either side of the gate bay where dam pier concrete repairs are being performed will be placed in restricted status. The concrete repairs may be performed in one gate bay or fixed weir section at a time. Gate schedules are provided in the solicitation documents. In two of the gate bays identified on the drawings, concrete repairs are required upstream of the lift gate and downstream of the dam bulkhead. The dam maintenance bulkheads will be installed by Government personnel in these two gate bays upon advanced notification by the Contractor. Water leakage will occur through the dam bulkheads and the Contractor will need to prepare this leakage within their workplans.

Currently there are two active Contracts performing construction at the Montgomery Locks and Dam. Additionally, future contractors will be added to the site to perform more work during this Contract Period of Performance. The contract work in this solicitation package is critical to be performed within the prescribed construction timeline to ensure this work is adequately completed prior to the new Lock contractor mobilizing to the site.

All construction demolition material shall be removed from the construction site and disposed of in an appropriately permitted facility.

Project Timeline:

The project is anticipated to commence on 6 January 2024 and must be completed by 30 June 2025. The contractor must adhere to the agreed-upon schedule to avoid any disruptions to other project work and dam operations.

Contract Requirements:

Interested contractors must possess relevant experience in dam pier concrete repair, epoxy grouting, and have access to floating plant equipment and be able to work along the downstream face of the dam within the Ohio River.

The work shall be completed within 540 calendar days after written Notice to Proceed.

Per FAR 36.204(g) the magnitude of construction is between $5,000,000 and $10,000,000.

This acquisition will be procured as unrestricted Solicitation. The resulting award will be for one (1) Firm-Fixed-Price (FFP) Contract. All responsible Bidders are encouraged to participate. The Invitation for Bid (IFB) will be issued on or about 29 September 2023, online through Procurement Integrated Enterprise Environment (PIEE) which posts the opportunity to SAM.gov; therefore, requests for hardcopies of the solicitation will not be honored.

The North American Industrial Classification System (NAICS) for this procurement is 237990 – “Other Heavy and Civil Engineering Construction” and the small business size standard is $45 Million.

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