HomeMy WebLinkAboutHumpback Creek Hydro Project Final Construction Report - Nov 2012 - REF Grant 2195386
HUMPBACK CREEK PROJECT
FERC No. P–8889-046
PHASE 2 - INTAKE/DIVERSION REHABILITATION
CONTRACT NO. CEC-08-HBC-02
Reconstruction of Intake/Diversion Facilities
FINAL CONSTRUCTION REPORT
Period October 24, 2009 through June 14, 2011
CORDOVA ELECTRIC COOPERATIVE, Inc.
Cordova, Alaska
Contact:
Clay Koplin, P.E., CEO
Cordova Electric Cooperative, Inc.
P.O. Box 20
Cordova, Alaska 99574
Telephone (907) 424-5555
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November 2012
Humpback Creek Rehabilitation Phase 2
Final Construction Report
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TABLE OF CONTENTS
Section Page No.
CERTIFICATIONS ....................................................................................... ii
BACKGROUND ............................................................................................ 1
1. CONSTRUCTION SEQUENCE ................................................................. 1
2. MAJOR DESIGN MODIFICATIONS ....................................................... 2
3. QUALITY CONTROL TESTING RESULTS ........................................... 5
4. CONSTRUCTION PROBLEMS ............................................................. 10
5. INSTRUMENTATION ............................................................................. 11
6. PHOTOGRAPHS ..................................................................................... 11
APPENDIX A – As-Constructed Record Drawings
Humpback Creek Rehabilitation Phase II
Final Construction Report
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CERTIFICATIONS
Certifications by the Owner, Project Manager/Design Engineer, Project Engineer and Resident Engineer
that all construction, installation and remedial work performed under CEC-08-HBC-02, Humpback Creek
Rehabilitation Phase 2 was completed in accordance with the design intent and objectives are attached
hereto.
Humpback Creek Rehabilitation Phase II
Final Construction Report
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BACKGROUND
The Humpback Creek Project, FERC No. 8889-AK, is a “run of the river” hydroelectric project
located on Humpback Creek approximately 5.5 miles northeast of Cordova, Alaska. The project
was originally constructed in 1908 (unlicensed) and the intake/diversion was a log crib structure and
a wood-stave penstock conveyance structure that was routed to a powerhouse near the mouth of
Humpback Creek (HBC). The log crib dam still exists and retains a large volume of
gravel/cobble/boulder bed load which supports the right bank terrace extending upstream to a
narrow canyon.
On October 21, 1988 FERC issued the original License 8889 for the Humpback Creek Project. This
comprised a timber frame intake/diversion system built at the mouth of the narrow canyon and a
flume routed along the right bank of HBC to a new penstock which conveyed the water over a new
bridge to the new power house located on the left bank of the creek at the upper end of the
anadromous fish spawning reach. Stream conditions above the powerhouse are unsuitable for
resident or anadromous fish due to stream morphology and hydrology.
The powerhouse facilities and the intake/diversion timber frame structure and upper section of the
conveyance system were severely damaged in October 2006 during an extreme flood event. The
powerhouse was restored prior to the current project work.
The Humpback Creek Project intake/diversion rehabilitation was authorized by FERC under a non-
capacity license amendment (P-8889-046) issued March 31, 2009 and comprises two phases:
Phase 1 was removal of the damaged timber frame intake/diversion and upper conveyance
system;
Phase 2 is the rehabilitation and reconstruction of the intake/diversion and upper conveyance
system so as to return the project to energy production.
Phase 1 has been completed and a final report was issued separately. This is the Phase 2 Final
Report.
1. CONSTRUCTION SEQUENCE
The sequence of construction of the Humpback Creek Intake/Diversion Rehabilitation project was
as listed below, beginning with contract award August 3, 2009 and ending with beneficial
occupancy June 14, 2011and final acceptance of the work December 01, 2011. Activities were
overlapping and worked around stream flows and erosion control and sedimentation plan
requirements. Activities were as follows:
Award contract and issue NTP’s August 3, 2009.
Mobilize to site and establish support facilities, begin October 24, 2009.
Establish environmental controls including erosion and sediment control measures.
Clear vegetation and remove overburden from construction areas.
Demolish and remove remnant old structures and conveyance.
Scale, drill and install rock bolts at penstock tunnel outlet portal.
Drill, blast, excavate, bolt and haul Penstock Tunnel muck.
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Scale, drill, blast and remove and haul muck from Intake.
Construct sheet pile coffer dam around Intake construction area.
Scale, drill, blast, bolt and haul muck from left abutment area.
Install shotcrete tunnel lining and install penstock pipe supports and pipe.
Install tunnel portal steel sets and shotcrete in place.
Install outside penstock, penstock pipe concrete encasement and thrust blocks.
Construct temporary stream diversion tunnel around intake and dam site.
Construct coffer dams upstream and downstream from dam construction area.
Construct isolation coffer dam around remnant Bentonite location at demolished old
diversion dam.
Remove coffer dam from around Intake construction area.
Excavate stream bed to bedrock and construct foundation pad for dam.
Drill and install vertical rock bolts in dam foundation.
Drill grout curtain holes and pressure grout.
Construct dam from foundation to top.
Install Spillway and Sluiceway Gates and trash racks.
Remove Bentonite remnant from old timber frame dam and associated cofferdam and
remove upstream and downstream cofferdams.
Divert stream through spillway and close, plug, backfill and grout temporary diversion
tunnel.
Site cleanup and demobilization by contractor June 14, 2011.
Project beneficial occupancy by Owner June 14, 2011.
Project Certificate of Final Acceptance December 01, 2011.
2. MAJOR DESIGN MODIFICATIONS
A number of significant design changes were made during the construction of the Humpback Creek
project due to the facts on the ground. The project works required adjustments from the original
design to accommodate the physical details of site geology and to interface with the existing
penstock.
2.1 - The first problem area that had to be designed around was the “shear zone” between TB-10
and TB-11A near the outlet portal of the penstock tunnel. It was determined that the risk to
the penstock integrity by burying it across the “shear zone” was too great. Therefore, the
penstock and the penstock supports in the area were redesigned to bridge over the faulted zone
and the penstock was provided with reinforced concrete encasement to protect the pipe from
slides. Exploration with an excavator at the tunnel portal determined that the face of the portal
dropped to the bottom of a canyon (presently filled with accumulated alluvial materials due to
the old, original timber crib dam installed in 1908) and resulted in the bedrock base originally
thought to be available for penstock support was not useable and/or absent. This situation was
ameliorated as follows:
A) TB-11B, Drawing H01-D-12-1005-R19 (Sheet S-41.5): This thrust block was added 10 LF
upstream of TB-10 where suitable bedrock was found near the surface. The sloped bedrock
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was stepped to support the concrete foundation and four horizontal and five vertical high
strength 20 LF rock anchors were added to pin this thrust block to the cliff.
B) Penstock Encasement, Drawing H01-D-12-1003-R19 (Sheet S-39.5): The penstock was
encapsulated with unsupported, reinforced concrete between TB-11B and TB-11A. This 53
LF span was designed with the assumption that the log crib dam would collapse, releasing
the trapped gravel from the vicinity of the shear zone, and leaving the penstock 20 feet in the
air. Consequently, this is in effect a beam that will carry the penstock in the air across the
plane of the shear zone.
C) Debris Slab, Drawing H01-D-12-1006-R19 (Drawing 43.1) DCVR 16: This was required to
prevent mass wasting debris from filling the gap between the shear zone cliff and the
penstock encasement, thus exerting a horizontal bending moment on the penstock
encasement. Nine rock bolts support a 20 LF long reinforced concrete corbel. Ten steel
plates resting on the sloped surface of the corbel bridge the gap to the penstock encasement
and prevent debris from filling up the gap.
D) TB-11A, Drawing H01-D-12-1003 thru 1006-R-19, DCVR 19: Although part of the
original design, TB-11A was moved upstream concurrent with the redesigned mouth of the
tunnel, enlarged and strengthened to become the moment connection for the penstock
encasement beam. The foundation was enlarged to rest on the submerged bedrock and
reinforced with six angled high strength rock anchors. The thrust block itself was reinforced
with four more rock anchors.
E) The Penstock Tunnel was realigned between the Intake and the Outlet Portal so as not to
cross any portion of the shear zone area. The tunnel mouth at TB-11A was moved upstream
and the penstock pipe angle of the tunnel at TB-12 changed somewhat. The Penstock
Tunnel length increased by less than a foot.
F) Tunnel Portal Steel Sets: Due to over break near the Penstock Tunnel Outlet Portal, the
shape of the tunnel was not conducive to using the multiplate shield. Instead, six custom
steel sets site fabricated from unused steel sets procured at outset of the project that were
available on site. These were placed and then shotcreted.
G) Shotcrete: Shotcrete liner was placed throughout the penstock tunnel, including the bottom
four feet of each side. In addition, the entire portal face was shotcreted for added strength
and durability. The measured shotcrete strength of 8,800 psi quality of rock inside the tunnel
obviated the need for more steel sets in the tunnel other than at the portal.
2.2 - The second change was in the Intake that had two significant design changes, one due to
contractor error and the other due to a design oversight. These were:
A) Stairways #1, #2 and #3 from the Penstock Tunnel to the operating level of the Intake:
Metal stairways were purchased to provide access from the tunnel to the control room as per
plan. However, the contractor did not excavate enough rock to provide seven feet of
headroom for Stairway #3 pedestrians. To compensate, the toe of Stairway #3 had to be
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moved closer to the intake, which required the use of concrete steps there and also impacted
the layout of the upper two stairways. The walls on either side of Stairway #2 were poured
one half inch closer together than the width of the metal steps meaning it too had to be made
from concrete. Stairway #1 remained metal; however, the new layout of Stairway #3 and #2
meant that the upper landing of Stairway #1 was pushed closer to the waterproof door and
past the door to the control room. The door to the control room was moved toward the 4-
line to compensate.
B) There was no drain pipe provided for in the plans to convey water past the pony wall near
gridlines A-4. A 6-inch PVC pipe visible in Photo 21 was buried in the El. 279 (operating
level) slab to correct this and carry the water draining from the upper intake to HBC at the 2-
line. To support the pipe and the relocated light pole, the A-line parapet wall and supporting
concrete were extended to the 2-line.
2.3 - The diversion dam had several design changes conform to the ground conditions as follows:
.
A) Curtain Grouting: The curtain grout schedule shown on Drawing H01-D-11-1008-R19
(Sheet C-10.3) was modified after the bedrock was mapped. In order to intersect more
joints, the holes were angled from the vertical following Figures 1 and 2 of DCVR 31.
B) Rock Anchors: Four vertical HS rock anchors were embedded 15 feet into bedrock and
tensioned against the foundation base slab (El. 257 level) of the dam to provide additional
strength against shear and overturning moment.
C) Spillway: The spillway shown on Drawing H01-D-11-2001-R19 (Sheet S-02.7), in contact
with the bedrock and sloping at a 45 degree angle, had to be abandoned due to cost and
constructability. The diversion dam was unknowingly sited on the top of a waterfall that
was completely submerged under streambed gravel. The lip of the waterfall aligned well
with Gridline E. The gravel was partially excavated downstream of the dam to El. 244 in
order to discover bedrock. None was found except by probes at El. 238. At this depth, the
spillway would require at least 250 CY of concrete. Instead, a cantilevered spillway using 20
CY was built according to Drawing H01-D-11-2006-R19 (Drawing S-44.1), DCVR 32.
2.4- The left abutment of the dam was composed of highly jointed rock. Several design
modifications were incorporated to ensure it would survive over the 50 year design life of the
dam including:
A) Curtain Grouting: Eight holes were added here to fill the joints according to Figures 1 and 2,
DCVR 31.Drawing H01-D-11-1008-R19 (Sheet C-10.3)
B) Rock Anchors: Four vertical HS rock anchors were embedded along the base of the left
abutment from El. 258 in the diversion dam to El. 243 as per Drawing H01-D-11-1004-R19
(Sheet S-06.3). Eight horizontal HS rock anchors were embedded 25 feet into the left
abutment, downstream of the dam, to stabilize this cliff.
C) Keyway: A 16-inch deep by four-foot long keyway was cut into the left abutment to anchor
the left abutment wall near gridline E, Drawing H01-Dd-11-3001-R19 (Sheet S-01.7)
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3. QUALITY CONTROL TESTING RESULTS
All quality control inspection and testing was done in accordance with Appendix E of the Quality
Control and Inspection Plan (QCIP).
3.1 – Structural Concrete -
The structural concrete mix design for the Humpback Creek Project was used for all structural
applications such as the intake structure and diversion dam and penstock encasement and thrust
blocks. The same concrete mix design was used for all non-structural requirements such as dental
concrete. The structural concrete was formally tested 85 times in 52 separate pours. These results
are tabulated in the next two pages. The 28-day compressive strengths reached 8,540 psi and
averaged 7,080 psi compared to the 4,000 psi specified. This average would have been higher but
for several low readings recorded from Pour 39 to Pour 45 in the winter of 2011. These were due to
the cylinders partially freezing in the ice chest before being recovered the next day for long-term
storage. Since the actual pours were kept heated, these cylinders underestimate the strength of the
product. Pours 16, 40 and 46 exceeded the specified slump limit of 7.5 inches. The 9.5-inch slump
measured in Test 3, Pour 16 was immediately mixed with the following 3 inch slump batch. No
shrinkage cracks were observed in the 5-wall area of this pour. Test 4, Pour 40, measured a slump
of 7.75 inches going into the top few inches of the diversion dam. This was due to a malfunctioning
glenium meter in the batch plant. No shrinkage cracks were observed. The 9-inch slump measured
in Test 3, Pour 46 was placed in the El. 270 level of the jib crane foundation. Several shrinkage
cracks were observed here in the weeks following the pour. The area was coated with Xypex and
no further cracking was discovered. See Table 3-1.
3.2 – Shotcrete-
The tunnel shotcrete strength was excellent; average 28-day strength of 8,800 psi, see Table 3-2
3.3 – Rock Bolting –
Rock bolting was performed in strict accordance with the specifications and tested in accordance
with Appendix E-2 of the QCIP. High Strength rock bolting was performed in accordance with
Appendix E-2 of the QCIP and approved submittal. All high strength rock bolting was tested and
passed. Drawing H01-D-11-1004-R19 shows the left abutment high strength rock bolting layout.
Rock bolting is summarized in Table 3.3.
3.4 – Curtain and Contact Grouting –
Curtain and contact routing was done in accordance with project plans and specifications.
Drawing H01-D-11-1008-R19 shows the foundation grouting plan and H01-11-V1009-R-19 shows
actual grout takes for each grout hole in the foundation curtain. Grouting reports are on file CEC.
3.5 – Penstock Steel Pipe field joint welding –
Welding of the field joints in the steel penstock pipe was done in accordance with the approved
project specifications and field weld Quality Assurance Inspection inspection was performed by
Materials Integrity, Inc. Contractor’s third party independent welding inspection was performed
by QA Services, Inc. Verification that each pen stock butt weld was a CJP connection was accomplished
by performing MT on the joint from the outside of the pipe after the back weld on the inside of the pipe,
and back gouging from the outside is complete. By performing MT at that time the inspector was able to
verify the seam at the joint created by the two sections of pen stock has been completely removed, allowing
the fill pass to tie directly into the backing weld. All field joint welds passed inspection.
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Table 3-1 – Concrete Testing Results.
NAME OF CONTRACTOR:Contract No. CEC‐08‐HBC‐02
MOWAT Construction Co. Contract Date: August 20, 2009
Woodinville, WA Last Up‐Date: 6/2/11
(206)793‐7026 Up‐Dated by: C. Hayter
Pour No. Test No. Date 28 Day 7 Day Unit Wt. Air Slump w/c Remarks Location Cy Used CY Waste
001 1 5/24/10 5.0 5.00 0.45 TB‐11A 44.00 0.00
001 2 5/24/10 6850 5820 147.1 5.9 4.75 0.45
001 3 5/24/10 6910 6160 147.7 5.5 5.00 0.45
002 1 5/27/10 7200 5790 6.2 4.75 0.45 (8 Day) TB‐11B 10.50 2.50
003 1 6/10/10 7410 6020 148.8 5.5 5.50 0.45 (11 Day) Penstock Saddles 2.00 8.00
004 1 6/14/10 7040 4860 147.2 6.2 4.50 0.45 Inlet Rat Slab 6.00 0.00
005 1 6/15/10 7070 5110 147.7 5.9 5.75 0.45 TB‐12 and Inlet Rat Slab 12.00 0.00
006 1 7/6/10 5710 4650 145.6 6.6 7.00 0.45 (9 Day) Inlet Rat Slab 31.00 0.00
007 1 7/17/10 8540 6560 149.8 4.8 5.00 0.45 A Wall 54.50 3.00
007 2 7/17/10 8350 5810 148.4 5.5 6.25 0.45
008 1 7/24/10 4.00 0.43 Inlet Slab 0.50 0.00
009 1 7/27/10 7980 4740 148.5 5.8 4.50 0.45 1 Day = 1940 C Wall 34.00 0.00
010 1 7/29/10 6490 4890 7.5 7.00 0.45 TB‐12 27.25 0.75
010 2 7/29/10 5.3 0.45
011 1 7/31/10 7040 6090 148.1 5.8 6.00 0.45 4 Wall 30.50 0.00
012 1 8/12/10 7440 5660 151.1 6.1 5.75 5 Wall 41.00 0.00
012 2 8/12/10 3.4 7.50
012 3 8/12/10 5.5 7.00
013 1 8/16/10 7.0 7.50 TB‐11A 19.00 1.00
013 2 8/16/10 8130 6680 154.1 3.5 5.25
014 1 8/17/10 8150 6530 150.9 5.3 3.75 Stair 3 5.50 0.00
015 1 8/20/10 TB‐11B 9.50 0.00
015 2 8/20/10 7170 5480 151.1 7.5 6.50
016 1 8/24/10 5.6 4.00 0.45 Intake 39.00 3.00
016 2 8/24/10 6470 4880 148.9 5.0 7.50 0.45
016 3 8/24/10 5630 4040 1.5 9.50 0.45
016 4 8/24/10 8.0 3.50 0.45
017 1 8/25/10 5.5 5.00 0.45 Penstock Beam 42.00 0.50
017 2 8/25/10 6770 4860 149.6 5.0 5.00 0.45
017 3 8/25/10 5.5 5.75 0.45
018 1 8/28/10 7820 6030 152.9 2.9 7.50 0.45 Portal Steel Sets 8.25 0.25
018 2 8/28/10 6830 5220 148.9 5.8 6.75 0.45
018 3 8/28/10 4.0 0.45
018 4 8/28/10 6.0 7.50 0.45
019 1 9/9/10 7170 5770 5.8 4.00 0.45 Stair 2 & 3 5.50 0.50
020 1 9/10/10 7950 6200 5.4 3.50 0.45 A Wall 6.50 5.00
021 1 9/11/10 7250 6550 5.3 6.00 0.45 (11 day) 279 Slab 31.00 0.00
022 1 9/17/10 7590 6120 148.5 5.2 6.00 0.45 A Wall 16.50 0.00
023 1 9/18/10 6980 5120 148.6 5.1 6.00 0.45 4 Line Grade Beam 4.25 0.25
024 1 9/23/10 7680 5730 147.3 6.2 6.50 0.45 3 Line GB, A2 Parapet 15.00 0.00
025 1 9/25/10 7590 6230 4.9 4.50 0.45 Stair 1 & 2 10.50 0.00
HUMPBACK CREEK PROJECT PHASE 2 INTAKE/DIVERSION REHABILITATION
CONCRETE TESTING SPREADSHEET
Humpback Creek Rehabilitation Phase II
Final Construction Report
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Pour No. Test No. Date 28 Day 7 Day Unit Wt. Air Slump w/c Remarks Location Cy Used CY Waste
026 1 9/29/10 150.3 4.6 3.50 C.1 Wall, 4 Wall 18.50 0.00
026 2 9/29/10 7360 6200 148.2 5.4 5.00 0.45 (12 day)
027 1 10/4/10 7070 5620 148.1 5.8 5.50 0.45 C, B, 5 Corner/Wall 8.00 0.00
028 1 10/7/10 7300 5840 147.0 6.4 5.25 0.45 5.4 Wall 39.50 0.50
028 2 10/7/10 149.0 5.0 4.25 0.44
029 1 10/8/10 148.1 5.9 4.25 0.45 A4 Retaining Wall 2.00 1.00
030 1 10/19/10 7095 5620 148.0 6.0 6.00 0.45 (10 day) 265 Slab, Stair 4 23.00 0.00
031 1 10/20/10 7810 6470 148.3 5.9 5.25 0.45 (9 day) 4 Line Weir 4.50 0.50
032 1 10/21/10 7570 5810 151.0 5.2 7.50 (8 day) 290 Slab 26.00 0.00
032 2 10/21/10 5.6 2.75 0.45
032 3 10/21/10 4.00
033 1 10/25/10 7990 6020 151.3 4.8 7.00 0.42 Penstock Vent Casing 12.00 0.00
034 1 10/26/10 151.6 5.4 2.00 Debris Slab 6.75 0.75
034 2 10/26/10 5.75
035 1 10/29/10 6620 5020 148.4 5.8 5.75 0.45 (14 day) Intake Slab 40.00 0.00
036 1 11/3/10 6890 5610 147.8 6.0 6.25 0.45 (9 Day) Sluice Ramp 10.50 6.50
037 1 11/10/10 7230 150.0 4.5 3.00 0.45 Dam Rat Slab 18.50 2.50
037 2 11/10/10 148.1 4.6 3.50 0.45 Fiber
038 1 11/20/10 7020 6060 7.3 6.00 0.45 Fiber Dam 63.00 0.00
038 2 11/20/10 148.4 5.5 4.50 0.45 Fiber
039* 1 1/17/11 4360 2980 147.1 6.0 5.50 0.45 (10 Day) Fiber Lt. Abut. Pony Wall 2.00 2.00
040 1 2/4/11 7480 5350 147.8 6.0 4.25 0.45 Fiber Dam 96.50 3.50
040 2 2/4/11 147.1 5.4 5.50 0.45 Fiber
040 3 2/4/11 5970 4800 148.0 5.3 5.50 0.45 Fiber
040 4 2/4/11 146.8 7.0 7.75 0.45 Fiber
041 1 2/16/11 7520 150.3 4.2 4.75 0.45 Fiber Sluiceway 43.00 2.00
041 2 2/16/11 149.4 5.2 6.25 0.45 Fiber
042* 1 3/1/11 3890 2450 148.0 5.0 5.25 0.45 Lt. Abut. Wall 45.00 1.00
042 2 3/1/11 146.6 5.5 5.00 0.45
043 1 3/4/11 147.6 5.3 3.75 0.45 Lt. Abut. Parapet 9.00 0.00
044 1 3/4/11 5590 3670 147.6 5.4 2.75 0.45 Fiber Spillway 11.00 2.50
045 1 3/10/11 5530 3980 147.7 4.8 2.75 0.45 Fiber Spillway 7.00 0.50
046 1 3/19/11 150.2 4.8 3.00 Jib Crane Sluice 65.00 3.50
046 2 3/19/11 7650 5480 149.5 4.7 5.50 0.44
046** 3 3/19/11 6640 4800 7.50
046 4 3/19/11 150.8 4.7 6.00 0.43
046 5 3/19/11 7460 5500 149.4 4.9 4.50 0.42
047 1 3/26/11 7970 6380 149.4 5.1 4.25 0.44 Middle Diversion Wall 14.50 0.50
048 1 4/2/11 7890 5910 149.2 4.5 3.25 0.45 Jib Crane Walkway 10.00 0.00
049 1 4/11/11 7740 6120 148.0 4.7 4.50 0.45 Fiber TDT Plug 39.50 2.50
049 2 4/11/11 147.0 5.2 5.25 0.45 (9 Day) Fiber
050 1 4/13/11 147.2 5.4 4.50 0.45 Jib Crane Parapet 4.00 0.00
051 1 4/24/11 5950 4690 144.3 7.1 7.00 0.45 U/S TDT Diaphragm 24.00 0.00
052 1 4/30/11 7460 5820 147.4 5.5 5.25 0.45 D/S TDT Diaphragm 22.50 1.50
*Cylinders were not properly field cured causing low strength results. Structures were heated and properly cured.
**Initial Slump tested at 9", waited, re‐tested at 7.5". Aggregate piles found to have ice in them. w/c unknown.
Avg. Avg.
28 Day 7 Day Air Slump CY Used CY Waste
psi 7080 5460 5.4 5.25 1171.00 56.00
STDV 911 886
Note: When the low strength outliers from the improperly field cured cylinders are removed, the STDV decreases by about 1/3.
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Final Construction Report
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Table 3-2 – Shootcrete Testing Results.
HUMPBACK CREEK PROJECT PHASE 2 INTAKE/
DIVERSION REHABILITATION SHOTCRETE TESTING
SPREADSHEET
NAME OF CONTRACTOR:Contract No. CEC‐08‐HBC‐02
MOWAT Construction Co. Contract Date: August 20, 2009
Woodinville, WA Last Up‐Date: 10/5/11
(206)793‐7026 Up‐Dated by: D. Wood
Date Date Test age Ultimate Length Area Compressive Strength Average 28‐Day
Sample Made Tested (Days) Load (Lbs) (In) (In^2) (kPa) (PSI) Strength (PSI)
1344 3/13/2010 3/16/2010 3 9800 5.32 5.70 11850 1720
1344 3/13/2010 3/17/2010 4 22780 5.52 5.66 27740 4020
1344 3/13/2010 3/20/2010 7 30740 5.51 5.68 37290 5410
1344 3/13/2010 3/20/2010 7 32260 5.55 5.64 39430 5720
1344 3/13/2010 4/10/2010 28 50240 5.61 5.61 60700 8810
1344 3/13/2010 4/10/2010 28 49700 5.56 5.56 60300 8750 8780
1347 3/27/2010 4/5/2010 9 41140 5.50 5.70 49700 7210
1347 3/27/2010 4/5/2010 9 42020 5.50 5.68 51000 7390
1347 3/27/2010 4/24/2010 28 46780 5.62 5.68 56700 8230
1347 3/27/2010 4/24/2010 28 53540 5.69 5.68 64800 9400 8820
28 Day
psi 8800
STDV 479
Table 3.3 - Rock Bolting
Contract No. CEC-08-HBC-02
Contract Date: August 20, 2009
Location of Rock Bolts ID Depth Drill date V-Angle Encap Encap Date Pull test PT date Lockoff
Debris slide (extra by JR)DS-1 6' 12-May 22 Epoxy 12-May 14K 17-May Yes
DS-2 6' 12-May 18 Epoxy 12-May 14K 17-May Yes
DS-3 6' 12-May 16 Epoxy 12-May 14K 17-May Yes
DS-4 6' 12-May 20 Epoxy 12-May 14K 17-May Yes
DS-5 6' 12-May 26 Epoxy 12-May 14K 17-May Yes
DS-6 6' 12-May 18 Epoxy 12-May 14K 17-May Yes
HUMPBACK CREEK PROJECT PHASE 2 INTAKE/DIVERSION
REHABILITATION ROCK BOLT INSTALLATION RECORD
MOWAT Construction Co.
Woodinville, WA
(206)793-7026
NAME OF CONTRACTOR:
Table 3.3 - Rock Bolting, continued
Humpback Creek Rehabilitation Phase II
Final Construction Report
Contains Critical Energy Infrastructure Information Page 9
Do not release – protection provided under 18 CFR § 388.112
Table 3.3 - Rock Bolting, continued
Location of Rock Bolts ID Depth Drill date V-Angle Encap Encap Date Pull test PT date Lockoff
TB11A Face TB11A-F1 18 8-May 15 Grout 11-May NT (per JR) NA No
TB11A-F2 18' 8-May 15 Grout 11-May NT (per JR) NA No
TB11A-F3 18' 8-May 15 Grout 11-May NT (per JR) NA No
TB11A-F4 18' 8-May 15 Grout 11-May NT (per JR) NA No
TB11A-F5 18' 8-May 30 Grout 11-May NT (per JR) NA No
TB11A-F6 18' 8-May 30 Grout 11-May NT (per JR) NA No
TB11A Slab TB11A-S1 18 3-Jun 60 Grout 3-Jun 41K 7-Jun Yes
TB11A-S2 18' 3-Jun 60 Grout 3-Jun 41K 7-Jun Yes
TB11A-S3 18' 3-Jun 60 Grout 3-Jun 41K 7-Jun Yes
TB11A-S4 18' 3-Jun 60 Grout 3-Jun 41K 7-Jun Yes
TB11A-S5 18' 3-Jun 60 Grout 3-Jun 41K 7-Jun Yes
TB11A-S6 18' 3-Jun 60 Grout 3-Jun 41K 7-Jun Yes
TB11A (Extra by JR)TB11A-4 18 4-Jun 5 Grout 5-Jun NT NA No
TB11A-1 18 4-Jun 70 Grout 5-Jun NT NA No
TB11A-2 18 4-Jun 70 Grout 5-Jun NT NA No
TB11A-3 9 5-Jun 90 Epoxy 5-Jun NT NA No
TB11B (Horizontal)TB11B-1 18 7-May 90 Grout 7-May NT NA No
TB11B-2 18 7-May 90 Grout 7-May NT NA No
TB11B-3 HS 25 7-May 90 Grout 7-May NT NA No
TB11B-4 HS 25 7-May 90 Grout 7-May NT NA No
TB11B (Vertical)TB11B-V1 18 12-May 90 Grout 18-May 41K 27-Aug Yes
TB11B-V2 18 12-May 90 Grout 18-May 41K 27-Aug Yes
TB11B-3 V3-HS 25 12-May 90 Grout 18-May 41K 27-Aug Yes
TB11B-4 VS-HS 25 12-May 90 Grout 18-May 41K 27-Aug Yes
extra by JR TB11B-V5 18 12-May 70 Grout 18-May NT NA No
Intake Cable Anchors ICA-1 8' 90 Grout No NA
ICA-2 8' 90 Grout No NA
ICA-3 8' 90 Grout No NA
ICA-4 8' 90 Grout No NA
ICA-5 8' 90 Grout No NA
ICA-6 8' 90 Grout No NA
ICA-7 8' 90 Grout No NA
ICA-8 8' 90 Grout No NA
ICA-9 8' 90 Grout No NA
ICA-10 8' 90 Grout No NA
ICA-11 8' 90 Grout No NA
ICA-12 8' 90 Grout No NA
ICA-13 8' 90 Grout No NA
ICA-14 8' 90 Grout No NA
ICA-15 8' 90 Grout No NA
ICA-16 8' 90 Grout No NA
Left Abutment HS Bolts LAB-1 25' 25-May 90 Grout 28-Jan 88K 2-Feb Yes
(Horizontal)LAB-2 25' 25-May 90 Grout 28-Jan 88K 2-Feb Yes
LAB-3 25' 25-May 90 Grout 28-Jan 88K 2-Feb Yes
LAB-4 25' 25-May 90 Grout 28-Jan 88K 2-Feb Yes
LAB-5 25' 25-May 90 Grout 28-Jan 88K 2-Feb Yes
LAB-6 25' 25-May 90 Grout 28-Jan 88K 2-Feb Yes
LAB-7 25' 25-May 90 Grout 28-Jan 88K 2-Feb Yes
LAB-8 25' 25-May 90 Grout 28-Jan 88K 2-Feb Yes
Left Abutment HS Bolts LAB-9 15' 10-Jan 0 Grout 22-Jan 88K 31-Jan Yes
(Vertical)LAB-10 15' 10-Jan 0 Grout 22-Jan 88K 31-Jan Yes
LAB-11 15' 10-Jan 0 Grout 22-Jan 88K 31-Jan Yes
LAB-12 15' 10-Jan 0 Grout 22-Jan 88K 31-Jan Yes
HUMPBACK CREEK PROJECT PHASE 2 INTAKE/DIVERSION
REHABILITATION ROCK BOLT INSTALLATION RECORD
Humpback Creek Rehabilitation Phase II
Final Construction Report
Contains Critical Energy Infrastructure Information Page 10
Do not release – protection provided under 18 CFR § 388.112
4. CONSTRUCTION PROBLEMS
The contractor had chronic problems in three areas: dealing with winter temperatures; diverting
HBC around the work area; and dealing with silty water. Working in freezing conditions was new
for this Seattle contractor. All their water lines routinely froze up because they never purged them
after the last use. This caused much delay on an almost daily basis in the winter of 2011. In
addition, the contractor constantly underestimated the amount of diesel required to heat the
concrete, causing them to run low on six occasions. When the fuel barge was not forthcoming, the
contractor had to divert man hours to hauling fuel from Cordova 300 gallons at a time in their crew
boat.
Several methods were used to divert HBC through or around the dam construction area. In the
winter of 2010, the contractor tried using submerged 42-inch and 54-inch pipes and gabion sluices
to convey water through the work area. These worked only at low water. Consequently they
submitted a Temporary Stream Diversion Plan to FERC, asking permission to blast a diversion
tunnel around the site through the left abutment. This was granted and work began on the
Temporary Diversion Tunnel (TDT) in July, 2010; see Photo 17. HBC was successfully diverted in
September, 2010, and flowed through the TDT until the dam and spillway were completed in April,
2011. The TDT was backfilled with shot rock and 832 sacks of grout before being abandoned.
The most persistent problem was dealing with the silty water generated by construction activities.
The sediment weirs shown in the plans and built in the winter of 2010 only worked during low
flows. The contractor was advised repeatedly that they needed to construct a pipeline to convey
silty water out of the canyon. Instead, they tried using the flume road to filter the silt out of the
water. This worked as long as they did no in-stream work at flows under 70 cfs, which would
generate too much water to filter; consequently they lost many low-flow days and the dry month of
September, 2010, to any construction of the dam. By October, 2010, the voids in the flume road
were full and it could filter no more silt. At that point the contractor mobilized an 8-inch HDPE
Location of Rock Bolts ID Depth Drill date V-Angle Encap Encap Date Pull test PT date Lockoff
Dam Rock Anchors DRA-1 15' 10-Jan 0 Grout 22-Jan 88K 31-Jan Yes
(Vertical)DRA-2 15' 11-Jan 0 Grout 22-Jan 88K 31-Jan Yes
DRA-3 15' 11-Jan 0 Grout 22-Jan 88K 31-Jan Yes
DRA-4 15' 11-Jan 0 Grout 22-Jan 88K 31-Jan Yes
Intake Slope Anchor Vertica ISAV-1 6' 16-Jun 90 Epoxy 16-Jun No
(extra by MCC)ISAV-2 6' 16-Jun 90 Epoxy 16-Jun No
ISAV-3 6' 16-Jun 90 Epoxy 16-Jun No
ISAV-4 6' 17-Jun 90 Epoxy 17-Jun No
ISAV-5 6' 17-Jun 90 Epoxy 17-Jun No
ISAV-6 6' 17-Jun 90 Epoxy 17-Jun No
Intake Brow IB-1 6' 8-Jun varies Epoxy 8-Jun No
IB-2 6' 8-Jun varies Epoxy 8-Jun No
IB-3 6' 8-Jun varies Epoxy 8-Jun No
IB-4 6' 8-Jun varies Epoxy 8-Jun No
IB-5 6' 8-Jun varies Epoxy 8-Jun No
IB-6 6' 8-Jun varies Epoxy 8-Jun No
IB-7 6' 9-Jun varies Epoxy 9-Jun No
IB-8 6' 9-Jun varies Epoxy 9-Jun No
IB-9 6' 9-Jun varies Epoxy 9-Jun No
IB-10 6' 9-Jun varies Epoxy 9-Jun No
HUMPBACK CREEK PROJECT PHASE 2 INTAKE/DIVERSION
REHABILITATION ROCK BOLT INSTALLATION RECORD
Humpback Creek Rehabilitation Phase II
Final Construction Report
Contains Critical Energy Infrastructure Information Page 11
Do not release – protection provided under 18 CFR § 388.112
pipeline leading from the dam to the Inlet, via the penstock. This was operational from December,
2010 through completion of in-stream work and greatly increased productivity.
5. INSTRUMENTATION
There is no instrumentation in the structures or foundations of the Intake/Diversion or conveyance
tunnel. All instrumentation is operational for gate control and water level monitoring. In the spring
of 2011, all the operational instrumentation was checked and/or calibrated. The mechanical gauges
in the APC cabinet, showing the flow rate and the pressure of the compressed air in the Obermeyer
air supply piping, operated normally. The inclinometer sensor recording the angle of the
Obermeyer gate was installed, calibrated and connected to SCADA and the PLC system. Two
pressure transducers installed in April became operational during May. The exterior transducer at
gridline A-2 was calibrated to show two elevations: El. 266 when water first enters the 3x8 sluice;
and El. 269 when water overtops the trashrack weir. The interior transducer near gridline A-3
shows the water level downstream of the El. 269 weir. A hole was drilled in each transducer conduit
to allow air to enter or escape in response to the changing water level.
6. PHOTOGRAPHS
See the following ten pages.
Humpback Creek Rehabilitation Phase II
Final Construction Report
Contains Critical Energy Infrastructure Information
Do not release – protection provided under 18 CFR § 388.112
PROGRESS PHOTOGRAPHS
Photo 1: Eighteen rock bolts at the outlet portal on
January 5, 2010.
Photo 2: Drilling to blast the tunnel at the outlet
portal on January 14, 2010.
Photo 3: Excavating overburden at the upper intake
on January 22, 2010.
Photo 4: Preparing to blast a bench into rock at the
intake on February 24, 2010.
Photo 5: Shotcreting the tunnel on March 5, 2010. Photo 6: Drilling another bench at the intake on
March 20, 2010.
Humpback Creek Rehabilitation Phase II
Final Construction Report
Contains Critical Energy Infrastructure Information
Do not release – protection provided under 18 CFR § 388.112
Photo 7: The future intake after a blast on
March 24, 2010.
Photo 8: Shotcreting the outlet portal on
March 31, 2010.
Photo 9: Excavating the intake on April 13, 2010.
Photo 10: Preparing to install the first HDPE
penstock section on April 15, 2010.
Photo 11: Drilling to install rock anchors under TB-
11A on May 8, 2010.
Photo 12: Pouring the TB-11A foundation on
May 24, 2010.
Humpback Creek Rehabilitation Phase II
Final Construction Report
Contains Critical Energy Infrastructure Information
Do not release – protection provided under 18 CFR § 388.112
Photo 13: Installing steel sets at the outlet portal on
May 27, 2010.
Photo 14: Intake, slope mats, and sheetpile
diversion wall on June 19, 2010.
Photo 15: MT inspection of penstock pipe field weld
July 29, 2010
Photo 16: MT inspection of penstock pipe field
weld July 30, 2010
Photo 17: Intake and penstock on July 15, 2010.
Photo 17: Beginning to drill the temporary
diversion tunnel on July 19, 2010.
Humpback Creek Rehabilitation Phase II
Final Construction Report
Contains Critical Energy Infrastructure Information
Do not release – protection provided under 18 CFR § 388.112
Photo 18: Welding new penstock to the existing
penstock at TB-10 on August 4, 2010.
Photo 19: The intake thimble within the 5-wall
rebar on August 9, 2010.
Photo 20: Preparing to pour the intake square to
round transition on August 12, 2010.
Photo 21: The modified Stairway 3 soffit prior
to the pour on August 21, 2010.
Photo 22: Penstock encasement reinforcing on
August 19, 2010
Photo 23: Thrust Block 11B reinforcing and
rock anchors on August 19, 2010
Humpback Creek Rehabilitation Phase II
Final Construction Report
Contains Critical Energy Infrastructure Information
Do not release – protection provided under 18 CFR § 388.112
Photo 24: Preparing to pour the El. 279 slab on
September 11, 2010.
Photo 25: Beginning to lay out handrail over the
manway, TB-11B and the penstock encasement
on September 17, 2010.
Photo 26: The tunnel walkway on October 5, 2010. Photo 27: Driving the downstream cofferdam
across HBC on October 16, 2010.
Photo 28: Investigating the old remnant bentonite
limits on October 20, 2010.
Photo 29: Pouring the debris slab at the outlet
portal on October 26, 2010.
Humpback Creek Rehabilitation Phase II
Final Construction Report
Contains Critical Energy Infrastructure Information
Do not release – protection provided under 18 CFR § 388.112
Photo 30: Pouring the internal sluice at the intake on
October 29, 2010.
Photo 31: Cleaning bedrock at the diversion
dam on November 3, 2010.
Photo 32: The completed debris slab on
November 4, 2010.
Photo 33: Pouring the diversion dam dental
concrete to El. 251 on the E-line,
November 10, 2010.
Photo 34: Rebar and curtain grouting guides to El.
257 of the dam on November 19, 2010.
Photo 35: Xypex waterproofing the El. 290 slab
of the intake on December 6, 2010.
Humpback Creek Rehabilitation Phase II
Final Construction Report
Contains Critical Energy Infrastructure Information
Do not release – protection provided under 18 CFR § 388.112
Photo 36: Curtain grouting dam foundation on
December 9, 2010 Photo 37: Curtain grouting dam foundation on
December 17, 2010
Photo 38: Building the portal wall on December 9,
2010.
Photo 39: Excavating the keyway in the left
abutment on January 8, 2011.
Photo 40: Drilling curtain grout holes in the left
abutment on January 12, 2010.
Photo 41: Rebar and anchor bolts between El.
257 and El. 264 of the dam on January 26, 2010.
Humpback Creek Rehabilitation Phase II
Final Construction Report
Contains Critical Energy Infrastructure Information
Do not release – protection provided under 18 CFR § 388.112
Photo 42: Curtain grouting hole 20 at the left
abutment of the dam on February 11, 2011.
Photo 43: The bottom mat of rebar under the
3x8 sluice on February 12, 2011.
Photo 44: Excavating bentonite near the old
abutments on February 19, 2011.
Photo 45: Trying to find bedrock on which to
found the spillway on February 22, 2011.
Photo 46: Terminating the SCADA cabinet in the
control room on February 28, 2011.
Photo 47: Pouring the left abutment wall on
March 1, 2011.
Humpback Creek Rehabilitation Phase II
Final Construction Report
Contains Critical Energy Infrastructure Information
Do not release – protection provided under 18 CFR § 388.112
Photo 48: Pouring the redesigned spillway on March
4, 2011.
Photo 49: Preparing to insert the left UHMW
plate in the middle wall of the dam on March
23, 2011.
Photo 50: Pouring the El. 279 deck under the jib
crane on April 2, 2011.
Photo 51: HBC re-diverted across the left bay
on April 4, 2011.
Photo 52: The upstream plug of the TDT on April 25,
2011.
Photo 53: Welding new handrail at TB-10 on
May 3, 2011.
Humpback Creek Rehabilitation Phase II
Final Construction Report
Contains Critical Energy Infrastructure Information
Do not release – protection provided under 18 CFR § 388.112
Photo 54: Installing the gabion wall on the right bank
on May 6, 2011.
Photo 55: Pressure grouting the voids between
the two diaphragm walls in the TDT on May 6,
2011.
Phot
o 56: Installing the Obermeyer gate on May 12, 2011.
Photo 57: HBC running over the Obermeyer
weir on May 17, 2010.
Photo 58: Looking upstream on May 26, 2011.
Photo 59: The almost finished intake and
diversion dam on May 28, 2011.
Humpback Creek Rehabilitation Phase II
Final Construction Report
Contains Critical Energy Infrastructure Information
Do not release – protection provided under 18 CFR § 388.112
APPENDIX A
AS-CONSTRUCTED RECORD DRAWINGS
(CEII) material under 18 CFR § 388.113(c).
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(CEII) material under 18 CFR § 388.113(c)
(CEII) material under 18 CFR § 388.113(c)
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c)
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c)
BAR # BAR
SIZE LD - CASE 1, ΨT =
1.0
LD - CASE 1, ΨT =
1.3
LD - CASE 2, ΨT =
1.0
LD - CASE 2, ΨT =
1.3
3 0.375 14.23 18.50 21.35 28.39
4 0.5 18.97 24.67 28.46 37.00
5 0.625 23.72 30.83 35.58 46.25
6 0.75 28.46 37.00 42.69 55.50
7 0.875 41.50 53.96 62.26 80.93
8 1 47.43 61.66 71.15 92.50
9 1.128 53.51 69.56 80.26 104.34
10 1.27 60.24 78.31 90.36 117.47
11 1.41 66.88 86.95 100.32 130.42
14 1.693 80.31 104.40 120.46 156.60
18 2.257 107.06 139.18 160.59 208.76
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c)
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
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(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
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(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c). (CEII) material under 18 CFR § 388.113(c).
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(CEII) material under 18 CFR § 388.113(c).
H01-D-11-V1009-R19
H01-D-11-V1009-R19
H01-D-11-V1009-R19(CEII) material under 18 CFR § 388.113(c)
(CEII) material under 18 CFR § 388.113(c)
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
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(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
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(CEII) material under 18 CFR § 388.113(c).
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(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
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(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
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(CEII) material under 18 CFR § 388.113(c).
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(CEII) material under 18 CFR § 388.113(c).
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(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
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(CEII) material under 18 CFR § 388.113(c).
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(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
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(CEII) material under 18 CFR § 388.113(c).
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(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
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(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
PLAN
ELEVATION
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
PLAN
ELEVATION
(CEII) material under 18 CFR § 388.113(c).
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(CEII) material under 18 CFR § 388.113(c).
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(CEII) material under 18 CFR § 388.113(c).
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(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).
(CEII) material under 18 CFR § 388.113(c).