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Home My WebLink AboutNC0001422_LVSuttonSARP_Rev0_AppendixH_20161201Appendix H CQA Plan CONSTRUCTION QUALITY ASSURANCE PLAN L.V. SUTTON ENERGY COMPLEX SITE ANALYSIS AND REMOVAL PLAN December 2016 Revision 0 Prepared for Duke Energy Progress, LLC 526 South Church Street Charlotte, North Carolina 28202 Prepared by Geosyntec Consultants of NC, PC 1300 South Mint Street, Suite 300 Charlotte, North Carolina 28203 License No. C-3500 Geosyntec Consultants of North Carolina, PC Duke Energy Coal Combustion Residuals Management Program Appendix H – Construction Quality Assurance Plan Revision 0 December 2016 i TABLE OF CONTENTS 1 INTRODUCTION ............................................................................................................... 1 1.1 Overview ..................................................................................................................... 1 1.2 Project Description ...................................................................................................... 1 1.3 CQA Plan Scope ......................................................................................................... 1 1.4 CQA Plan Organization ............................................................................................... 2 2 CQA PLAN DEFINITIONS ................................................................................................ 3 2.1 Construction Quality Assurance and Construction Quality Control ............................. 3 2.2 Plans and Specifications ............................................................................................. 3 2.3 Geosynthetics .............................................................................................................. 3 2.4 Construction Activities ................................................................................................. 4 2.5 CQA Lines of Communications ................................................................................... 4 3 PROJECT ORGANIZATION AND PERSONNEL ............................................................ 5 3.1 Overview ..................................................................................................................... 5 3.2 Construction Manager ................................................................................................. 5 3.3 Design Engineer .......................................................................................................... 5 3.4 Contractor .................................................................................................................... 6 3.5 CQA Consultant .......................................................................................................... 7 3.5.1 Definition ............................................................................................................. 7 3.5.2 Qualifications ...................................................................................................... 7 3.5.3 Responsibilities ................................................................................................... 8 3.5.3.1 CQA Certifying Engineer ........................................................................... 9 3.5.3.2 CQA Site Manager..................................................................................... 9 3.5.3.3 CQA Field Monitors ................................................................................. 10 3.6 Soils CQA Laboratory ................................................................................................ 11 3.6.1 Definition ........................................................................................................... 11 3.6.2 Qualifications .................................................................................................... 12 3.6.3 Responsibilities ................................................................................................. 12 3.7 Geosynthetics CQA Laboratory ................................................................................. 12 3.7.1 Definition ........................................................................................................... 12 3.7.2 Qualifications .................................................................................................... 13 3.7.3 Responsibilities ................................................................................................. 13 3.8 Geosynthetics Manufacturers .................................................................................... 13 3.9 Geosynthetics Installers ............................................................................................ 14 3.10 Surveyor .................................................................................................................... 14 4 DOCUMENTATION ........................................................................................................ 15 Geosyntec Consultants of North Carolina, PC Duke Energy Coal Combustion Residuals Management Program Appendix H – Construction Quality Assurance Plan Revision 0 December 2016 ii 4.1 Overview ................................................................................................................... 15 4.2 Daily Record Keeping ................................................................................................ 15 4.2.1 Daily Summary Reports .................................................................................... 15 4.2.2 CQA Monitoring Logs and Test Data Sheets ................................................... 16 4.2.3 Nonconformance Identification and Reporting ................................................. 16 4.3 Photographic Documentation .................................................................................... 17 4.4 Design and/or Specifications Changes ..................................................................... 18 4.5 Nonconformances ..................................................................................................... 18 4.6 CQA Certification Report ........................................................................................... 18 4.7 Storage of Records ................................................................................................... 19 5 SOILS CONSTRUCTION ............................................................................................... 20 5.1 Introduction ................................................................................................................ 20 5.2 Soil Components ....................................................................................................... 20 5.3 Record Drawings and As-Built Surveys .................................................................... 20 5.4 Related Construction Drawings and Technical Specifications .................................. 20 5.5 Subgrade ................................................................................................................... 21 5.6 Conformance Testing ................................................................................................ 21 5.6.1 Test Methods .................................................................................................... 22 5.6.2 Test Frequency ................................................................................................. 22 5.7 Construction Monitoring ............................................................................................ 22 5.8 Performance Testing ................................................................................................. 23 5.8.1 Test Methods .................................................................................................... 23 5.8.2 Test Frequency ................................................................................................. 23 5.9 Deficiencies ............................................................................................................... 24 5.10 Documentation .......................................................................................................... 25 6 GEOTEXTILES ............................................................................................................... 26 6.1 Introduction ................................................................................................................ 26 6.2 Transportation, Handling, and Storage ..................................................................... 26 6.3 Conformance Testing ................................................................................................ 27 6.3.1 Sampling Procedures ....................................................................................... 27 6.3.2 Testing Procedure ............................................................................................ 27 6.3.3 Test Results ...................................................................................................... 27 6.3.4 Conformance Test Failure ................................................................................ 27 6.3.5 Placement ......................................................................................................... 28 6.4 Seams and Overlaps ................................................................................................. 28 6.5 Repair ........................................................................................................................ 29 6.6 Placement of Soil Materials ....................................................................................... 29 Geosyntec Consultants of North Carolina, PC Duke Energy Coal Combustion Residuals Management Program Appendix H – Construction Quality Assurance Plan Revision 0 December 2016 iii 7 ROAD CONSTRUCTION ................................................................................................ 30 7.1 Introduction ................................................................................................................ 30 7.2 Subgrade Preparation ............................................................................................... 30 7.3 Subbase Layer .......................................................................................................... 30 7.4 Base Layer ................................................................................................................ 30 7.5 Quality Assurance Testing ........................................................................................ 30 7.6 Repairs ...................................................................................................................... 31 8 GENERAL SITE WORK ................................................................................................. 32 8.1 Introduction ................................................................................................................ 32 8.2 Conformance Testing ................................................................................................ 32 Tables Table 5-1 Minimum Conformance Testing Frequencies for Sutton Closure Plan Soil Components Table 5-2 Minimum Performance Testing Frequencies for Sutton Closure Plan Soil Components Table 6-1 Geotextile Conformance Testing Requirements Figures Figure 3-1 Sutton Landfill Construction Organization Chart Figure 3-2 Sutton Landfill CQA Organization Chart Appendices Appendix A CQA Forms and Logs Appendix B Required Geotextile Properties: Tables 31 02 19.13-1 and 31 02 19.13-2 Geosyntec Consultants of North Carolina, PC Duke Energy Coal Combustion Residuals Management Program Appendix H – Construction Quality Assurance Plan Revision 0 December 2016 1 1 INTRODUCTION 1.1 Overview This Construction Quality Assurance (CQA) Plan describes the quality assurance and construction quality control (CQC) activities that will be undertaken during construction of the Duke Energy Progress, LLC (DEP) L.V. Sutton Energy Complex (Sutton) closure of the 1971 and 1984 Basins and the Lay of Land Area (LOLA) located near Wilmington, North Carolina. The purpose of this document is to define the scope, formal organization, and procedures necessary to achieve a high level of quality and assure that the construction of the Sutton closure is in compliance with the approved design as shown or indicated in the Construction Drawings and the Technical Specifications. This plan addresses the CQA and CQC activities to be performed during construction. 1.2 Project Description The construction required to develop the Sutton Closure is presented in the Construction Drawings and Technical Specifications. The development of the closure includes the following general activities; however, the project specific construction activities are included in the contract documents for the project. • excavation of Coal Combustion Residuals (CCR) from the basins and LOLA; • removal of parts of the dikes of the 1971 and 1984 Basins and the LOLA; • reconstruction of dikes in the 1971 Basin and LOLA; • filling and regrading in the 1984 Basin; • construction of surface water management system; and/or • general site work including earthwork and the establishment of vegetation. 1.3 CQA Plan Scope The CQA Plan establishes the quality assurance activities to be implemented during construction at Sutton. The CQA Plan was developed in consideration of the current North Carolina Department of Environment and Natural Resources (NCDENR) guidelines and regulations. The scope of the CQA Plan includes: • defining the responsibilities of parties involved with the construction of the Sutton Closure; • providing guidance in the proper construction of Sutton Closure components; Geosyntec Consultants of North Carolina, PC Duke Energy Coal Combustion Residuals Management Program Appendix H – Construction Quality Assurance Plan Revision 0 December 2016 2 • establishing testing protocols for the evaluation of Sutton Closure components; • establishing procedures for construction documentation; and • providing the means for assuring that the overall construction conforms to the Construction Drawings and Technical Specifications. The CQA Plan is intended to establish procedures for the CQA Consultant and to inform the Contractor of CQA activities during the construction of the Sutton Closure. The CQA Plan is considered a supplement to the Technical Specifications and a part of the construction contract. In the case of any conflict between the CQA procedures described in this plan and the requirements of the Technical Specifications, the Technical Specifications will govern. 1.4 CQA Plan Organization The remainder of this CQA Plan is organized as follows: • definitions of key terms are presented in Section 2; • project organization and descriptions, responsibilities, and qualifications of key parties involved with the construction at Sutton are presented in Section 3; • requirements for CQA documentation are described in Section 4; • CQA activities for the soil components of the Sutton Closure, to include fill placement and general earthwork, are presented in Section 5; • CQA activities for geotextiles and geocomposites are presented in Section 6; • CQA activities for piping and fittings are covered in Section 7; • CQA activities for concrete associated work are outlined in Section 8; and • CQA activities for road construction and general civil site work are presented in Sections 9 and 10, respectively. Geosyntec Consultants of North Carolina, PC Duke Energy Coal Combustion Residuals Management Program Appendix H – Construction Quality Assurance Plan Revision 0 December 2016 3 2 CQA PLAN DEFINITIONS 2.1 Construction Quality Assurance and Construction Quality Control In the context of this document, construction quality assurance and construction quality control are defined as follows: • Construction Quality Assurance (CQA) - The planned and systematic means and actions designed to assure with adequate confidence that materials and/or services meet Construction Drawing and Technical Specification requirements. • Construction Quality Control (CQC) - Those actions which provide a means to measure and regulate the characteristics of an item or service in relation to contractual and regulatory requirements. In the context of this document: • CQA refers to means and actions employed by the CQA Consultant, Engineer, or DEP to assure conformity of the various components of the Sutton Closure construction project with the requirements of the Construction Drawings and Technical Specifications. • CQC refers to those actions taken by the Contractor, Manufacturers, or Installers to ensure that the materials and the workmanship of the various components of the Sutton Closure construction project meet the requirements of the Construction Drawings and Technical Specifications. In the case of the geosynthetic components of these systems, CQC is provided by the Manufacturers and Installers of the various geosynthetics and reviewed by the CQA Consultant. 2.2 Plans and Specifications In this CQA Plan, reference to Construction Drawings and Technical Specifications is understood to mean those plans and specifications issued as a part of a specific contract for construction of a component or phase at Sutton. In all cases, it is expected that this CQA Plan will conform to the Construction Drawings and Technical Specifications. In case of conflict, the approved Construction Drawings and Technical Specifications will govern. 2.3 Geosynthetics Geosynthetics is the generic term for all synthetic materials used in geotechnical engineering applications; the term includes geotextiles, geogrids, geonets, geomembranes, geosynthetic clay liners (GCL), and geocomposites. There is only one type of geosynthetic products referenced in this CQA Plan that are included in the Sutton Closure construction. This geosynthetic is the geotextiles used as filters or separators. Geosyntec Consultants of North Carolina, PC Duke Energy Coal Combustion Residuals Management Program Appendix H – Construction Quality Assurance Plan Revision 0 December 2016 4 2.4 Construction Activities In the context of this CQA Plan, the Sutton Closure construction is understood to include: • excavation of CCR; • surface-water management system components; • other site work including grading and general earthwork; • road work; and • other construction activities as assigned by DEP. 2.5 CQA Lines of Communications Successful execution of this CQA Plan is dependent on open and continuous communication between all parties having a role in the project. The lines of communication between DEP, Design Engineer, Construction Manager, Contractor, and CQA Consultant are defined in the organization charts included in Section 3 of this CQA Plan. Geosyntec Consultants of North Carolina, PC Duke Energy Coal Combustion Residuals Management Program Appendix H – Construction Quality Assurance Plan Revision 0 December 2016 5 3 PROJECT ORGANIZATION AND PERSONNEL 3.1 Overview The Sutton Closure construction organization chart is shown in Figure 3-1. It is understood that the Project Manager will act on behalf of the DEP in all matters relating to the construction of the Sutton Closure. Day-to-day construction activities at Sutton will be managed through the direct interaction of several parties below Project Manager level including but not limited to the Construction Manager, Design Engineer, Contractor, and CQA Consultant. The organization chart for the Sutton Closure CQA Consultant is presented in Figure 3-2. The description, qualifications, and responsibilities of the parties responsible for construction and CQA at Sutton project are described below. 3.2 Construction Manager The Construction Manager shall be an individual employed by the Project Manager and who is responsible for overall management of the construction project at Sutton. In this CQA plan the term "Construction Manager" shall refer specifically to an authorized representative of the Project Manager at Sutton. The Construction Manager will hold a minimum of a baccalaureate degree in construction management, engineering, or related field or have 10 years of construction management experience. The Construction Manager will also have 3 years of earthworks construction experience. The Construction Manager shall be responsible for coordination and oversight of all construction activities including: (i) contract administration; (ii) construction management; (iii) review of any modifications or changes to the construction contract documents; and (iv) final approval authority for contract or shop drawings and submittals. 3.3 Design Engineer The Design Engineer is the individual representing the firm having responsibility for Sutton Closure design. The Design Engineer will hold a minimum of a baccalaureate degree in engineering, be a Professional Engineer registered in the state of North Carolina, and have 10 years’ experience in engineering, or related fields. The Design Engineer shall have expertise which demonstrates significant familiarity with geosynthetics and soils, as appropriate. The Design Engineer is responsible for approving all design and specification changes and making design clarifications that may be required during Closure construction at Sutton. The Design Engineer shall assist the Construction Manager in reviewing and approving the Contractor's shop drawings and submittals, as necessary. The Design Engineer will not be present on-site full time, but will visit the project during construction and attend the project coordination meetings as required to assure conformance with plans and specifications. The Design Engineer will be capable of discussing and interpreting all elements of the Sutton Closure design. The Design Engineer shall have the authority to recommend changes or modifications to the Construction Drawings and Technical Specifications for approval by DEP and NCDENR, as required. Geosyntec Consultants of North Carolina, PC Duke Energy Coal Combustion Residuals Management Program Appendix H – Construction Quality Assurance Plan Revision 0 December 2016 6 3.4 Contractor The Contractor is the firm or corporation having a legally binding agreement to construct components of the Sutton Closure, or shall be qualified construction personnel hired directly by DEP and working under the direct supervision of a construction foreman and superintendent. The Contractor is represented on-site by a qualified individual who is authorized to act on behalf of the Contractor in all matters pertaining to the construction at Sutton. The Contractor shall be qualified, as required by the contract, to perform all aspects of work required to successfully construct the project. The Contractor shall be registered in accordance with applicable local, state, and federal requirements and shall demonstrate adequate (as defined by DEP) prior related experience. The Contractor’s field representative shall be a qualified individual who is able to perform all tasks associated with the Sutton Closure construction activities. The Contractor’s field representative shall demonstrate experience similar to the Construction Manager. The Contractor’s field representative shall have the authority to direct and instruct the Contractor’s crews and its subcontractors. The Contractor is responsible for all construction materials and activities. The Contractor is also responsible for scheduling and coordination of the required work with its subcontractors to complete the project within the construction schedule approved by the Construction Manager. The Contractor shall provide an experienced supervisory representative at all times during any construction activity on-site. The Contractor is responsible for furnishing as-built record drawings and a copy of all documentation required during the construction at Sutton. The Contractor is also responsible for updating all construction drawings for any deviations from the original plans and specifications on a regular basis. The Contractor’s field representative is responsible for coordinating and supervising the work of all subcontractors on-site. At a minimum, the Contractor’s field representative will be responsible for the following: • informing the Construction Manager of any discrepancies between the plans and specifications and the field conditions; • submitting all documentation required by the Construction Drawings and Technical Specifications in a timely manner; • attending all project coordination meetings held on-site; • scheduling all phases of the construction; • maintaining a daily log of all construction activities on-site; • implementing and verifying all QC procedures required of the Contractor and/or subcontractors; and • submitting proposed alternative materials or construction methods to the Construction Geosyntec Consultants of North Carolina, PC Duke Energy Coal Combustion Residuals Management Program Appendix H – Construction Quality Assurance Plan Revision 0 December 2016 7 Manager for approval prior to acquisition, use, and/or implementation. 3.5 CQA Consultant 3.5.1 Definition The CQA Consultant is the party, independent from DEP and the Contractor, responsible for observing, testing, and documenting activities related to the CQA and CQC (e.g., review submittals) of the soil and geosynthetic components and other activities related to the construction at Sutton as described in this CQA Plan. The CQA Consultant and Design Engineer may be the same. 3.5.2 Qualifications The CQA Consultant shall be a firm with documented experience specializing in geotechnical engineering, construction management, and CQA. The CQA Consultant shall possess the equipment, personnel, and licenses necessary to conduct the monitoring and testing activities required by this CQA Plan and the Sutton Closure Construction Drawings and Technical Specifications. The CQA Consultant shall also be experienced in the installation and CQA of soil and geosynthetic materials similar to those materials to be used for the Sutton Closure construction. The CQA Consultant will be experienced in the preparation of CQA documentation including CQA plans, field documentation, field testing procedures, laboratory testing procedures, construction specifications for construction, construction plans, and CQA certification reports. The CQA Consultant shall provide qualified staff for the project. In addition, the CQA Consultant shall provide the following, in writing, to DEP as required: • corporate background and information; • a detailed summary of the firm's CQA capabilities; • a detailed summary of the firm's CQA experience; and • a representative list of at least 10 completed facilities for which the CQA Consultant has provided CQA monitoring services. The CQA Consultant shall provide resumes of personnel to be involved in the project including: • the CQA Certifying Engineer, who operates from the office of the CQA Consultant and who conducts periodic visits to Sutton as required; • the CQA Site Manager, who is located at Sutton; and • CQA Field Monitors, who will be located at Sutton and working under the direction of the CQA Site Manager. Geosyntec Consultants of North Carolina, PC Duke Energy Coal Combustion Residuals Management Program Appendix H – Construction Quality Assurance Plan Revision 0 December 2016 8 The CQA Consultant organization will be led by the CQA Certifying Engineer, who will hold, at a minimum, a baccalaureate degree in engineering and be a Professional Engineer registered to practice in the state of North Carolina. The CQA Site Manager will be the representative of the CQA Consultant at Sutton and will have experience in similar construction and be specifically familiar with the construction of soil and geosynthetic components of the landfill. 3.5.3 Responsibilities The CQA Consultant shall be responsible for monitoring and documenting the activities of the Contractor relative to the installation of the various appurtenances related to the construction at Sutton. The CQA Consultant will be responsible for monitoring the compliance of construction materials delivered to Sutton with the submittals and/or shop drawings previously reviewed and approved by the Construction Manager. The CQA Consultant shall assure that the Contractor’s construction methods and workmanship are performed in accordance with the Construction Drawings and Technical Specifications. The CQA Consultant shall be responsible for obtaining and testing samples of the various construction materials in accordance with the testing frequencies identified in this plan. The CQA Consultant shall also be responsible for obtaining, labeling, and shipping samples for off-site laboratory testing in accordance with the requirements of this plan and the appropriate specifications. The CQA Consultant shall be responsible for soils quality assurance testing to be performed by both the on-site and off-site testing laboratories. The CQA Consultant shall be responsible for staffing and operating the on-site soils laboratory, if required. Test results from the on-site and off-site laboratories shall be submitted to the Construction Manager within a time frame that will not impede or delay construction activities. The on-site soils laboratory, if required, shall be equipped to perform routine index testing including, but not limited to: • standard Proctor (ASTM D 698); • particle-size analysis (ASTM D 422 and ASTM C 136); • Atterberg limits (ASTM D 4318); • moisture content (ASTM D 2216 and ASTM D 4643); • soils classification (ASTM D 2487); and • percent passing No. 200 sieve (ASTM D 1140). The CQA Consultant shall also be responsible for conducting routine field tests during construction of the Sutton closure, which shall include: • moisture content by nuclear methods (ASTM D 6938); Geosyntec Consultants of North Carolina, PC Duke Energy Coal Combustion Residuals Management Program Appendix H – Construction Quality Assurance Plan Revision 0 December 2016 9 • in-place density by nuclear methods (ASTM D 6938); • lift thickness by direct measurement; • sand cone (ASTM D 1556); and • drive cylinder (ASTM D 2937). The CQA Consultant will be responsible for the quality control of its on-site laboratory testing program and for documenting the calibration of the soils laboratory testing equipment. Equipment calibration certificates shall be maintained in the CQA Consultant's on-site project file. All tests will be conducted in accordance with ASTM or other applicable state or federal standards. Test results shall be submitted to the Construction Manager within a time frame that will not impede or delay construction of activities. The duties of the CQA Personnel are discussed in the following subsections. 3.5.3.1 CQA Certifying Engineer The CQA Certifying Engineer: • reviews the Closure Construction Drawings and Technical Specifications; • reviews soils and geosynthetics-related documents (such reviews are for familiarization and for evaluation of constructability only); • attends scheduled and project-specific meetings related to construction quality activities; • administers the CQA program (i.e., assigns and manages on-site CQA personnel, reviews field reports, and provides engineering review of CQA-related activities); • provides quality control of CQA documentation; • reviews changes to the construction design and assures any major changes are submitted to NCDENR for approval prior to incorporation into the Construction Drawing and Technical Specifications; and • with the CQA Site Manager, prepares the final certification report. 3.5.3.2 CQA Site Manager The CQA Site Manager: • acts as the on-site representative of the CQA Consultant; Geosyntec Consultants of North Carolina, PC Duke Energy Coal Combustion Residuals Management Program Appendix H – Construction Quality Assurance Plan Revision 0 December 2016 10 • familiarizes all CQA Field Monitors with the site, project documents, and the CQA requirements; • manages the daily activities of the CQA Field Monitors; • attends regularly scheduled CQA-related meetings on-site; • reviews the ongoing preparation of the construction record drawings; • reviews test results provided by the Contractor; • verifies the calibration and condition of on-site testing equipment; • reviews the CQA Field Monitors' daily reports and logs; • provides reports to the Construction Manager, and documents in a daily report, any reported relevant observations by the CQA Field Monitors; • prepares a daily report for the project; • oversees the collection and shipping of laboratory test samples; • reviews results of laboratory testing and makes appropriate recommendations; • reports unresolved deviations from the CQA Plan and Construction Drawings and Technical Specifications to the Construction Manager; • assists with the preparation of the final certification report; • reviews appropriate certifications and documentation from the Contractor and the Geosynthetics Manufacturer and Installer, and makes appropriate recommendations; • reviews the Geosynthetics Manufacturer's QC documentation; • reviews the geosynthetics Installer's personnel qualifications for conformance with those required by the Technical Specifications; and • performs duties of CQA Field Monitor as needed. 3.5.3.3 CQA Field Monitors The duties of the CQA Field Monitors are monitoring and documenting construction of the soils and geosynthetics components of the Closure and other Sutton Closure activities, as assigned by the CQA Site Manager. The duties of the CQA Field Monitors will include: Geosyntec Consultants of North Carolina, PC Duke Energy Coal Combustion Residuals Management Program Appendix H – Construction Quality Assurance Plan Revision 0 December 2016 11 • monitoring material stockpiles for any deterioration of materials; • monitoring surface-water drainage in the areas of soil and geosynthetic material stockpiles; • preparing daily field reports; • recording CQA activities on field logs; • reporting problems to the CQA Site Manager; • collection of samples from the constructed soil components in accordance with the CQA Plan; • monitoring soil placement and compaction operations; • monitoring the unloading and on-site handling and storage of the geosynthetics; • monitoring geosynthetic repair operations; • monitoring geosynthetic material deployment and installation operations; and • collecting conformance samples for testing by CQA laboratories. In addition to these specific duties, CQA Field Monitors will document on-site activities that could result in damage to the soils or geosynthetic components of the Closure. Observations so noted by the CQA Field Monitors shall be reported immediately to the CQA Site Manager. 3.6 Soils CQA Laboratory 3.6.1 Definition The Soils CQA Laboratory is the party, independent from DEP and Contractor, responsible for conducting geotechnical laboratory tests in accordance with standards referenced in the Construction Drawings and Technical Specifications and this CQA Plan. The testing results generated by the Soils CQA Laboratory shall be used by the CQA Consultant to verify compliance of the soils construction materials with the plans and specifications and submittals previously approved by the Construction Manager. It is anticipated that the on-site Soils CQA Laboratory will be utilized to perform the conformance evaluation testing of the various soils components at Sutton. The off-site soils CQA Laboratory may be for more sensitive performance testing required during construction. Geosyntec Consultants of North Carolina, PC Duke Energy Coal Combustion Residuals Management Program Appendix H – Construction Quality Assurance Plan Revision 0 December 2016 12 3.6.2 Qualifications The Soils CQA Laboratory will be experienced in testing of soils similar to those proposed for use in the construction at Sutton in accordance with ASTM and other applicable soil test standards. The Soils CQA Laboratory will be capable of providing test results within a maximum of 7 working days of receipt of samples and will maintain that capability throughout the duration of the earthwork construction. Prior to construction, the Soils CQA Laboratory, if different from the CQA Consultant, shall submit their qualifications and QA/QC procedures to the Construction Manager for review and approval. The qualifications presented by the Soils CQA Laboratory shall, as a minimum, include: • corporate background and statement of qualifications; • list of testing capabilities including reference to ASTM test methods; • a laboratory QA/QC plan; • information on staff size and experience; and • information regarding test result turnaround time. 3.6.3 Responsibilities The Soils CQA Laboratory will be responsible for testing the various soils components at Sutton. These tests shall include, but not be limited to, material qualification (conformance) tests and material construction quality control (performance) tests as described in Construction Drawings and Technical Specifications. The CQA Consultant will be responsible for coordinating the Soils CQA Laboratory testing. 3.7 Geosynthetics CQA Laboratory 3.7.1 Definition The Geosynthetics CQA Laboratory is the party, independent from DEP, Contractor, and geosynthetics Manufacturer and Installer, responsible for conducting tests on samples of geosynthetic materials used in construction of the Closure in accordance with standards referenced in the Construction Drawings and Technical Specifications and this CQA Plan. The testing results generated by the Geosynthetics CQA Laboratory shall be used by the CQA Consultant to verify compliance of the geosynthetic materials with plans and specifications and submittals previously approved by the Construction Manager. Geosyntec Consultants of North Carolina, PC Duke Energy Coal Combustion Residuals Management Program Appendix H – Construction Quality Assurance Plan Revision 0 December 2016 13 3.7.2 Qualifications The Geosynthetics CQA Laboratory shall hold current accreditation by Geosynthetic Research Institute (GRI) or be approved by the Design Engineer and have experience in testing geosynthetics similar to those proposed for use during construction at Sutton. The Geosynthetics CQA Laboratory shall be familiar with ASTM and other applicable geosynthetic test standards. Prior to construction, the Geosynthetics CQA Laboratory, if different from the CQA Consultant, shall submit their qualifications to the Construction Manager for review and approval. The qualifications presented by the Geosynthetics CQA Laboratory shall, as a minimum, include: • corporate background and statement of qualifications; • listing of testing capabilities including reference to ASTM or other applicable test methods; • a laboratory QA/QC plan; • information on staff size and experience; and • information regarding test result turnaround time. 3.7.3 Responsibilities The Geosynthetics CQA Laboratory will be responsible for testing the geosynthetic component of the Closure. These tests shall include, but not be limited to, geosynthetic conformance and performance tests as described in the Construction Drawings and Technical Specifications. The CQA Consultant will be responsible for coordinating the Geosynthetics CQA Laboratory testing. 3.8 Geosynthetics Manufacturers The geosynthetics Manufacturers are the firms or corporations responsible for production of the geosynthetic materials to be used in construction at Sutton. The geosynthetics Manufacturers shall be able to provide sufficient production capacity and qualified personnel to meet the demands of the project schedule. Prior to shipment of any material to Sutton, each geosynthetics Manufacturer shall be pre-qualified and approved by the Construction Manager. The geosynthetic Manufacturers shall meet the qualifications outlined in the Technical Specifications, respectively. Each geosynthetics Manufacturer is responsible for the production and quality control of its respective geosynthetic product. In addition, each geosynthetics Manufacturer is responsible for the condition of the geosynthetic until the material is accepted by the Contractor. Each geosynthetics Manufacturer shall produce a consistent high quality product that shall meet all the requirements of the Technical Specifications. Each geosynthetics Manufacturer shall submit Geosyntec Consultants of North Carolina, PC Duke Energy Coal Combustion Residuals Management Program Appendix H – Construction Quality Assurance Plan Revision 0 December 2016 14 quality control documentation to the Construction Manager for its respective products as required by the Technical Specifications. 3.9 Geosynthetics Installers The geosynthetics Installers will be experienced and qualified to install the geosynthetic materials of the type specified for this project. The geosynthetics Installers will be approved and/or licensed by the geosynthetics Manufacturers. A copy of the approval letter or license will be submitted by the Contractor to the Construction Manager as required by the Technical Specifications. The geosynthetics Installers shall meet the qualifications outlined in the Technical Specifications. The geosynthetics Installers will designate one representative as its supervisor, who will be responsible for acting as the geosynthetics Installer's spokesman at Sutton. The geosynthetics Installer's supervisor will be responsible for installation of the geosynthetics used in construction at Sutton and for providing supervision and guidance to the installation crew. The geosynthetics Installer's supervisor is also responsible for the following: (i) obtaining samples, as required by the CQA Plan and the specifications; (ii) field testing; (iii) documenting quality control testing activities; and (iv) coordinating the geosynthetics installation activities with the Construction Manager. The geosynthetics Installer's supervisor will be responsible for documenting the geosynthetics installation activities, including, but not limited to, on-site personnel, material inventories, production figures, the Installer’s quality control, test results, installation deficiencies, and resolution of construction problems. 3.10 Surveyor The Surveyor is responsible for lines and grades required for control of the work on an ongoing basis during all phases of the Sutton Closure construction. The Surveyor may be retained by the Contractor, however, they will be independent (not from the same company or parent company) and be available as needed by the CQA Consultant to perform any necessary surveying that may be required for their program. Close interaction between the Surveyor, Contractor, and the CQA Consultant is essential to ensure that construction at Sutton is completed in accordance with the Construction Drawings and Technical Specifications. The project Surveyor shall be a state of North Carolina licensed Professional Land Surveyor or registered Professional Engineer who shall sign and seal all construction survey record drawings. All surveying personnel shall be experienced in the provision of surveying services, including detailed accurate documentation as required in the Technical Specifications. The Surveyor is responsible for all surveying activities and products in accordance with the Technical Specifications. Geosyntec Consultants of North Carolina, PC Duke Energy Coal Combustion Residuals Management Program Appendix H – Construction Quality Assurance Plan Revision 0 December 2016 15 4 DOCUMENTATION 4.1 Overview An effective CQA Plan depends largely on recognition of all construction activities that should be monitored and the assignment of responsibilities for the monitoring of each activity. This is most effectively accomplished and verified by the documentation of quality assurance and quality control activities. The CQA Consultant shall be responsible for assuring that the Contractor's quality control requirements have been addressed and satisfied. The CQA Site Manager shall provide the Construction Manager descriptive daily field reports, data sheets, and logs, as requested, which document that monitoring activities have been accomplished. Examples of some of the forms that will be used to document CQA activities are included in Appendix A. The CQA Site Manager shall also maintain at the job site a complete file of Construction Drawings and Technical Specifications, this CQA Plan, the Contractor's Quality Control Plan(s), checklists, test procedures, daily logs, and other pertinent construction and CQA documents. 4.2 Daily Record Keeping The CQA Consultant's daily reporting procedures shall include: (i) daily summary report; (ii) monitoring logs; (iii) testing data sheets; and (iv) when appropriate, problem identification and corrective measures reports. 4.2.1 Daily Summary Reports The CQA Consultant's daily summary reports shall include the following information as applicable: • an identifying sheet number for cross referencing and document control; • date, project name, location, and other pertinent project identification; • data on weather conditions; • summary on meetings held and their results; • process description(s) and location(s) of construction activities underway during the time frame of report; • descriptions and specific locations of areas, or units, of work being tested and/or observed and documented; • description of locations where tests and samples were taken; • a narrative summary of field test results; Geosyntec Consultants of North Carolina, PC Duke Energy Coal Combustion Residuals Management Program Appendix H – Construction Quality Assurance Plan Revision 0 December 2016 16 • off-site materials received, including quality control documentation; • decisions made regarding acceptance of units of work, and/or corrective actions to be taken in instances of substandard testing results; • identifying sheet numbers of data sheets and/or problem reporting and corrective measures reports used to substantiate the decisions described above; and • signature of the respective CQA Site Manager and/or the CQA Field Monitor. 4.2.2 CQA Monitoring Logs and Test Data Sheets Monitoring observations, sampling information, and test results shall be recorded on the appropriate monitoring logs and test data sheets. The CQA Consultant shall use the monitoring logs and test data sheets to ensure completeness of the required CQA activities. Any corrections to the monitoring logs and test data sheets shall be single line crossed out, initialed by the CQA personnel responsible for the correction and dated. Examples of relevant monitoring logs are presented in Appendix A. The CQA Consultant's monitoring logs and test data sheets shall include the following information as applicable: • project specific information such as project name and location; • the date the CQA activity was performed; • a unique identifying sheet number for cross-referencing and document control; • description or title of the CQA activity or test procedure; • location of the CQA activity or location from which the sample was obtained; • type of CQA activity or procedure used (reference to standard method when appropriate); • recorded observation or test data, with necessary calculations; • results of the CQA activity and comparison with specification requirements (pass/fail); and • the initials or signature of personnel involved in CQA inspection activity. 4.2.3 Nonconformance Identification and Reporting A nonconformance is defined herein as material or workmanship that does not meet the specified requirement(s). Nonconformance identification and corrective measures reports Geosyntec Consultants of North Carolina, PC Duke Energy Coal Combustion Residuals Management Program Appendix H – Construction Quality Assurance Plan Revision 0 December 2016 17 should be cross-referenced to specific summary reports, logs, or test data sheets where the nonconformance was identified. The reports should include the following information as applicable: • a unique identifying sheet number for cross-referencing and document control; • detailed description of the problem; • location of the problem; • probable cause; • how and when the problem was located; • estimation of how long problem has existed; • suggested corrective measures; • documentation of corrections (reference to inspection data sheets); • suggested methods to prevent similar problems; and • signature of the appropriate CQA Field Monitor and concurrence by the CQA Site Manager. In some cases, not all of the above information will be available or obtainable. However, when available, such efforts to document nonconformances can help avoid similar nonconformances in the future. The CQA Site Manager shall distribute copies of the report to the Construction Manager for further actions. 4.3 Photographic Documentation The CQA Site Manager will be responsible for obtaining photographic documentation of the Contractor’s activities, materials installation methods, and testing procedures. Photographs will serve as a pictorial record of work progress, problems, and corrective measures. Photographic reporting data sheets should be utilized to organize and document photographs taken during construction at Sutton. Such data sheets could be cross-referenced or appended to summary reports, CQA monitoring logs, or test data sheets and/or problem identification and corrective measures reports. At a minimum, photographic reporting data sheets should include the following information: • a unique identifying number on data sheets and photographs for cross-referencing and document control; • person responsible for photograph; Geosyntec Consultants of North Carolina, PC Duke Energy Coal Combustion Residuals Management Program Appendix H – Construction Quality Assurance Plan Revision 0 December 2016 18 • the date and location where the photograph was taken; and • location and description of the work; Digital files shall be organized and kept in a protected and secure file or database. 4.4 Design and/or Specifications Changes Design and/or specifications changes may be required during construction. In cases of Contractor initiated changes, the Contractor must submit written requests for such changes to the Construction Manager. The Design Engineer shall review and respond to these requests in a timely manner. All design and/or specifications changes will be made only with the approval of the Engineer of Record and Design Engineer and approval by NCDEQ as required. Such changes will take the form of a design change notice (DCN). 4.5 Nonconformances The Construction Manager will be informed, by the CQA Consultant, in writing of any significant recurring nonconformance by the Contractor, surveyor, geosynthetic Installer, or their subcontractors with the Construction Drawings, Technical Specifications, or CQA Plan. The cause of the nonconformance will be determined by the CQA Consultant. The Contractor will be directed by the Construction Manager to make appropriate changes in materials or procedures in order to correct the nonconformance. When this type of evaluation is made, the results will be documented, and any revision to procedures or specifications must be approved by the Design Engineer. 4.6 CQA Certification Report At the completion of construction phases, the CQA Consultant will provide DEP with a construction phase final certification report for submittal to NCDENR. This report will acknowledge: (i) that the work has been performed in compliance with the approved Construction Drawings, Technical Specifications, and approved modifications; (ii) physical sampling and testing has been conducted at the appropriate frequencies; and (iii) that the summary documentation provides the necessary supporting information. At a minimum, the report will include: • summary of CQA activities; • CQA monitoring logs and testing data sheets including sample location plans; • laboratory test results; • problem identification and reports of corrective measures reports; Geosyntec Consultants of North Carolina, PC Duke Energy Coal Combustion Residuals Management Program Appendix H – Construction Quality Assurance Plan Revision 0 December 2016 19 • a descriptive summary of any changes to the Construction Drawings or Technical Specifications; and • a summary statement indicating compliance with the Construction Drawings or Technical Specifications and any approved changes that are signed and sealed by the CQA Certifying Engineer. The record drawings, which include scale drawings depicting the location of the construction and details pertaining to the extent of construction (e.g., depths, plan dimensions, elevations, soil component thicknesses, etc.), will also be included as part of the final certification report. 4.7 Storage of Records The CQA Site Manager will be responsible for the CQA document storage during the construction at Sutton. This includes the CQA Consultant's copy of the Construction Drawings and Technical Specifications, the CQA Plan, and the originals of the data sheets and reports. When the Sutton Closure construction is complete and upon issuance of the final certification report, the CQA document originals will be organized and retained by the CQA Consultant until requested by DEP. Required records shall include, but not be limited to, field logbooks, other data collections forms, equipment calibration records, costs data, drawings, maintenance records, and associated reports. Geosyntec Consultants of North Carolina, PC Duke Energy Coal Combustion Residuals Management Program Appendix H – Construction Quality Assurance Plan Revision 0 December 2016 20 5 SOILS CONSTRUCTION 5.1 Introduction CQA monitoring and testing shall be performed during installation of the soils components. Criteria to be used for determination of acceptability of the various soil components are identified in the Construction Drawings and Technical Specifications and this CQA Plan. 5.2 Soil Components All general fill placement, grading, and compaction will be monitored and tested in accordance with the Construction Drawings, Technical Specifications, and this CQA Plan. 5.3 Record Drawings and As-Built Surveys During construction of the soil components at Sutton, the CQA Consultant shall routinely review record drawings submitted by the Contractor. The drawings are used to verify location of work, percent of work completed, layer thickness, or final grades. Prior to the placement of successive soil layers, the CQA Consultant shall review as-built surveys that indicate compliance of the preceding layer thickness, lines, and grades. Once an as-built survey has been received, it will be the responsibility of the CQA Consultant to review the information in a timely manner and notify the Contractor of any noncompliance. 5.4 Related Construction Drawings and Technical Specifications Several sections of the Technical Specifications should be referenced by the CQA Consultant for pertinent soil materials physical properties and construction requirements. Related specifications include the following: • Section 02 21 00 Surveying • Section 31 00 00 Earthwork • Section 31 02 19.13 Geotextiles • Section 31 05 16 Granular Drainage Material • Section 31 11 00 Clearing, Grubbing, and/or Stripping • Section 31 23 33 Trenching and Backfilling • Section 31 25 00 Sediment and Erosion Control • Section 31 31 19 Vegetation • Section 31 37 00 Riprap • Section 32 92 19 Seeding • Section 33 42 13 Pipe Culverts • Section 33 49 00 Storm Water Structures and Swales Geosyntec Consultants of North Carolina, PC Duke Energy Coal Combustion Residuals Management Program Appendix H – Construction Quality Assurance Plan Revision 0 December 2016 21 • Section 34 71 00 Road Construction Prior to the start of soils construction, the CQA Consultant shall review the information required by the Technical Specifications listed above. Compliance of the submittals with the Technical Specifications shall be determined by the Construction Manager. 5.5 Subgrade During construction, monitoring of the subgrade preparation shall be performed by the CQA Consultant. This subgrade shall be the base over which structural fill is placed (reconstructed dikes or other pertinent structures). The CQA Consultant shall monitor the subgrade to assure a firm and smooth surface that is free of vegetation and other deleterious materials is achieved. Material placed to achieve grades indicated on the Construction Drawings shall be monitored by the CQA Consultant to verify that the subgrade material and fill placement, grading, and compaction complies with the Technical Specifications. Areas that do not meet the Technical Specifications will be delineated and nonconforming areas will be reworked by the Contractor. This process will be repeated until acceptable results are achieved. The CQA Consultant shall monitor the repair and rework of fill material that is damaged by excess moisture (causing softening). If such conditions are found to exist, the CQA Consultant shall evaluate the suitability of the subgrade by the following methods as applicable: • moisture/density testing; and/or • continuous visual inspection during proof-rolling. The subgrade for the basin only needs to support topsoil placement and does not need to be free of vegetation or smooth before topsoil placement. 5.6 Conformance Testing The CQA Consultant will observe and test the soil components to ensure they are uniform and conform to the requirements of the Technical Specifications. For soil materials obtained from on-site sources, visual inspections and conformance tests shall be performed by the CQA Consultant prior to the materials being used. If soil materials are obtained from off-site borrow sources, visual inspection and conformance tests shall be performed at the source location or as the materials arrive at Sutton. Borrow area inspections may also be utilized by the CQA Consultant to ensure that only suitable soil materials are transported to the Sutton Closure. For off-site borrow areas containing non-uniform materials, it shall be necessary for the Contractor and the CQA personnel to coordinate excavation and monitoring of the segregation of substandard materials. All materials failing to comply with conformance standards shall be rejected for use at Sutton. Initial evaluation of various soil types by CQA personnel during construction shall be largely visual; therefore, the CQA personnel must be experienced with visual-manual soil classification procedures. CQA personnel shall be aware that changes in color or texture can be indicative of Geosyntec Consultants of North Carolina, PC Duke Energy Coal Combustion Residuals Management Program Appendix H – Construction Quality Assurance Plan Revision 0 December 2016 22 a change in soil type. CQA personnel shall observe soils for deleterious materials (e.g., roots, stumps, and large objects). When necessary, the visual-manual procedure for the description and identification of soils shall be conducted by the CQA Consultant in accordance with test method ASTM D 2488. 5.6.1 Test Methods Conformance tests used to evaluate the suitability of soil materials during construction shall be performed in accordance with the current ASTM or other applicable test procedures indicated in Table 5-1. Documentation and reporting of the test results shall be the responsibility of the CQA Consultant. The standard Proctor test (ASTM D 698) shall be used for the evaluation of moisture/density relationships unless otherwise indicated. Any conflict regarding acceptance of test results shall be resolved by the Design Engineer. 5.6.2 Test Frequency The frequency of conformance tests shall conform to the minimum frequencies presented in Table 5-1. The frequency of testing may be increased at the discretion of the CQA Consultant or if variability of the materials is observed. The testing frequencies described herein for general fill shall also apply to materials used by the Contractor in areas outside the limits of the liner and final cover systems at Sutton. 5.7 Construction Monitoring During installation of the various soil components, the CQA Consultant shall visually observe and document the Contractor's earthwork activities for the following: • changes in the soil consistency; • the thickness of lifts as loosely placed and as compacted; • soil conditioning prior to placement including general observations regarding moisture distribution, clod size, etc.; • placement method which may damage or cause displacement or wrinkling of geosynthetics; • the action of the compaction and heavy hauling equipment on the construction surface (sheepsfoot penetration, pumping, cracking, etc.); • the number of passes used to compact each lift; • desiccation cracks or the presence of ponded water; and Geosyntec Consultants of North Carolina, PC Duke Energy Coal Combustion Residuals Management Program Appendix H – Construction Quality Assurance Plan Revision 0 December 2016 23 • final lift or layer thickness. 5.8 Performance Testing During construction, the CQA Consultant shall observe and test the soil components to ensure they are installed in accordance with the requirements of the Construction Drawings and Technical Specifications. The CQA Consultant shall also evaluate the procedures, methods, and equipment used by the Contractor to install the various soil components. 5.8.1 Test Methods All performance testing shall be conducted in accordance with the Technical Specifications or as directed by the Design Engineer. The field testing methods used to evaluate the suitability of soils during their installation shall be performed by the CQA Consultant in accordance with current ASTM test procedures indicated in Table 5-2. Documentation and reporting of the test results shall be the responsibility of the CQA Consultant. The standard Proctor test (ASTM D 698) shall be used for the evaluation of moisture/density relationships unless otherwise indicated. In-place surface moisture/density by nuclear test methods (ASTM D 6938) shall be used for in-situ field testing. At the discretion of the CQA Consultant, the sand cone test method (ASTM D 1556) or drive cylinder test method (ASTM D 2937) may be used to establish correlations of moisture and density in cases of uncertainty, and as a check of the nuclear surface moisture/density gauge calibration. Any conflict regarding acceptance of test results shall be resolved by the Design Engineer. 5.8.2 Test Frequency Performance testing shall be conducted during the course of the work. The minimum construction performance testing frequencies are presented in Table 5-2. The frequency may be increased at the discretion of the CQA Consultant or if variability of the materials is observed by the CQA Consultant. Sampling locations shall be selected by the CQA Consultant. If necessary, the location of routine in-place density tests shall be selected using a non-biased sampling approach. A special testing frequency shall be used at the discretion of the CQA Consultant when visual observations of construction performance indicate a potential problem. Additional testing for suspected areas shall be considered when: • rollers slip during rolling operations; • lift thickness is greater than specified; • material is at improper and/or variable moisture content; • it is suspected that less than the specified number of roller passes are made; Geosyntec Consultants of North Carolina, PC Duke Energy Coal Combustion Residuals Management Program Appendix H – Construction Quality Assurance Plan Revision 0 December 2016 24 • dirt-clogged rollers are used to compact the material; • rollers may not have used optimum ballast; • there is change to subgrade condition since subgrade approval; • fill materials differ substantially from those specified; • the degree of compaction is doubtful; and • as directed by the Design Engineer or the Construction Manager. During construction, the frequency of testing may also be increased in the following situations: • adverse weather conditions; • breakdown of equipment; • at the start and finish of grading; • material fails to meet specifications; and • the work area is reduced. 5.9 Deficiencies If a defect is discovered in the soils construction, the CQA Consultant shall immediately determine the extent and nature of the defect. If the defect is indicated by an unsatisfactory test result, the CQA Consultant shall determine the extent of the deficient area by additional tests, observations, a review of records, or other means that the CQA Consultant deems appropriate. If the defect is related to adverse site conditions, such as overly wet soils or surface desiccation, the CQA Consultant shall define the limits and nature of the defect and the appropriate remedy. As soon as possible, after determining the extent and nature of substandard materials, noncompliant construction practice, or other such deficiency in materials or workmanship which cannot be immediately resolved on-the-spot, the CQA Consultant shall notify the Construction Manager and Contractor and schedule appropriate retests when the work deficiency is to be corrected. The CQA Consultant shall verify that the Contractor has corrected all noted deficiencies. If a specified criterion cannot be met, or unusual weather conditions hinder work, the Contractor shall submit suggested solutions or alternatives to the Construction Manager for review. At locations where the field testing indicates conditions which do not comply with the requirements of the Technical Specifications, the failing area shall be reworked to the satisfaction of the CQA Consultant. Alternatively, at the CQA Consultant’s option, undisturbed Geosyntec Consultants of North Carolina, PC Duke Energy Coal Combustion Residuals Management Program Appendix H – Construction Quality Assurance Plan Revision 0 December 2016 25 samples of in-place material shall be obtained for appropriate testing. All retests performed by the CQA Consultant must verify that the deficiency has been corrected before any additional work is performed by the Contractor in the area of the deficiency. 5.10 Documentation The documentation of soils CQA testing activities is an important factor in assuring the successful construction, performance, and approval of the soil components of the Sutton Closure. The CQA monitoring observations, sample location descriptions, field test results, and on-site laboratory test results shall be documented by the CQA Consultant on forms specifically designed for their purpose. Reports and forms shall be submitted to the Construction Manager as requested. Geosyntec Consultants of North Carolina, PC Duke Energy Coal Combustion Residuals Management Program Appendix H – Construction Quality Assurance Plan Revision 0 December 2016 26 6 GEOTEXTILES 6.1 Introduction The CQA Consultant shall perform conformance testing and shall monitor the installation of geotextile filters and separators as required by Section 31 05 19.13 of the Technical Specifications and this CQA Plan. The testing used to evaluate the conformance of the geotextiles with the requirements of the Technical Specifications shall be performed by the CQA Consultant. The testing shall be performed in accordance with the current versions of the ASTM or other applicable test procedure indicated in Table 6-1. DEP shall be notified prior to installation of any geosynthetics material. 6.2 Transportation, Handling, and Storage The CQA Consultant shall monitor the on-site transportation, handling, and storage of the geotextile. The Construction Manager shall designate a geotextile storage location. During transportation, handling, and storage, the geotextile shall be protected from ultraviolet light exposure, precipitation or other inundation, mud, dirt, dust, puncture, cutting or any other damaging or deleterious conditions. Handling of the geotextile rolls shall be performed in a competent manner such that damage does not occur to the geotextile or to its protective wrapping. Rolls of geotextiles shall not be stacked upon one another to the extent that deformation of the core occurs or to the point where accessibility can cause damage in handling. Furthermore, geotextile rolls shall be stacked in such a way that access for conformance sampling is possible. Protective wrappings shall be removed less than one hour prior to unrolling the geotextile. After unrolling, a geotextile shall not be exposed to ultraviolet light for more than 30 calendar days. Outdoor storage of geotextile rolls shall not exceed the Manufacturers recommendations or longer than six (6) months whichever is less. For storage periods longer than six (6) months a temporary enclosure shall be placed over the rolls or they shall be moved to an enclosed facility. The location of temporary field storage shall not be in areas where water can accumulate. The rolls shall be elevated off the ground to prevent contact with ponded water. Upon delivery at Sutton, the Contractor, Installer, and CQA Consultant shall conduct an inspection of the rolls for defects and damage. This inspection shall be conducted without unrolling the materials unless defects or damages are found or suspected. The CQA Consultant shall indicate to the Construction Manager: • rolls, or portions thereof, which should be rejected and removed from Sutton because they have severe flaws; and • rolls which include minor repairable flaws. Geosyntec Consultants of North Carolina, PC Duke Energy Coal Combustion Residuals Management Program Appendix H – Construction Quality Assurance Plan Revision 0 December 2016 27 The CQA Consultant shall also monitor that equipment used to handle the geotextiles on-site is adequate and does not pose any risk of damage to the geotextiles when used properly. 6.3 Conformance Testing 6.3.1 Sampling Procedures Samples shall be taken across the entire width of the roll and shall not include the first three (3) feet of the roll. Unless otherwise specified, samples shall be three (3) feet long by the roll width. The required minimum geotextile conformance sampling frequencies are provided in Table 6-1. The CQA Consultant shall mark the machine direction on the samples with an arrow and affix a label, tag, or otherwise mark each sample with the following information: • date sampled; • project number; • lot/batch number and roll number; • conformance sample number; and • CQA personnel identification. The geotextile rolls which are sampled shall be immediately rewrapped in their protective coverings to the satisfaction of the CQA Consultant. 6.3.2 Testing Procedure Conformance testing of the geotextile materials will be conducted to ensure compliance with both the Technical Specifications and the Manufacturer's list of minimum average roll values. As a minimum, the geotextile conformance test procedures listed in Table 6-1 shall be performed by the Geosynthetics CQA Laboratory. 6.3.3 Test Results The CQA Consultant shall review all laboratory conformance test results and verify compliance of the test results with the specification shown in Appendix B prior to deployment of the geotextiles. Any non-conformance shall be reported to the Construction Manager. 6.3.4 Conformance Test Failure In the case of failing test results, the Contractor may request that another sample from the failing roll be retested by the Geosynthetics CQA Laboratory with the Manufacturer's technical representative present during the test procedure. If the retest fails or if the option to retest is not exercised, then two isolation conformance samples shall be obtained by the CQA Consultant. These isolation samples shall be taken from rolls, which have been determined by correlation Geosyntec Consultants of North Carolina, PC Duke Energy Coal Combustion Residuals Management Program Appendix H – Construction Quality Assurance Plan Revision 0 December 2016 28 with the Manufacturer's roll number, to have been manufactured prior to and after the failing roll. This method for choosing isolation rolls for testing should continue until passing tests are achieved. All rolls that fall numerically between the passing roll numbers shall be rejected. The CQA Consultant will verify that the Contractor has replaced all rejected rolls. The CQA Consultant shall document all actions taken in conjunction with geotextile conformance failures. 6.3.5 Placement The CQA Consultant shall monitor the placement of all geotextiles to assure they are not damaged in any way, and the following conditions are met. • On slopes, the geotextiles shall be securely anchored in the anchor trench and then deployed down the slope in such a manner as to continually keep the geotextile in tension. • In the presence of wind, geotextiles shall be weighted with sandbags or the equivalent. Such sandbags shall be installed during placement and shall remain until replaced with earth cover material. • Trimming of the geotextiles shall be performed using only an upward cutting hook blade. Special care must be taken to protect other materials from damage which could be caused by the cutting of the geotextiles. • The CQA Consultant shall monitor that the Installer is taking necessary precautions to prevent damage to underlying layers during placement of the geotextile. • During the placement of geotextiles, care shall be taken not to entrap stones, excessive dust, debris, or moisture that could generate clogging of drains or filters. • A visual examination of the geotextile shall be carried out over the entire surface, after installation, to ensure that no potentially harmful foreign objects, (e.g., stones, sharp objects, small tools, sandbags, etc.) are present. 6.4 Seams and Overlaps All geotextile filters shall be continuously sewn (i.e., spot sewing is not allowed). Geotextiles shall be overlapped a minimum of six (6) inches prior to seaming. No horizontal seams shall be allowed on side slopes that are steeper than 10 horizontal to 1 vertical (i.e. seams shall be along, not across, the slope), except as part of a patch. Sewing shall be done using polymeric thread with chemical and ultraviolet resistance properties equal to or exceeding those of the geotextile. The seams shall be sewn using a single row type "401" two-thread chain stitch. The CQA Consultant shall monitor the geotextile seaming procedures to verify that seams and overlaps are in accordance with Section 31 05 19.13 of the Technical Specifications. Geosyntec Consultants of North Carolina, PC Duke Energy Coal Combustion Residuals Management Program Appendix H – Construction Quality Assurance Plan Revision 0 December 2016 29 Geotextile separators may be overlapped a minimum of two (2) feet in lieu of sewing. 6.5 Repair The CQA Consultant shall monitor that any holes or tears in the geotextile are repaired as follows: • On-slopes: A patch made from the same geotextile is double seamed into place (with each seam 1/4 in. to 3/4 in. apart and no closer than 1 in. from any edge) with a minimum 12-in. overlap. Should any tear exceed 50 percent of the width of the roll, that roll shall be removed from the slope and replaced. • Non-slopes: A patch made from the same geotextile is sewn in place with a minimum of 12 in. overlap in all directions away from the repair area. Care shall be taken to remove any soil or other material which may have penetrated the torn geotextile. The CQA Consultant shall observe all repairs and assure that any non-compliance with the above requirements is corrected. 6.6 Placement of Soil Materials The CQA Consultant shall monitor the Contractor's placement of all materials located on top of a geotextile to verify that: • no damage occurs to the geotextile; • no shifting of the geotextile from its intended position occurs and underlying materials are not exposed or damaged; • excess tensile stress does not occur in the geotextile; and • equipment ground pressure on geotextiles overlying geomembranes does not exceed those specified in Section 31 05 19.13 of the Technical Specifications. Soil backfilling shall be completed within 30 days of placement of the geotextiles. On side slopes, soil layers shall be placed over the geotextile from the bottom of the slope upward. Geosyntec Consultants of North Carolina, PC Duke Energy Coal Combustion Residuals Management Program Appendix H – Construction Quality Assurance Plan Revision 0 December 2016 30 7 ROAD CONSTRUCTION 7.1 Introduction The CQA Consultant shall monitor and test materials used in the construction of the various roads to assure compliance with Construction Drawings and Technical Specifications. 7.2 Subgrade Preparation In-place moisture/density testing by nuclear methods (ASTM D 6938) shall be performed by the CQA Consultant for all compacted fill materials. Fill placement and compaction shall be conducted in accordance with Section 31 00 00 of the Technical Specifications. For road subgrades, nuclear moisture/density tests shall be performed at a minimum frequency of 1 test per 200 lineal feet per lift. The CQA Consultant shall monitor the Contractor's proof rolling of cut sections. 7.3 Subbase Layer The CQA Consultant shall monitor and test the subbase layer to ensure it is constructed to the thickness grades and density as required by the Construction Drawings and the Technical Specifications. Moisture/density tests shall be performed at a minimum frequency of 1 test per 200 lineal feet per lift. 7.4 Base Layer The CQA Consultant shall monitor the installation of the base aggregate to ensure it is constructed to the thickness, grades, and limits shown on the Construction Drawings. The CQA Consultant shall monitor the test section required in Section 34 71 00 of the Technical Specifications. 7.5 Quality Assurance Testing Quality assurance testing of the materials used in construction of the roads shall be the responsibility of the CQA Consultant. The frequency of CQA testing for the subbase aggregate and base aggregate materials is as follows: • particle size analysis (ASTM C136) at a frequency of one test per 5,000 yd3; and • density and moisture (ASTM D 6938) at a frequency of one test per 300 lineal feet per lift. Requirements for in-situ density of base aggregates shall be defined during the compaction of a test strip. The base aggregate shall be compacted in accordance with the requirements of Section 34 71 00 of the Technical Specifications. Geosyntec Consultants of North Carolina, PC Duke Energy Coal Combustion Residuals Management Program Appendix H – Construction Quality Assurance Plan Revision 0 December 2016 31 7.6 Repairs If a defective area is discovered, the CQA Consultant will evaluate the extent and nature of the defect. After this determination the Contractor shall correct the deficiency to the satisfaction of the Construction Manager. The Contractor shall not perform additional work in the area until the Construction Manager approves the correction of the defect. In the event of damage, the Contractor shall immediately make repairs and replacements as necessary to the satisfaction of the Construction Manager. Geosyntec Consultants of North Carolina, PC Duke Energy Coal Combustion Residuals Management Program Appendix H – Construction Quality Assurance Plan Revision 0 December 2016 32 8 GENERAL SITE WORK 8.1 Introduction The CQA Consultant shall monitor the activities that are to be performed for various general site work items including, but not limited to riprap, erosion and sediment control, culverts, fences and gates, and vegetation for compliance with Construction Drawings and Technical Specifications. 8.2 Conformance Testing Conformance testing of materials to ensure compliance with the Construction Drawings and Technical Specifications shall be performed by the CQA Consultant at the discretion of the Construction Manager. If non-conformances or other deficiencies are found by the CQA Consultant in the Contractor’s materials or completed work, the Contractor will be required to repair or replace the deficiency at no cost to DEP. Any noncompliant items shall be reported to the Construction Manager. FIGURES Figure 3-1 Sutton Closure Construction Organization Chart Responsible Official DEP Project Manager DEP Construction Manager Construction* Contractor Design Engineer CQA Consultant Other Subcontractors Surveyor Geosynthetics Installer Geosynthetics Manufacturer *The Construction Contractor is assumed to have earthwork capabilities as an integral part of the firm. Otherwise, the earthwork subcontractor is a major entity in this chart under the prime contractor. Figure 3-2 Sutton Closure CQA Organization Chart CQA Consultant CQA Certifying Engineer Site Manager Geotechnical Laboratory Geosynthetics Laboratory Soils Field Monitors Geosynthetics Field Monitors TABLES TABLE 5-1 MINIMUM CONFORMANCE TESTING FREQUENCIES FOR SOIL COMPONENTS TEST NAME/ TEST METHOD GENERAL FILL GRANULAR DRAINAGE MATERIAL VEGETATIVE LAYER SPECIFICATION SECTION 31 00 00 31 05 16 31 31 19 Particle Size Analysis/ASTM D 422 1 test per 10,000 yd3 N/A 1 test per 5,000 yd3 Particle Size Analysis/ASTM C 136 N/A 1 test per 2,000 yd3 N/A Atterberg Limits/ASTM D 4318 (for plastic soils only) N/A N/A N/A Soil Classification/ASTM D 2487 1 test per 10,000 yd3 1 test per 2,000 yd3 1 test per 5,000 yd3 Standard Proctor/ASTM D 698 1 test per 25,000 yd3 N/A N/A Hydraulic Conductivity/ ASTM D 2434 N/A 1 test per 2,000 yd3 N/A Organic Content/ASTM D2974 N/A N/A 1 test per 5,000 yd3 N/A = Not Applicable TABLE 5-2 MINIMUM PERFORMANCE TESTING FREQUENCIES FOR SOIL COMPONENTS TEST NAME/ TEST METHOD GENERAL FILL/ MISC. SOILS SPECIFICATION SECTION 31 00 00 In-Situ Moisture/ASTM D 6938 1 tests per lift per acre or 1 test per 250 lf per lift In-situ Density/ASTM D 6938 1 tests per lift per acre or 1 test per 250 lf per lift Sand Cone/ASTM D 1556 or Drive Cylinder/ASTM D 2937 1 test per 25 nuclear tests (at the discretion of the CQA Consultant) TABLE 6-1 GEOTEXTILE CONFORMANCE TESTING REQUIREMENTS TEST NAME TEST METHOD MINIMUM TESTING FREQUENCY Mass per Unit Area ASTM D 5261 1 test per 100,000 ft2 Grab Strength ASTM D 4632 (1) 1 test per 100,000 ft2 Trapezoidal Tear Strength ASTM D 4533 (2) 1 test per 100,000 ft2 Puncture Resistance ASTM D 4833 (3) 1 test per 100,000 ft2 Static Puncture Strength ASTM D 6241 1 test per 100,000 ft2 Apparent Opening Size (5) ASTM D 4751 1 test per 200,000 ft2 Permittivity (5) ASTM D 4491 1 test per 200,000 ft2 Notes: 1. Minimum of values measured in machine and cross machine directions with 1 inch clamp on Constant Rate of Extension (CRE) machine. 2. Minimum value measured in machine and cross machine direction. 3. Tension testing machine with a 1.75-inch diameter ring clamp, the steel ball being replaced with 0.31-inch diameter solid steel cylinder with a flat tip centered within the ring clamp. 4. At least one test shall be performed for each lot. A lot is defined by ASTM 4354. 5. Apparent opening size and permittivity testing shall be performed for geotextile filter only. Appendix A CQA Forms and Logs WEEKLY FIELD REPORT PROJECT: LOCATION: PROJECT NO.: TASK NO.: DESCRIPTION: WEEK ENDING: COPY TO: PER: Blank - Weekly Report Form.doc SHEET NO 1 OF 1 Blank - Nuclear Gauge Standard Count Log.xls Page 1 of 1 NUCLEAR GAUGE STANDARD COUNT LOG (ASTM D 6938) PROJECT: LOCATION: DESCRIPTION: NUCLEAR GAUGE MODEL: SERIAL NO.: DATE ARRIVED ON-SITE: DATE DEPARTED SITE: DATE OF MOST RECENT LEAK TEST: DATE (day/mo) DATE (day/mo) MOISTURE COUNT (< 2%)QA IDMOISTURE COUNT (< 2%) DENSITY COUNT (< 1%)FA I L PA S S DENSITY COUNT (< 1%)PA S S FA I L QA ID YEAR: PROJECT NO.: TASK NO.: Blank - Material Inventory.xls REVIEWED BY: _______SHEET _____ OF _____ MATERIAL INVENTORY PROJECT: LOCATION: DESCRIPTION: MATERIAL TYPE: PA S S FA I L PA S S FA I L (ft) AVERAGE ROLL LENGTH (ft) (ft2) COMMENTS: NUMBER OF ROLLS ABOVE:CUMULATIVE NUMBER OF ROLLS: AVERAGE ROLL WIDTH: CUMULATIVE AREA:NO. OF CONFORMANCE TESTS (page/total): MANUFACTURER: DATE REC'VED DATE CHECKED Q.A. CONFORMANCE TASK NO.: DATE QA IDBATCH / ROLL NUMBER INVENTORY QA ID Q.C. DOCUMENTS DATE SAMPLED SAMPLE NO.QA ID YEAR: PROJECT NO.: Bl a n k - F i e l d N u c l e a r M o i s t u r e D e n s i t y T e s t L o g . x l s Page 1 of 1 FI E L D N U C L E A R M O I S T U R E / D E N S I T Y T E S T L O G ( A S T M D 6 9 3 8 ) P R O J E C T : L O C A T I O N : D E S C R I P T I O N : da y month year S P E C I F I C A T I O N R E Q U I R E M E N T S : MA T E R I A L T Y P E : F I L L S U B G R A D E S U B B A S E C L A Y O T H E R : MA X . L I F T T H I C K N E S S : (in.) MI N I M U M C O M P A C T I O N : (% ) A S T M D 6 9 8 A S T M D 1 5 5 7 - of OPT. NU C L E A R G A U G E T Y P E : NO T E S : ( 1 ) F I E L D M O I S T U R E C O N T E N T = G A U G E R E A D I N G / C O R R E C T E D M O I S T U R E C O M M E N T S : CH E C K E D B Y : DA T E : PR O J E C T N O . : T A S K N O . : RE-TEST NO.to + MA T E R I A L S O U R C E : LA B O R A T O R Y R E S U L T S GA U G E S E R I A L N O . : CO R R E C T I O N F A C T O R : Y = MO I S T U R E C O N T E N T R A N G E : FAIL DR Y U N I T WT (p c f ) TE S T L O C A T I O N MA X . D R Y UN I T W T . ( p c f ) TE S T N O . PR O B E DE P T H / LI F T N O . SA M P L E N O . OM C (% ) FI E L D M O I S T U R E CO N T E N T 1 ( % ) WE T U N I T WT (p c f ) RE-TEST PASS FAIL PE R C E N T CO M P A C T . (% ) PASS FI E L D T E S T R E S U L T S Appendix B Required geotextile filter and separator properties Tables 31 02 19.13-1 and 31 02 19.13-2 (from Technical Specification Section 31 02 19.13) Section 31 02 19.13: Geotextiles Sutton Removal Plan, Rev 0 GC5770\31 02 19.13 Geotextiles.docx 31 02 19.13-6 December 2015 TABLE 31 02 19.13-1 REQUIRED PROPERTY VALUES FOR GEOTEXTILE FILTER Properties (6) Qualifier Units (5) Specified Values(1) Test method Product Requirements Type -- -- Nonwoven needle-punched -- Polymer composition Minimum % 95 polypropylene or polyester by wt -- Mass per unit area Minimum oz/yd2 8 ASTM D 5261 Filter Requirements Apparent opening size Maximum mm O95 ≤ 0.21 ASTM D 4751 Permittivity Minimum sec-1 0.5 ASTM D 4491 Mechanical Requirements Grab strength Minimum lb 200 ASTM D 4632(2) Tear strength Minimum lb 75 ASTM D 4533(3) Static puncture strength Minimum psi 500 ASTM D 6241 Durability Requirements Ultraviolet Resistance Minimum % 70 ASTM D 4355 Notes: 1. All values represent minimum average roll values. 2. Minimum of values measured in machine and cross machine directions with 1 inch clamp on Constant Rate of Extension (CRE) machine. 3. Minimum value measured in machine and cross machine direction. 4. Not Used. 5. mm = millimeter % = percent oz/yd2 = ounce per square yard sec = second lb = pound psi = pound per square inch 6. See Paragraph 2.02 for required MQC test frequencies. Section 31 02 19.13: Geotextiles Sutton Removal Plan, Rev 0 GC5770\31 02 19.13 Geotextiles.docx 31 02 19.13-7 December 2015 TABLE 31 02 19.13-2 REQUIRED PROPERTY VALUES FOR GEOTEXTILE SEPARATOR Properties (6) Qualifier Units (5) Specified Values (1) Test method Product Requirements Type -- -- Nonwoven needle- punched -- Polymer composition Minimum % 95 polypropylen e or polyester -- Mass per unit area Minimum oz/yd2 8 ASTM D 5261 Mechanical Requirements Grab strength Minimum lb 200 ASTM D 4632(2) Tear strength Minimum lb 75 ASTM D 4533(3) Static puncture strength Minimum psi 500 ASTM D 6241 Durability Requirements Ultraviolet Resistance Minimum % 70 ASTM D 4355 Notes: 1. All values represent minimum average roll values. 2. Minimum of values measured in machine and cross machine directions with 1 inch clamp on Constant Rate of Extension (CRE) machine. 3. Minimum value measured in machine and cross machine direction. 4. Not Used 5. % = percent oz/yd2 = ounce per square yard lb = pound psi = pound per square inch 6. See Paragraph 2.02 for required MQC test frequencies. [END OF SECTION]