Infrastructure, Innovation and Standardization Infrastructure, Innovation and Standardization. A look at how one lock closure at Montgomery locks and dam lead to an innovation in standardization of critical components. Josh Nickel, Structural Engineer, USACE-Pittsburgh District

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Conventional Installation Method Wet Method System Level adaptability Agenda Background Courses of Action Task Defined Conventional Installation Method Wet Method System Level adaptability Impacts Lessons Learned Way Ahead Allegheny L/D 5

1936 10 - Vertical Dam Gated bays 1 - Overflow Section 1 - 56’ x 360’ auxiliary chamber 1 - 110’ x 600‘ main chamber lock

Poiree Dam Upstream, needle beam slots 56’ x 360’ auxiliary chamber 110’ x 600‘ main chamber lock, no closure structure

Background Main chamber Bulkhead Slot Construction Scheduled May 2016 Use Existing USACE Bulkhead NTNI issued, lockage's in Auxiliary during construction Auxiliary Chamber sill was damaged Preparing for construction, auxiliary was dredged Dredge damaged the lower sill

Background Red tagged closure structure, poiree dam, no bulkhead slots, no other closure structure Red tagged = Not Fit For Service Dredging damage to sill, no way to work in the dry Lock struts for monolith stabilization during dewatering were in fabrication and not available

Courses of Action Evaluation Criteria Course of Action (COA) Cost Regional Schedule Nav Impacts Safety Quality Risk TOTALS 1) Request a waiver from EC to use the Poiree Dam so that the Auxiliary Chamber can be dewatered Moderate moderate advantage neutral 2) Sheet pile closure device significant 3) Make repairs to the sill in the wet WAY AHEAD Needle beam maintenance closure system Eliminated – no current supporting feature -> design, construct-> large cost, long schedule and integration into structure is complex Use of Gravity Blocks Eliminated – investigated and will not work at the pool elevation needed Dam sill dewatering box Eliminated – significant structural modifications needed, only repair small sections->design and install modifications->large cost, long schedule Evaluation Criteria - Cost: within $1.8m budget - Regional schedule: Nov-Dec, 2015 (26 days) - Navigation impacts: timeliness of repair - Safety: workforce - Quality: reliability & longevity Risk: unanticipated impact to cost, schedule, navigation, safety, and quality

Task Defined Design new sill system, installed in the wet (dry) Bonus points (Efficient Engineering? System Understanding?) Look beyond isolated problem. Systems Perspective Problems = Opportunities Incorporate features that would make it universally adaptable to all LRP sites therefore replacing all previous sill designs Designed to facilitate an efficient localized change out of the seal and other assemblies should normal wear or damage require replacement of any piece of the sill system

Conventional Installation Method Schedule 21 workdays, 7392 hours Chamber dewatered Note - Miter Gates are not in place

Wet Method Design / Fabrication ? As-Builts/differing site Conditions ? Near zero visibility Demo ? Installation ? Alignment ? Grout pumping ? Grout formwork ?

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Miter Gates Concrete Removal Area

Miter Assembly Installation Procedure Open Miter Gates Drop Miter Assembly in Close Miter Gates, Lock Into Place Push Miter Assembly to Miter Gates Install Temporary Anchors

Repeat Installation Procedure Open Miter Gates Drop Assemblies in Close Miter Gates, Lock Into Place Push Assemblies to Miter Gates Install Temporary Anchors

Installation Procedure Cycle Miter Gates Install Permanent Hilti Anchors Place Grout Behind Assemblies

Note - Miter Gates are in place Schedule Phase 1 – Demo 29 workdays, 3712 hours (learning curve) 14 work days, 1792 hours (future, estimated) Phase 2 - Installation 18 workdays, 2304 hours Chamber NOT dewatered Note - Miter Gates are in place

Systems Level adaptability Adjustability in every part Upstream / downstream / height / leveling Pintle is the only site specific assembly due to geometries of the walls/pintle/recess

Impacts Streamlined Maintenance, increased efficiency Corrosion Protection, longer life span Reduced future closure duration When system is damaged, change out localized assembly or sub assembly in as little as 1 work day! Reduction of parts inventory (Space and $$$) Time to react, NTNI, reductions to levels of service

Lessons Learned Every Solution offers opportunity for continuous improvement No such thing as over communicating Design is important but so is “Partnering” and Leading change with innovative solutions and ideas. Demo was the hardest and longest component Underwater concrete saw ordered but did not arrive in time, but believed to drastically reduce time. Bolted assembly had different bolt sizes and threads.

Way Ahead 2217 lockage's since installation April 2016 Diver inspection the week of 9/11/17 to verify condition

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Questions