1. 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

2. USACE Vision
Engineering Solutions for our Nations' toughest challenges

3. 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

4. 1936
10 - Vertical Dam Gated bays
1 - Overflow Section
1 - 56’ x 360’ auxiliary chamber
’ x 600‘ main chamber lock

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

6. 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

8. 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

9. 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

10. 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

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

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

18. VIDEO

20. Miter Gates
Concrete Removal Area

21. 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

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

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

29. 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

30. 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

31. 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

32. 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.

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

34. VIDEO

35. Questions