CONSTRUCTION QUALITY ASSURANCE FINAL REPORT ON-SITE DISPOSAL FACILITY, PHASE I1 CELL 3 November 1999 Revision 0 United States Department of Energy Fernald Environmental Management Project Fernald, Ohio Prepared by GeoSyntec Consultants Fernald Field Office 7400 Willey Road, Mail Stop 3 8 Hamilton, Ohio 4.50 13 Under , Fluor Daniel Fernald Subcontract 95PS005028 GeoSyntec Consultants TABLE OF CONTENTS 1. INTRODUCTION ............................................................................................................................ 1 1.1 TERMSOF REFERENCE.................................................................................................................... 1 1.2 BACKGROUND................................................................................................................................ 1 1.3 REPORTORGANIZATION ................................................................................................................... 3 2 . PROJECT DESCRIPTION ............................................................................................................. 4 3. CONSTRUCTION QUALITY ASSURANCE PROGRAM ............ :............................................ 8 3.1 SCOPEOF SERVICES........................................................................................................................ .8 3.1.1 Overview...................................... ..................................................................... 8 3.1.2 Review of Documents ........................................................... 8 3.1.3 CQA Field Operations ... .................................................................................... 9 3.1.1 Final Report and Record Drawings .... ....................................................... 13 3.2 PERSONNEL.................................................................................................................................. 17 3.2.1 . Project Personnel ........................ ...................................................................... 17 . 3.2.2 GeoSyntec 's On-Site Personnel Schedules ............... ........................ 20 4 . CONSTRUCTION QUALITY ASSURANCE .EARTHWORK .............................................. 21 4.1 GENERAL...................................................................................................................................... 21 4.2 CHANGESIN EARTHWORKSPECIFICATIONS .................................................................................. 23 4.3 CONFORMANCEACTIVITIES .................................................. .................................................. 23 4.4 FIELDMON~~~RING ACTIVITIES .................................................................................................... 25 1.1.1 General.......................................................... ....................................................... 25 4.4.2 Excavation ................................................................................ ..................... 25 . 4.4.3 Compacted Fill., .............................. :....... .................................................... ....... 26 1.1.4 Compacted Clay Liner .......... .................................... ............................................ 26 4.4.5 Leak Detection System Layer ..................... ............................................... 4.1.6 Leachate Collection System Layer .................................... .................................... 29 4.4.7 Protective Layer .................................... ....................................... 4.5 FIELDTESTING AcmInEs .............................. ........................................................ 30 4.5.1 Geotechnical Testing ......................................................................... ................... 30 4.j.3 Compacted Clay Liner/Clay Wedge ....................... ........................................... 4.5.4 Leak Detection System Layer ............ ........................................... 4.5.5 Leachate Collection System Layer ........................ .................................. 37 4.5.6 Protective Layer ........................................................................ ........................... 38 4.6 SOILANCHORAGE OF GEOSYNTHEnCS ......................................................................................... 38 4.6.1 General .................................................................................. ...................................... 38 4.6.2 Perimeter Anchor Trenches ...................................................................... GQ0409-03.1/F9900 14 1 99.12.13 GeoSyntec Consultants TABLE OF CONTENTS 5. CONSTRUCTION QUALITY ASSURANCE - GEOSYNTHETICS........................................ 43 5.1 GENERAL...................................................................................................................................... 43 5.2 CHANGESIN GEOSYNTHETICSSPECIFICATIONS ............................................................................. 43 5.3 CQA OF GEOSYNTHETICCLAY LINER .......................................................................................... 44 5.3.1 Conformance Testing and Documentation......................................................................... $4 5.3.2 Field Monitoring Activities.................... ................................................... 17 5.3.2.1 Delivery and On-Site Storage ............................................. .................................. 47 5.3.2.2 Deployment ................................................................. .............................................. 47 5.4 CQA OF GEOMEMBRANE.............................................................................................................. 49 5. 4.I Conformance Testing and Documentation................................ 5.4.2 Field Monitoring Activitie ..................................................... 5.4.2.2 Deployment ........................................ ......................................................... 5.4.2.3 Trial Seams ......................... 5.4.2.4 Production Seams ........ ......................... 52 ...................................... 53 . 5.4.3.1 Scope ............................... ................................................. ...................... 53 5.4.3.3 Vacuum-Box Testing ......... ............................................... ..................... 54 5.4.I Destructive Seam Sample Testing ..................................................... 5.4.4.1 Scope ........................................................ ............................................ 5.4.4.2 Sampling Procedures ................................ .......................................... j.4.4.3 Test Results ......................................... ................................................ 5.4.3 Geomembrane Repairs ................ ......................................... ................... 57 5.4.6 Electrical Leak Detection Testing ........... ........................................ j.j CQA OF GEOTEXTILE................................................................................................................... 59 5.5.1 Conformance Testing and Documentation........................ ................................. 59 . 5.52 Field Monitoring Activities........... j.j.2.1 Delivery and On-Site Storage........................ 5.5.2.2 Deployment ...................... ..................................... 5.6 CQA OF LINERp~ETR4TlON BO 5.7 CQA OF HDPE PIPING................................................................................................................. -62 5.7.1 Pipe Conformance Testing and Documentation. .................. 63 5.7.2 Field Monitoring Activities .63 6. CONSTRUCTION QUALITY ASSURANCE - ENHANCEMENT TO LEACHATE . CONVEYANCE SYSTEM ................................................................................................................ 71 6.1 GENERAL...................................................................................................................................... 71 6.2 CHANGES IN DRAWINGSAND SPECIFlCATION~.............................................................................. 72 6.3 PIPECONFORMANCE TESTING AND DOCUMENTA~ON.................................................................. 72 .. GQ0409-03.1/F990014 11 99.12.13 000003 L GeoSyntec Consultants TABLE OF' CONTENTS 6.4 FIELDMONITORING ACnVmES .................................................................................................... 72 6.4.I Delivery and Placement ....................................................................... .? ..... 1 ...................... 72 6.4.2 Testing Activities ................................................................................................................ 71 7. SUMMARY AND CONCLUSIONS ............................................................................................. 76 REFERENCES APPENDICES Appendix A: Cell 3 Interim Construction Certification Letter Appendix B: Photographic Documentation Appendix C: Weekly Field Reports Appendix D: Minutes of OSDF Weekly Construction Meetings Appendix E: Personnel Logs Appendix F: Geotechnical Laboratory Test Results Compacted Fill Compacted Clay Liner and Clay Wedge Phase II Cell 2 (1998) Laboratory Testing Phase II Cell 3 (1999) Laboratory Testing APZ Curves Used for Cell 3 Construction Stockpile 98-1 3 Stockpile 99- 1 Stockpile 99-2 Stockpile 99-3 Stockpile 99-4 Stockpile 99-5 Pipe