Photos

Princeton Dam
35% Design Report
DFD Project Number 13K1I
Prepared by
For
State of Wisconsin
Wisconsin Department of Administration
Division of Facilities Development
February 2015
Princeton Dam 35% Design
Princeton Dam
Wisconsin Department of Natural Resources
Green Lake County, WI
DFD Project No. 13K1I
35% Design Report Appendix
Appendix A – Background and Design Concept
Appendix B – Reduction of Downstream Hydraulic
Appendix C – Raised Fixed Crest to Replace Flashboard System
Appendix D – Bypass Fishway
Appendix E – Site Improvements
Appendix F – Construction Considerations
Appendix G – Opinion of Probable Construction Cost
Appendix H – Project Schedule
Attachment A – 35% Design Drawings
Attachment B – Site Improvement Photographs
Final Report
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Princeton Dam 35% Design
DISCLAIMER
The findings, interpretations of data, recommendations, specifications or professional opinions
presented in this report are based upon available information at the time the report was
prepared. Studies described in this report were conducted in accordance with generally
accepted professional engineering and geological practice, and in accordance with the
requirements of the Client. There is no other warranty, either expressed or implied.
The findings of this report are based on the readily available data and information obtained
from public and private sources, and information obtained from the State of Wisconsin and
Lake Puckaway Association. Additional studies (at greater cost) may or may not disclose
information that may significantly modify the findings of this report. MWH accepts no liability
for completeness or accuracy of the information presented and/or provided to us, or for any
conclusions and decisions that may be made by the Client or others regarding the subject site
or project.
The Client acknowledges that MWH has no control over costs of labor, materials, competitive
bidding environments and procedures, unidentified field conditions, financial and/or market
conditions, or other factors likely to affect any Opinion of Probable Construction Cost of the
concepts described in this report, all of which are and will unavoidably remain in a state of
change, especially in light of the high volatility of the market attributable to Acts of God and
other market events beyond the control of the parties. Client further acknowledges that any
cost opinions are a “snapshot in time” and that the reliability will inherently degrade over time.
Client agrees that MWH cannot and does not make any warranty, promise, guarantee, or
representation, either express or implied, that proposals, bids, project construction costs, or
cost of operation or maintenance will not vary substantially from MWH’s good faith estimates
of Opinion of Probable Construction Cost or Schedule.
This report was prepared solely for the benefit of the Client. No other entity or person shall use
or rely upon this report or any of MWH's work products unless expressly authorized by MWH.
Any use of or reliance upon MWH's work product by any party, other than the Client, shall be
solely at the risk of such party.
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Princeton Dam 35% Design
Appendix A – Background and Design Concept
Operation of the Princeton Dam in its current configuration presents a significant safety hazard with
potentially perilous consequences. Recent evidence of this is the near drowning by the contract
operator in 2012 while removing flashboards to lower the summer water levels for the winter season.
Aside from the primary purpose of reducing the safety risk, modifying the dam may stabilize water levels
for the residents of the Lake Puckaway Association and may help implement future water quality and
fisheries improvements. These are the desired outcomes for both the Wisconsin Department of Natural
Resources (WDNR) and the local public both upstream and downstream from the existing dam.
Subsequently, MWH was retained by the WDNR to prepare a 35% design for modifications to Princeton
Dam to meet WDNR objectives. The project consists of the placement of rip rap downstream of the
dam to reduce the downstream hydraulic, replacement of the flashboard system with a raised fixed
crest, and construction of a bypass fishway structure within the dam’s left abutment (looking
downstream). Additional site improvements include:
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Replacement of the lock slide gates, guides and upgraded actuators;
Removal of trees and brush adjacent to the dam and lock dry masonry structures:
Reconstruction of the lock gate structure access steps;
Relocation of the gate operations control panel;
Replacement of the wooden gateway decking with steel grating; and
Additional security fencing.
The 35% design also includes the deactivation of the existing electric fish barrier.
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Princeton Dam 35% Design
Appendix B – Reduction of Downstream Hydraulic
Operation of the Princeton Dam in its current configuration presents a significant safety hazard with
potentially perilous consequences. Recent evidence of this is the near drowning by the contract
operator in 2012 while removing flashboards to lower the summer water levels for the winter season.
The potential for a hydraulic forming downstream of Princeton Dam can be greatly reduced by filling in
the area downstream of the dam with a gently sloping rip rap fill. The rip rap would have to be large
enough to prevent movement when subjected to flows plunging over the dam’s raised fixed crest. The
35% design assumes that the downstream rip rap can be placed in the wet, and that sufficient quantities
of material can be obtained within 20 miles of the project site.
Previous studies(1) have been conducted to identify means of reducing dangerous hydraulics from
forming downstream of fixed crest dams in Illinois. The studies have indicated that the rip rap would be
placed approximately 2 feet below the fixed crest and have a slope no steeper that 1V:10H. These
studies have also indicated that a D30 of 1.3 feet would be required.
In addition, the rip rap would have to be sufficiently sized to resist movement resulting from plunging
flow velocities associated with an assumed drop of 2 feet over the raised fixed crest. Using USACE HDC712-1(2) and assuming turbulent flow similar to the condition downstream of a stilling basin, the required
size for rip rap would have a D15 of 1.0 foot, D50 of 1.9 feet, and D100 of 2.4 feet.
WSDOT extra heavy rip rap gradation meets the D100 requirement regarding the maximum size, but
would not meet the size requirement over the entire gradation. Consequently, the WSDOT extra heavy
rip rap material would need to be further processed to improve its gradation to reduce the hydraulic as
well as resist movement during the critical plunging flow condition.
During final design, reducing the size of the rip rap beneath the upper layer of extra heavy rip rap will be
studied to utilize more locally available and lower cost material. The possibility of terminating the
“feathering” at the downstream end of the rip rap and changing the rip rap gradation immediately
downstream of the bypass fishway will also be considered during the final design phase to further
reduce the costs.
References:
(1) Evaluation of Public Safety at run-of-River Dams, and Illinois Statewide Program, Capital
Development Board of Illinois, CDB Project # 102-00-061, CTE/AECOM, July20, 2007
(2) US Army Corps of Engineers, Hydraulic Design Criteria, Vicksburg, Mississippi
Final Report
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Princeton Dam 35% Design
Appendix C – Raised Fixed Crest to Replace Flashboard System
Current operations involve installing flashboards in the late spring-early summer to increase Lake
Puckaway summer recreational levels, and removing them in late summer-early fall to lower lake levels
for the winter season. The current flashboard system consists of placement of three levels of 2-in by 6in (nominal) wooden boards totaling 16.5 inches in height against steel pins inserted in the crest 4-foot
on centers. The flashboard installation and removal often occurs with flow passing over the dam which
subjects workers to difficult and potentially dangerous working conditions.
The 35% design features replacing the flashboard system with a 16.5-in thick by 15-foot-wide raised
fixed crest concrete slab overlay. The overlay would be sloped to match the slope of the existing crest.
The sloping crest would allow floating debris which is currently collecting in the flashboards to pass over
the dam. The sloping crest would also reduce the winter ice loads on the dam.
The reinforced cast-in-place concrete slab overlay would be doweled into the existing 6-in-thick overlay
and supporting timber cribbing. The design assumes that dowels would be spaced one foot on centers
and the slab would be placed in a “checkerboard” fashion with waterstops along the upstream edge
intermediate construction-contraction joints.
The 35% design assumes that the Fox River can be lowered sufficiently to place the slab overlay in the
dry without the use of a cofferdam during summer low flow conditions while diverting flows through the
lock gate structure.
The 35% design layout of the raised fixed crest slab overlay is presented on Drawings 01 and 02.
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February 2015
Princeton Dam 35% Design
Appendix D – Bypass Fishway
The ability to provide seasonal fish passage is an important feature of the 35% design. A stepped bypass
fishway located in the left abutment of the dam will allow fish passage at critical times, as well as
incorporate a stop log system to provide a barrier to unwanted species.
The 35% design bypass fishway (Drawings 01 and 02) was prepared with dimensions similar to those at
the upstream Montello Dam. The bypass fishway features stepped stilling pools approximately 24-feetwide by 30-feet-long located within the dam’s left abutment. The bypass fishway consists of two
“steps” featuring rest pool boulders, located at the upstream and downstream sections. The upstream
section of the bypass fishway projects approximately 15 feet into the reservoir upstream of the dam and
has an entrance weir at a level approximately 6 inches lower than the raised fixed crest level. The
downstream section is located within the timber crib dam and has a weir in line with, and at a level 18
inches lower than, the raised fixed crest dam.
The upstream section forming half of the bypass fishway is a sheetpile “box”. The 35% design assumes
that the most appropriate and available sheeting for this application would be PZC 13 sheeting. The
sheeting would be driven in the wet.
The downstream section of the bypass fishway consists of a precast concrete-lined channel placed
within the timber crib dam. Placement of the channel would require the removal of 7.5 feet of the rockfilled timber crib dam in the wet. The upstream sheetpile cutoff and bypass fishway sheetpile “box”
would serve as the upstream cofferdam to divert flow around the work area during the removal of the
timber cribbing and placement of the pre-cast concrete-lined channel.
The 35% design assumes that each of the timber crib “cells” measure 15-feet by 12-feet, which sets the
interior width of the concrete bypass fishway channel at 22 feet. During the final design the dimensions
of the timber cribbing cells will be verified and the final precast bypass fishway width will be selected.
Should the cribbing width be 15 feet, the bypass fishway will be reduced to 13 feet, and if the cribbing
width be 10 feet, the bypass fishway will be reduced to 18 feet.
In order to reduce the weight of the precast concrete-lined channel and construction crane
requirements, the channel would be fabricated in two pieces. During the final design phase
consideration could be given to precast the base slab and walls separately to further reduce the weight
and crane requirements.
The precast channel would feature a center pier at the downstream end with access walkway to allow
the placement of wooden stoplogs to close the bypass fishway to prevent the upstream migration of
invasive species during warm water conditions.
The downstream rip rap gradation and depth associated with the reduction of the hydraulic would be
altered immediately downstream to attract and pass game fish through the bypass fishway. The bypass
fishway would be lined with WISDOT light rip rap similar to the material gradation used to line the
Montello Dam, and will provide randomly placed rest pool boulders.
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February 2015
Princeton Dam 35% Design
Appendix E – Site Improvements
The evaluation study included a site visit to observe the condition of the primary water retaining
structures. The observation included the dam, intermediate embankment, and lock walls and lock gate
system located at the upstream entrance to the lock.
The 35% design includes the following site improvements:







Removal of brush and trees near and in the dam and lock dry masonry abutments and walls.
Removal of the brush within the gate control panel area and lining the area with geotextile
material and stone to prevent future growth.
Construction of concrete stairs at both entrances to the lock gate walkway, replacing the
deteriorated wooden steps.
Replacement of the timber walkway decking with steel grating.
Relocate the motor control panel to the walkway sufficiently high to prevent future water
damage during high flow events.
Replacement of the lock slide gates with new upstream frame supporting new gate guides, gates
and actuators.
Installation of security fencing around the perimeter of the lock abutments and walkway.
Since the 35% design features a raised fixed crest to replace the flashboard system, the upstream safety
cable system will no longer need to be improved. In addition, the ability to close the bypass fishway
with stoplogs, the electric fish barrier will no longer be required, and will be deactivated.
Drawing 03 indicates the general areas where the site improvements will be made. Photographs of the
critical areas needing improvements are provided as an attachment to the Appendix.
Final Report
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February 2015
Princeton Dam 35% Design
Appendix F – Construction Considerations
The timber crib rockfill dam serves as a fixed crest spillway. The project improvements are to reduce the
downstream hydraulic by placing processed extra heavy rip rap downstream of the dam, and replace the
seasonal installation and removal of the flashboards with a 16.5-in thick concrete slab overlay on the
crest of the dam. Finally, a 24-foot-wide section of the timber crib dam will be removed for the
installation of a two-section precast concrete bypass fishway channel. A sheetpile “box” located
upstream of the precast channel will complete the bypass fishway.
It is MWH’s opinion that due to the high water levels, excessive scour downstream of the dam, and
difficulty in dewatering the construction area for placing the slab overlay, the use of a cofferdam may
not be an economically viable option. The 35% design assumes that the placement of the slab overlay
could be completed without a cofferdam during the summer low flow period with the Fox River diverted
through the opened lock gates. However, the construction bid documents will allow the contractor to
propose a cofferdam arrangement in their bid.
The partial demolition of the timber crib and placement of the bypass fishway will be performed in the
wet behind the sheetpile cutoff wall and upstream sheet pile “box”. The placement of the fixed crest
slab overlay can be performed in the dry during the diversion of the low Fox River summer flows
through the adjacent lock gates. The placement of the downstream rip rap rockfill will be placed in the
wet after the completion of the dam improvements.
The 35% design included a preliminary constructability review resulting in the development of a possible
sequence of possible construction activities that could be used to avoid the use of an expensive
cofferdam. The flowing possible sequence of construction activities is presented on Drawings 01 and 02.
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


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

Stage 1 – Place a partial sheetpile cutoff along the upstream face of the dam
Stage 2 – Place the bypass fishway sheetpile “box” upstream of the dam
Stage 3 – Remove the 24-foot-wide section of the timber crib dam
Stage 4 – Place the precast concrete bypass fishway channel sections with walkway and
flashboards within the left dam abutment
Stage 5 – Excavate the interior of the sheetpile “box and place rip rap liner into the bypass
fishway
Stage 6 – Place the 16.5-in raised fixed crest slab overlay
Stage 7 – Place the downstream extra heavy processed rip rap rockfill downstream of the dam
Modifications to the dam could be completed in a three month period during low flow summer
conditions.
Final Report
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February 2015
Princeton Dam 35% Design
Appendix G – Opinion of Probable Construction Cost
The following spreadsheet provides MWH’s Level 5 opinion of probable construction cost to modify the
Princeton Dam and implement site improvements is based on the 35% design concept selected by the
WDNR. Unit and lump sum prices are based on costs for similar projects, engineering judgment,
published cost data, and budgetary quotes from contractors. A 25% contingency was applied to the unit
costs for site conditions which may impact final construction costs. The opinion probable construction
cost is in 2018 dollars.
Opinion of Probable Construction Cost
Date:
Project
Client
Location
Prepared by
Estimator:
J. Bello
Checked by: J. Borg
Item
1.0
2.0
3.0
Princeton Dam
DFD
Green Lake County
MWH
Description
Quantity
Units
1
1
LS
LS
Hydraulic Rip Rap
2.1 WISDOT Extra Heavy Rip Rap
2.2 Adjustment for Transportation
2.3 Material Placement
5555
5551
5555
Fixed Crest Raise
3.1 Surface Preparation
3.2 Dowels
3.3 Wire Mesh
3.4 Formwork
3.5 Waterstops
3.6 CIP Concrete (pumped)
3.7 Surface Finish
2348
1200
120
510
90
120
2348
Site Preparation
1.1 Insurance and Bonds
1.2 Mobilization/Demobilization
Final Report
9
16-Feb-15
Unit Cost
Total
$ 10,000.00 $
$ 90,000.00 $
Subtotal: $
10,000.00
90,000.00
100,000.00
Ton
LCY
Ton
$
$
$
42.00
23.63
47.25
Subtotal:
$
$
$
$
233,310.00
131,147.10
262,473.75
626,930.85
SF
EA
Sheet
LF
LF
CY
SF
$
$
$
$
$
$
$
1.31
3.81
177.19
16.94
26.91
34.13
1.08
Subtotal:
$
$
$
$
$
$
$
$
3,081.75
4,573.80
21,262.50
8,637.62
2,422.04
4,095.00
2,539.36
46,612.06
February 2015
Princeton Dam 35% Design
4.0
5.0
6.0
Bypass Fishway
4.1 Upstream Sheetpile Cutoff
4.2 Sheetpile Box Walls
4.3 Timber Crib Demolition
4.4 Timber Crib Offsite Disposal
4.5 Precast Concrete Channel
4.6 WISDOT Light Rip Rap
4.7 WISDOT Medium Rip Rap
4.8 Walkway and Stoplogs
4.9 Security Fencing
732
891
1
72
2
66
38
1
100
SF
SF
LS
LCY
EA
Ton
Ton
LS
LF
$
65.63 $
$
65.63 $
$ 26,250.00 $
$
23.63 $
$ 21,000.00 $
$
98.44 $
$
98.44 $
$ 19,031.25 $
$
65.63 $
Subtotal: $
48,040.78
58,471.88
26,250.00
1,690.37
42,000.00
6,496.88
3,740.63
19,031.25
6,562.50
212,284.28
Equipment Rental
5.1 Crane Rental (20 ton)
5.2 Backhoe Rental
5.3 Miscellaneous Equipment
1
1
1
LS
LS
LS
$ 59,062.50 $
$ 59,062.50 $
$ 98,437.50 $
Subtotal: $
59,062.50
59,062.50
98,437.50
216,562.50
Site Improvements
6.1 Tree Removal
5.2 Brush removal
5.3 Access Stairs
5.4 New Decking
5.5 Relocated Control Panel
5.6 Lock Gate Preplacements
5.7 Security Fencing
8
300
28
300
1
5
100
EA
SF
LFSN
SF
LS
EA
LF
$
459.38 $
$
6.56 $
$
40.69 $
$
6.56 $
$ 39,375.00 $
$ 33,468.75 $
$
65.63 $
Subtotal: $
3,675.00
1,968.75
1,139.25
1,968.75
39,375.00
167,343.75
6,562.50
222,033.00
Subtotal (Items 1-6 above):
Construction Contingency (10%):
DFD Management Fee:
Phase II Final Design:
Construction Residence Engineering:
Other Fees:
Total Estimated Cost:
$ 1,424,422.69
$ 142,442.27
$ 62,674.60
$ 141,017.85
$ 62,674.60
$ 23,625.00
$ 1,856,857.00
Other fees include the following reimbursable expenses:
Final Report
Dam Failure Analysis:
Topo Survey:
Geotechnical
Investigations:
10
Dam Stability Analysis:
$
7,875.00
$
1,575.00
$ February
10,500.00
2015
$
3,675.00
Subtotal: $ 23,625.00
Princeton Dam 35% Design
Other fees include the following reimbursable expenses:
Dam Failure Analysis:
Topo Survey:
Geotechnical Investigations:
Dam Stability Analysis:
Final Report
11
$
$
$
$
Subtotal: $
7,875.00
1,575.00
10,500.00
3,675.00
23,625.00
February 2015
Princeton Dam 35% Design
Appendix H – Project Schedule
It is the WDNR’s goal to construct the modifications to Princeton Dam and to the project site
improvements in accordance with the following schedule milestones:
Submission of 35% Design Documents for Review:
February 16, 2015
Submission of Final Design Documents for Review:
Fall 2017
Bid Opening:
Spring 2018
Start of Construction:
Summer 2018
Substantial Completion / Occupancy:
Summer 2019
Final Report
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February 2015
Princeton Dam 35% Design
Attachment A
35% Design Drawings
Final Report
A-1
February 2015
Princeton Dam 35% Design
Attachment B
Site Improvement Photographs
Final Report
B-1
February 2015
Princeton Dam 35% Design
Photograph 1 – Flashboard Installation with Safety Cable System
Photograph 2 – Flashboard Installation with Safety Cable System
Final Report
B-2
February 2015
Princeton Dam 35% Design
Photograph 3 – South Access to Lock Gate Structure
Photograph 4 – North Access to Lock Gate Structure
Final Report
B-3
February 2015
Princeton Dam 35% Design
Photograph 5 – South Lock Abutment Brush
Photograph 6 – North Lock Abutment Brush
Final Report
B-4
February 2015
Princeton Dam 35% Design
Photograph 5 – North Lock Wall Brush
Photograph 6 – North Lock Wall Tree
Final Report
B-5
February 2015
Princeton Dam 35% Design
Photograph 7 – South Lock Wall Tree
Photograph 8 – South Dam Abutment Brush and Trees
Final Report
B-6
February 2015
Princeton Dam 35% Design
Photograph 9 – North Dam Abutment Brush and Trees
Photograph 10 - Lock Gate Motors, Switches and Screw Drives
Final Report
B-7
February 2015