Rough River Dam Safety Modification Phase 2: New Outlet Works and Cutoff Wall Project

A market survey is being conducted to determine if there are a reasonable number of interested small business concerns to set this future project aside for them. If your firm is a Small Business, certified HUBZone, 8A, Woman-Owned Small Business or Service-Disabled Veteran Owned Business and you are interested in this project please respond appropriately. If interested in subcontracting opportunities rather than performing as the Prime Contractor on this procurement, please be sure to identify the feature(s) of work you are interested in and your socio-economic category (small business, veteran-owned small business, service-disabled veteran owned small business, HUBZone small business, small-disadvantaged business, and women-owned small business).

Project Location: Rough River Dam; Falls of Rough, KY; Grayson County/Breckinridge County

Project Description: The Rough River Dam Safety Modification Phase II Project includes the construction of a new left abutment outlet works in order to facilitate cutoff wall construction. Completion of the new outlet works must require a new approach channel, control tower, service bridge, outlet conduit tunnel, stilling basin, and retreat channel along with commissioning of the new control tower. Completion of the cutoff wall requires abandonment of the existing right abutment outlet works, construction of a work platform, slurry control grouting, construction of a cutoff wall into the dam foundation and through the existing outlet conduit, abandonment of the existing control tower, backfilling the existing retreat channel, instrumentation installation/relocations, and relocation of Highway 79 back to the dam crest.

1. Approach Channel: The approach channel is 945 feet long and 50 feet wide with 6V:1H side slopes. The excavation consists of a combination of underwater dredging, underwater intact rock excavation, and surface excavation in predominately hard bedrock.


2. Control Tower: The control tower will be 177 feet tall and be composed of reinforced concrete having a footprint of 56 feet by 60 feet. The control tower will have two 6.25-feet x 14-feet service and emergency gates for primary flow conveyance. The tower will have a 150-feet long service bridge extending to the left abutment. A 600 feet long cohesive earth cofferdam founded on dentally treated bedrock will be required to protect the excavation up to the top of active storage for the reservoir. A double line grout curtain will be completed below the cofferdam and extend to surround the perimeter of the control tower pit excavation to minimize groundwater and seepage entering the excavation work area.


3. Tunnel: The approximate 970 feet long tunnel will have a 14 feet inside diameter tunnel with a 12-inch abrasion resistant reinforced concrete liner. The tunnel heading shall be from the downstream portal. The upstream portal shall be constructed integral to the control tower. The portals and portions of the tunnel extending below the dam footprint shall be mechanically excavated.


4. Stilling Basin: The stilling basin will be 115 feet long, 40 feet wide, and approximately 55 feet below the ground surface. The stilling basin excavation shall be staged to facilitate tunnel completion. The excavation will have a 15-foot horizontal bench, and rock fence located above the training walls. The bedrock excavation will continue downstream of the stilling basin and will be protected via a 2-foot thick concrete apron before transitioning to KYTC Class III Channel Lining at the intersection with the historic river channel.


5. Abandonment of the Existing Control Tower: Once the new outlet works is operational and fully commissioned, the existing control tower and conduit will be abandoned by permanently sealing the existing service gates and filling the lower control tower and outlet conduit with balanced, stable, high mobility cement/bentonite grout or non-shrink concrete.


6. Cutoff Wall: A new and complete 1,640 feet + long, 2 feet minimum thick, concrete cutoff wall through the embankment and into the foundation rock. Depth of the wall varies across the dam but can be as great as 200¡¯ from the crest of the dam. Additional slurry control grouting will be required near the existing conduit. The cutoff wall will sever the existing conduit and extend through to the bedrock below. The work at the conduit area shall not proceed until the new outlet works is fully functioning and the existing outlet works has been suitably abandoned.


7. Relocations: Highway 79 will be located back to the crest of the dam and dam restoration.

Construction duration is estimated at 2,190 calendar days. The estimated cost rage is between $250,000,000.00 and $500,000,000.00. NAICS code is 237990 All interested Small Business, certified HUBZONE, 8(a), Women-Owned Small Businesses or Service-Disabled Veteran Owned Small Business contractors should respond to this survey by email on

Responses should include:

1. Identification and verification of the company¡¯s small business status.


2. Contractor¡¯s DUNs Number(s) and CAGE Code(s).


3. Documentation from the firm¡¯s bonding company showing current single and aggregate performance and payment bond limits.


4. Descriptions of Experience: Interested construction firms must provide no more than three (3) example projects with either greater than 95% completion or project completed in the past five (5) years where the interested firm served as the prime contractor. Each project much include the name, title, project role, e-mail address, and telephone number of at least one reference. References may be used to verify project size, scope, dollar value, percentages, and quality of performance. Example projects must be of similar size and scope.

Projects similar in size and scope to this project include:

1. Cutoff Walls: Experience with at least two other cut-off wall projects similar in size with a minimum concrete seepage barrier that is 500-feet in length and installed at a minimum depth of 100 feet from the dam crest.


2. Tunnels: Experience with at least two tunnels at least 200-feet in length which were mechanically excavated excluding tunnel boring machines and blasting.


3. Dam Foundation Grouting (Slurry Control): Experience with at least two other grouting projects on high hazard dams requiring over 10,000 LF of rock drilling/grouting, the use of an automated grouting control data collection system, and ability to comply with Solicitation requirements to use instrumented packers and isolate the dam embankment from hydro-fracture per USACE requirements of the solicitation.


4. Mass excavation: Experience with at least two projects with over 50,000 cubic yards of mass excavation in hard rock (includes surface and underwater blasting).


5. Hydraulic Structures: Experience with at least two projects consisting of at least 20,000 cubic yards of mass concrete for locks, dams, or other concrete structures for high velocity water conveyance.


6. Data Management: Experience with at least 2 projects providing real-time digital data in an enterprise database, web-based spatial and numerical interface, and secure file sharing site throughout the course of construction project of similar scale and complexity and with similar features of work.

Based on definitions above, for each project submitted should include:

1. Current percentage of construction complete and the date when it was or will be completed.


2. Scope of the project.


3. Size of the project.


4. The dollar value of the construction contract and whether it was design-bid build or design-build.


5. The percentage of work that was self-performed as project and/or construction management services or physical construction type work. Must be at least 15% self-performed.


6. Identify the number of subcontractors by construction trade utilized for each project.

Small Business are reminded under FAR 52.219-14, Limitations on Subcontracting; they must perform 15% of the cost of the contract, not including the cost of materials, with the firm¡¯s own employees for general construction-type procurement. Include the percentage of work that will be self-performed on the project, and how it will be accomplished.

NOTE: Total submittal package shall be no longer than 8 pages. Please only include a narrative of the requested information; additional information will not be reviewed.

Email responses and any questions to Andrew.J.Fleming@usace.army.mil. This is NOT a Request for Proposal and does not constitute any commitment by the Government. Responses to this sources sought notice will be used by the Government to make appropriate acquisition decisions. All interested sources must respond to future solicitation announcements separately from responses to this market survey.

NOTICE: The following information is provided for situational awareness and is not required to respond to this Sources Sought.

All contractors must be registered in the System for Award Management (www.SAM.gov) prior to award of a contract. All proposed contractors are highly encouraged to review FAR Clause 52.232-33 Payments by Electronic Funds Transfer ? System for Award Management, which indicated ¡°All payments by the Government under this contract shall be made by electronic funds transfer (EFT).¡± Those not currently registered can obtain registration by going to the website hhtp://www.SAM.gov. The process can usually be completed from 24 to 48 after submission. Contractors will need to obtain a Unique Entity Identifier (formerly DUNS number) for processing their registration. If you do not already have a Unique Entity Identifier, one can be obtained from hhtp://www.SAM.gov. Refer to www.SAM.gov for information formerly found in CCR, EPLS, ORCA, and FedReg.

Please begin the registration process immediately in order to avoid delay of the contract award should your firm be selected.

ALERT: You must submit a notarized letter appointing the authorized Entity Administrator before registration will be activated. This requirement now applies to both new and existing entities. Effective 29 April 2018, the notarized letter process is now mandatory on all CURRENT registrants at SAM who have a requirement to update data on their SAM record. The notarized letter is mandatory and is required before the GSA Federal Service Desk (FSD) will activate the entity's registration.

Effective 29 June 2018, vendors creating or updating their registration can have their registration activated prior to the approval of the required notarized letter. However, the signed copy of the notarized letter must be sent to the GSA Federal Service Desk (FSD) within 30 days of activation or the vendor risks no longer being active in SAM.

Vendors can check whether an account is active by performing a query by their CAGE or Unique Entity Identifier (known as DUNS). The new registration process may now take several weeks, so vendors are highly encouraged to begin registering as soon as possible to avoid any possible delays in future contract awards. Remember, there is no cost to use SAM.

To find out additional information about the changes of the SAM registration process, contractors should visit the Frequently Asked Questions (FAQ) link located at the top of the SAM homepage (www.sam.gov).