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AD-R155 397 NATIONAL PROGRAM FOR INSPECTION OF NON-FEDERAL DAMS i/iZERO MANUFACTURING CO..(U) CORPS OF ENGINEERS MALTHAMMA NEM ENGLAND DIV AlPR 8i

UNCLASSIFIED F/G 13/13 ML

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MICROCOPY RESOLUTION TEST CHARTNATIONAL BUREAU OF STANDAROS-1963-A

1.0 CONNECTICUT RIVER BASIN

in) MONSON, MASSACHUSETT'S

ZERO MANUFACTURING COMPANY DAMMA 00551

PHASE I INSPECTION REPORTNATIONAL DAM INSPECTION PROGRAM-...

Copy availcibla to Dp1: does notpwait fully legilla v.pc~duction

C-O

DEPARTMENT OF THE ARMYU-'-'NEW ENGLAND DIVISION, CORPS OF ENGINEERS

WALTHAMP MASS. 02154

~Mmcmr Ar APRIL 1981.-7APPwveld im public 1el10i5I

rmtik&'t unlimited

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REPRODUCED AT GOVERNMtNT EXPENSE

N.:-

DISCLAIMER NOTICE

THIS DOCUMENT IS BEST QUALITYPRACTICABLE. THE COPY FURNISHEDTO DTIC CONTAINED A SIGNIFICANTNUMBER OF PAGES WHICH DO NOTREPRODUCE LEGIBLY.

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EIW ~ TTnSECURITY CLASSIFICATION OF THIS PAGE (When Doi. Emoed)

REPOT DCUMNTATON AGEREAD INSTRUCTIONSREPOT DCUMNTATON AGEBEFORE COMPLETING FORM

1. REPORT NUMBER : 4GVT ACC SI~M CAA

MA 00551 ). N S L UWR

4. TITLE (anidSubtlill) S. TYPE OP REPORT & PERIOD COVERED

Zero Manufacturing Company DamINPCONROT

NATIONAL PROGRAM FOR INSPECTION OF NON-FEDERAL S EFRIGOG EOTNME

DAMS__ _ _ _ _ _ _ _ _ _ _ _ _ _

7. AUTHOR(s) 11. CONTRACT OR GRANT NUMBER(&)

U.S. ARMY CORPS OF ENGINEERSNEW ENGLAND DIVISION

I. PERFORMING ORGANIZATION NAME AND ADDRESS 10. PROGRAM ELEMENT. PROJECT. TASKAREA & WORK UNIT NUMBERS

It. CONTROL.LING OFFICE NAME AND ADDRESS 12. REPORT OATS

DEPT. OF THE ARMY, CORPS OF ENGINEERS April 1981NEW ENGLAND DIVISION, NEDED 1~h iAGS

424 TRAPELO ROAD, WALTHAM, MA. 02254 _____________

14. MONITORING AGENCY NAME a ADDRESS(## different from CmUU.Uha#%d 000..) 19. SECURITY CLASS. (of this tw~l)

UNCLASSI FIEDIts. DECL ASSI PIC ATION/ DOWNGRADING

SCH EDULE

* IS. DISTRIBUJTION STATEMENT (of ofl* Repot)

APPROVAL FOR PUBLIC RELEASE: DISTRIBUTION UNLIMITED

*17. DISTR18UTION STATEMENT (of the abstract entred in &lock 20. it differen from Aelw)

IS. SUPPLEMENTARY NOTES

* Cover program reads: Phase I Inspection Report, National Dam Inspection Program;however, the official title of the program is: National Program for Inspection ofNon-Federal Dams; use cover date for date of report.

I9. KEY WORDS (Coin*Iue on roerso d. e JO noeooewy and 0~001lP' OF 6l0CA NN0116)

DAMS, INSPECTION, DAM SAFETY,Connecticut River BasinMonson, MassachusettsChicopee Brook, tributary of the Connecticut River

* I*. ABSTRACT (Coim o reves 00Uft* itd 0106044"I Grid Oftm*#DI'bF 6lOCkl nmato)

This dam is a 150 ft. long stone masonry-concrete dam with a height of 18.2 ft.There are deficiencies which must be corrected to assure the continualperformance of the dam. Generally the dam is in fair condition. Seepage atthe base of the wall directly below the low-level outlet was obseved. Thedam is classified as small in size having a high hazard potential.

DD IIJAN 73 14731 &DITION1 or I 00OV as is O8SOLETEE

* DEPARTMENT OF THE ARMYNEW ENGLAND DIVISION. CORPS OF ENGINEERS

424 TRAPELO ROADWALTHAM, MASSACHUSETTS 02254

UREPLY TO -"ATTENTION OF:S E E,1 3

NEDED SEP O,19B1

Honorable Edward J. KingGovernor of the Commonwealth ofMassachusetts

State HouseBoston, Massachusetts 02133

Dear Governor King:

Inclosed is a copy of the Zero Manufacturing Company Dam (MA-00551)Phase I Inspection Report, prepared under the National Program for

6 Inspection of Non-Federal Dams. This report is based upon a visualinspection, a review of the past performance and a brief hydrological

* study of the dam. I approve the report and support the findings and - -

* recommendations described in Section 7 and ask that you keep me informedof the actions taken to implement them. This follow-up action is vitallyimportant.

Copies of this report have been forwarded to the Department of Environ-mental Quality Engineering, and to the owner, Zero Corporation, Monson,MA. Copies will be available to the public in thirty days.

I wish to thank you and the Department of Environmental QualityEngineering for your cooperation in this program.

Sincerely ,

Accession For i' J

/FTIS GRA&I"'"- " -

, " DTIC TARDIncl C. E. EDGAR, III Unanno'n:odAs stated Colonel, Corps of Engineers Justifc-t. -,.;

Division Engineer

Dist:-, - .;0

. . .. . . . . . . . . . . . . . . . . . . . .

ZERO MANUFACTURING COMPANY DAM

* MA 00551

CONNECTICUT RIVER BASINMONSON,~ MASSACHUSETTS

PHASE I I14SPECTION REPORTNATIONAL DAM INSPECTION

PROG RAM

NATIONAL DAM INSPECTION PROGRAM

PHASE I INSPECTION REPORT

BRIEF ASSESSMENT

Identification No.: MA00551:m Name of Dam: Zero Manufacturing Company Dam 0

Town: Monson

County and State: Hampden County, Massachusetts

Stream: Chicopee Brook, tributary of the Connecticut River 0

Date of Inspection: December 2, 1980

Zero Manufacturing Company Dam, also known as Ellis MillsUpper Dam is a 150-foot long stone masonry-concrete dam built in1900. The dam has a maximum height of 18.2 feet. The top of thedam is at Elevation (El) 434.6, (National Geodetic Vertical Datumof 1929). The spillway is a narrow crested weir, 76 feet long,with the crest at El 427.0. Flashboards have been added to raisethe pond an additional 1.85 feet to El 428.85. The outlet conduitis a 2.5 foot square box sluiceway and is controlled by a slidegate. The outlet works are located at an intake area to the rightof the spillway. There are three additional outlets in the intake

- area. One of these outlets which is always open controls flowinto a 16-inch diameter pipeline, that supplies water to a

* downstream power plant for heating the buildings at the dam.None of the outlets have been operated since 1962 and are con-sidered to be inoperable.

There are deficiencies which must be corrected to assurethe continued performance of this dam. This conclusion is basedon the visual inspection of the site and a review of the available

* data. Generally the dam is in fair condition.

The following deficiencies were observed at the site:heavy siltation upstream of the dam resulting in blocking thelow-level outlet; displaced stone blocks at the toe of thespillway; inoperable outlets; seepage at the base of the walldirectly below the low-level outlet; leakage through one of theoutlets; severely spalled and eroded concrete along the upstreamwalls of the intake area; and a growth of saplings through themasonry walls at the abutments of the spillway.


".0 °,-

:'.4 -_w:j -_4

Based on Corps of Engineers' guidelines, the dam has beenclassified in the small size and high hazard categories. A testflood equal to one-half the probable maximum flood (PMF) was used Sto e-ialuate the capacity of the spillway. The test flood inflowis calculated to be 5,760 cubic feet per second (cfs). The test.-flood outflow with flashboards on the spillway is 5,730 cfs, -resulting in a pond level at El 437.2. The test flood wouldovertop the dam by 2.6 feet. Hydraulic analyses indicate thatthe spillway with flashboards can discharge 3,600 cfs, or 62percent of the test flood outflow before the dam is overtopped.Without flashboards, the pond would rise to El 436.7 and the -

spillway would discharge 4,250 cfs or 74 percent of the testflood outflow before the dam is overtopped.

It is recommended that the Owner employ a qualifiedregistered professional engineer to determine the limits of

" dredging required upstream of the dam in the vicinity of thelow-level outlet; investigate the source of leakage downstreamof one of the outlets; investigate the seepage noted at the baseof the spillway; investigate the extent of the deterioration ofthe concrete walls of the intake area; and establish a procedurefor removing trees from the spillway abutments. In addition,the Owner should repair the deficiencies listed above, as ' -described in Section 7.3. The Owner should also implement aprogram of annual technical inspections, a plan for surveillanceof the dam during and after periods of heavy rainfall, and aplan for notifying downstream residents in the event of an -0emergency at the dam.


................................................. ..... ...

................................... .

The measures outlined above arnd in Section 7 should beimplemented by the Owner within a period of 1 year after receiptof this Phase I Inspection Report.

$' OF4

EDWARD

~ ICHAEL ~~ GRCO ~Edward M. Greco, P.E.

,p No 2980 40 Project Manager1, 'r- Metcalf & Eddy, Inc.

Massachusetts RegistrationNo. 29800

Approved by.

Steh~hL. ishp, .E STEPHEN 1 AVice Presiden L. SMetcalf & Eddy, Inc. BIHP

No. 19703

Massachusetts Registration GS

No 190

ZERO MANUFACTURING COMPANY DAM ..

I.o

This Phase I Inspection Report on Zero Manufacturiug Company Dam (MA-00551) O

has been revieved by the undersigned Review Board members. to ouopinion, the reported findings, conclusions, and recoinendstLons areconsistent with the Recomended Guidelines for Safety nspnection ofDA_, and with good engineering judguent and practice, and is herebysubmitted for approval.

VS

CARNEY M. TERZIAN, KMERDesign BranchEngineering Division

JOSE W. FINEGAN, JR. MERWate ontrol Branc.Engineering Division

ARAWAT XQUrESIAN, OIARNAGeotechnical Engineering BranchEngineering Division

hfl'3VhL U2COMMM3~s_ _ _ _ _ '7

C.*° 9

......................................

.. . ft. .... ...Chist, Ra-Sat"l~ Dil'isoa~m'""

PREFACE

This report is prepared under guidance contained in SRecommended Guidelines for Safety Inspection of Dams, for a PhaseI Investigation. Copies of these guidelines may be obtained fromthe Office of Chief of Engineers, Washington, D.C. 20314. Thepurpose of a Phase I Investigation is to identify expeditiouslythose dams which may pose hazards to human life or property. Theassessment of the general condition of the dam is based upon -available data and visual inspections. Detailed investigations,and analyses involving topographic mapping, subsurfaceinvestigations, testing, and detailed computational evaluationsare beyond the scope of a Phase I investigation; however, theinvestigation is intended to identify any need for such studies.

In reviewing this report, it should be realized that thereported condition of the dam is based on observations of fieldconditions at the time of inspection along with data available tothe inspection team. In cases where the reservoir was lowered ordrained prior to inspection, such action, while improving thestability and safety of the dam, removes the normal load on the Sstructure and may obscure certain conditions which might otherwisebe detectable if inspected under the normal operating environmentof the structure.

It is important to note that the condition of a dam dependson numerous and constantly changing internal and externalconditions, and is evolutionary in nature. It would be incorrectto assume that the present condition of the dam will continue torepresent the condition of the dam at some point in the future.Only through continued care and inspection can there be any chancethat unsafe conditions will be detected.

Phase I inspections are not intended to provide detailedhydrologic and hydraulic analyses. In accordance with the

- established Guidelines, the Spillway Test Flood is based on the* [ estimated "Probable Maximum Flood" for the region (greatest

reasonably possible storm runoff), or fractions thereof. Becauseof the magnitude and rarity of such a storm event, a finding that .a spillway will not pass the test flood should not be interpretedas necessarily posing a highly inadequate condition. The testflood provides a measure of relative spillway capacity and servesas an aid in determining the need for more detailed hydrologic andhydraulic studies, considering the size of the dam, its generalconditions and the downstream damage potential. J

The Phase I Investigation does not include an assessment of

the need for fences, gates, no-trespassing signs, repairs toexisting fences and railings and other items which may be neededto minimize trespass and provide greater security for the facilityand safety to the public. An evaluation of the project for -compliance with OSHA rules and regulations is also excluded.

ZERO MANUFACTURING COMPANY DAM-9...

TABLE OF CONTENTS

Page

BRIEF ASSESSMENT i

PREFACE v

OVERVIEW PHOTO vi

LOCATION MAP vii

REPORT

SECTION 1 - PROJECT INFORMATION

1.1 General 11.2 Description of Project 11.3 Pertinent Data 4

SECTION 2 - ENGINEERING DATA 9

2.1 General 92.2 Construction Records 92.3 Operating Records 9

e 2.14 Evaluation 9 ,

SECTION 3 - VISUAL INSPECTION 10 .

3.1 Findings 103.2 Evaluation 12

SECTION 4 OPERATING AND MAINTENANCEPROCEDURES 13

4.1 Operating Procedures 134.2 Maintenance Procedures 13

r 4.3 Evaluation 13

SECTION 5 - EVALUATION OF HYDRAULIC/HYDROLOGIC FEATURES 14

5.1 General 145.2 Design Data 145.3 Experience Data 145.4 Test Flood Analysis 14

5.5 Dam Failure Analysis 15


" -" - - " " ' L " "- "- 2 ..'- , -.• - ' . - ' .-.' ' '.a" " -' -"-' -"-' - " ... '._. _._ '- ''m " ' ""' " --9 -'

-. " ; " . .. . . . . . . • . . -- . . . .. . . . . .. . .' .. - - . .

TABLE OF CONTENTS (Continued)

Page

SECTION 6 - STRUCTURAL STABILITY 17

6.1 Visual Observations 176.2 Design and Construction Data 176.3 Post Construction Changes 176.4 Seismic Stability 17

SECTION 7 - ASSESSMENT, RECOMMENDATIONS,AND REMEDIAL MEASURES 18

7.1 Dam Assessment 187.2 Recommendations 187.3 Remedial Measures 197.4 Alternatives 20

APPENDIXES

APPENDIX A - PERIODIC INSPECTION CHECKLIST

APPENDIX B - PLANS OF DAM AND PREVIOUSINSPECTION REPORTS 0

APPENDIX C - PHOTOGRAPHS

APPEN4DIX D -HYDROLOGIC AND HYDRAULICCOMPUTATIONS

APPENDIX E - INFORMATION AS CONTAINED IN THENATIONAL INVENTORY OF DAMS


.-- .

OVERVIEW

ZERO MFG. CO. DAMMIONSON, M&SSACHUSEflS-

Z.!, aim)

I MONSON. MSJCONN.

MASS

0£

AREA /

LOCATION a~

100

LOCATION MAP - ZERO MFG. CO. DAM

NATIONAL DAM INSPECTION PROGRAM

U PHASE I INSPECTION REPORT .


SECTION 1

* PROJECT INFORMATION 0

1.1 General

a. Authority. Public Law 92-367, August 8, 1972, authorizedthe Secretary of the Army, through the Corps of SEngineers, to initiate a national program of daminspection throughout the United States. The New EnglandDivision of the Corps of Engineers has been assigned theresponsibility of supervising the inspection of damswithin the New England Region. Metcalf & Eddy, Inc. has . .

been retained by the New England Division to inspect and @report on selected dams in the State of Massachusetts.Contract No. DACW 33-80-C-0054, dated April 18, 1980, hasbeen assigned by the Corps of Engineers for this work.

b. Purpose

(1) Perform technical inspection and evaluation ofnon-Federal dams to identify conditions whichthreaten the public safety and thus permitcorrection in a timely manner by non-Federalinterests.

(2) Encourage and assist the States to quickly initiateeffective dam safety programs for non-Federal dams.

(3) Update, verify and complete the National Inventoryof Dams.

1.2 Description of Project

a. Location. The dam is located on the Chicopee Brook inthe Town of Monson, Hampden County, Massachusetts and inthe Connecticut River Basin. The coordinates of thislocation are Latitude 42 deg. 5.3 min. north andLongitude 72 deg. 18.8 min. west. The Chicopee Brookjoins the Chicopee River 6 miles downstream of the dam.

ZERO MANUFACTURING COMPAN4Y DAM

1' -

b- 0

................................................. . *..,.x..-.'..-.-"

r~~~ 7 77 --

b. Description of Dam and Appurtenances

Zero: Manufacturing Company Dam consists primarily of astone masonry spillway and an intake area with verticalconcrete walls on the upstream face and stone masonrywalls on the downstream face. The area between these twowalls contains earthfill. The dam and spillway areapproximately 150 feet long and the crest width variesfrom 9 to 22 feet, with a maximum height of 18.2 feet(see plan of Dam and Sections in Appendix B andphotographs in Appendix C). The top of the dam (concretewalls in intake area) varies between El 434.6 and 434.7.The spillway is a 76 foot long narrow crested weir with adownstream slope of 6V to I1 (vertical to horizontal).The slope of the upstream face could not be determineddue to its submerged condition and siltation of the pondto within 1 foot of the spillway crest. Wooden flash-boards 1.85 feet high are mounted with steel pipes on thecrest of the spillway. The crest of the spillway is atEl 427 and the top of the flashboards is at El 428.8. Atthe center of the spillway, there is a 6 foot wide by 0.6 .foot deep notch in the flashboards. Directly below thisnotch there is a 6 foot wide by 4 foot deep opening inthe stone masonry with stoplogs in place. The top of thestoplogs is at the spillway crest (El 427).

The discharge channel between the dam and the bridge hascut-stone masonry side walls. Approximately 25 feetdownstream of the dam, the stream passes beneath afactory building with an opening 80 feet wide by 4.5 feethigh. There are approximately 10 building supportcolumns founded on piers which obstruct flow in thechannel. Beneath this structure, the channel narrows to D _

a width of 26 feet at which point it passes beneath abridge with a 29 foot wide by 9 foot high concreteopening. Downstream from the bridge, the channel isadjacent to and partially beneath a second building withflow partially obstructed by a 3 foot wide pier. Thisresults in a channel width of 22 feet. The concrete side _

walls adjacent to this structure are 10 feet high.Approximately 230 feet downstream of the dam the streamreturns to its natural unlined earth channel and has awidth of 80 feet. The floor of the stream is the naturalstreambed and slopes at 5 percent.

The low level outlet (Outlet No. 1 as shown in FigureB-l) for the dam is a 2-1/2 foot square, stone box sluiceway with a 4 foot square slide gate on the upstream endcontrolled by a hand wheel operator. The downstreaminvert of this outlet is at El 422.9 and if operablecould discharge at a flow of 58.5 cfs into the spillway Schannel. Reportedly Outlet No. I is inoperable.


2

There are three additional outlets at the dam. OutletNo. 2 controlled flow to a 16-inch diameter pipelinewhich was cut and sealed downstream of the dam at Hampden _9Road during sewer construction in 1977. Outlet No. 3controls flow to a second 16-inch diameter pipeline andis protected upstream by a steel trash rack and screen.The outlet is used to provide water for boilers at adownstream heating plant and the gate is always kept -

open. Outlet No. 4I is a slide gate which at one timecontrolled flow to a water wheel that powered machineryat the factory. Outlet Nos. 2 and ~4 are reportedlyinoperable.

c. Size Classification. For a dam to be classifed as smallit must have a height between 25 feet and 40 feet and a9maximum storage capacity between 50 acre-feet and 1,000acre-feet. Zero Manufacturing Company Dam has beenclassified as "small" on the basis of its storagecapacity of 70 acre-feet.

d. Hazard Classification. Immediately downstream of the damthere are 2 factory buildings located directly above thestream channel beginning approximately 25 feet downstreamof the dam (see Flood Impact Area shown on the LocationMap). The foundations of these structures are partiallyfounded on the floor of the channel. The sill of thefirst building downstream is 4.5 feet above the streambedand an assumed failure of the dam under dry weather condi-t ions with the pond level at the top of the flashboardswould result in a flood wave 11 feet high or 6.5 abovethe floor of the building causing a potential forbuilding failure. It is possible that more than a few

P lives could be lost and a significant amount of propertydamage could occur. Accordingly, the dam has been placedin the "high" hazard category.

e. Ownership. The dam is owned by Zero Corporation, 288Main Street, Monson, Massachusetts 01057. Mr. Hess,General Manager, (telephone 617-267-5561) granted per- 0mission to enter the property and inspect the dam.

f. Operator. The dam is operated by personnel from ZeroCorporation.

g. Purpose of the Dam. The water in the pond is supplied toeboilers for heating purposes by the Zero Corporation.The original purpose of the dam was to provide water forheating and also power generation for the mill located atthe dam.

ZERO MANUFACTURING COMPANY DAM3

h. Design and Construction. Construction of Zero Manu-facturing Company Dam was completed in 1900. There areno drawings or specifications available.

Previous inspection reports indicate that for the past 12years, the dam has been in fair condition. The onlyknown repairs made in the last 20 years were thereplacing of the flashboards in 1975.

i. Normal Operating Procedures. There are no operating 0procedures for the dam. The only maintenance work per-formed is to periodically clean the trash racks andscreens at the intake to the 16 inch supply pipe. Noneof the hand wheel operator mechanisms have reportedlybeen operated or maintained for the past 18 years.

1.3 Pertinent Data

a. Drainage Area. The drainage area is approximately 9,500acres (14 square mile) and consists of flat and gentlyrolling land (see Figure D-1 in Appendix). The watershedranges from El 1,150 to El 427. The drainage areaincludes drainage from Norcross Pond Numbers 1 through 4,Vinica, Squire, Duck, Calkins and Smith Ponds, ConantBrook Dam, and Chicopee and Conant Brooks. Conant BrookDam, located 1.6 miles upstream from Zero ManufacturingCompany Dam, was designed for flood control within a 7.8square mile drainage area by the New England Division ofthe Corps of Engineers. The dam was designed to retain 9inches of rainfall (spillway level) on the watershed.About 2.7 percent of the drainage area is ponds andswamps. In general, the undeveloped portions of thedrainage area consist of 80 percent woodland, and 20percent open fields. Light residential and commercialdevelopment occurs in the area.

b. Discharge. Discharge from Zero Manufacturing Company Dam?lows over the flashboards on the spillway and into anunlined stream where it passes beneath a factoryapproximately 25 feet downstream of the spillway. Wateralso discharges from the outlet into the spillwaydischarge channel.

(1) Outlet: Size- 2-1/2 foot square opening. InvertEl. - 422.9.Discharge Capacity - 58.5 cfs at El 427.

(2) Maximum known flood at damsite: El 437+ (1955)

(3) Ungated spillway capacity at top of dam3600 cfs at El 434.6 (with flashboards) 04250 cfs at El 434.6 (without flashboards)


°.%...

...................................................................

(4) Ungated spillway capacity at test flood elevation:

5260 cfs at El 437.2 (with flashboards)W 5530 cfs at El 436.7 (without flashboards)

(5) Gated spillway capacity at normal pool elevation:Not applicable.

(6) Gated spillway capacity at test flood elevation: •° -.Not applicable. •

(7) Total spillway capacity at test flood elevation:5260 cfs at El 437.2 (with flashboards)5530 cfs at El 436.7 (without flashboards)

(8) Total project discharge at top of dam:3600 cfs at El 434.6 (with flashboards)4250 cfs at El 434.6 (without flashboards)

(9) Total project discharge at test flood elevation:5730 cfs at El 437.2 (with flashboards)

r 5760 cfs at El 436.7 (without flashboards)

c. Elevation (feet above National Geodetic Vertical Datum of -.

1929 (NGVD)). A benchmark was established at El 427 at ."-

the crest of the spillway. This elevation was estimatedfrom a United States Geological Survey (U.S.G.S.)topographic map. p

(1) Streambed at toe of dam: 416.4

(2) Bottom of cutoff: unknown

* (3) Maximum tailwater: unknown

(4) Normal pool (without flashboards): 427.0(with flashboards): 428.85

(5) Full flood control pool: N/A

(6) Spillway crest: 427.0

(7) Design surcharge (Original design): unknown

(8) Top of dam: 434.6

(9) Test flood surcharge: 436.7 (without flashboards)437.2 (with flashboards)


* -.. *".......

d. Reservoir (Length in feet)

5 (1) Normal pool: 1,200

(2) Flood control pool: N/A

(3) Spillway crest pool: 1,200

-- (4) Top of dam: 1,200

(5) Test flood pool: 1,200

e. Storage (acre-feet)

(1) Normal Pool (with flashboards): 70

(2) Flood control pool: not applicable

(3) Spillway crest pool (without flashboards): 50

Vy(4) Top of dam: 156

(5) Test flood pool: 182

f. Reservoir surface (acres)

(1) Normal pool: 13

(2) Flood-control pool: N/A

(3) Spillway crest: 13

* *(4) Test flood pool: 13 JV_

'(5) Top of dam: 13

g. Dam

(1) Type: stone masonry and concrete

(2) Length: 150 feet

(3) Height: 18.2 ft.

*Based on the assumption that the surface area will not signifi-cantly increase with changes in pool elevation from 427 to437.7.


6

....................................

(4) Top width: intake area varies between 22 feet and 9feet; spillway - unknownp@

(5) Side slopes: intake area - upstream - verticaldownstream 6V:lH

spillway - upstream - unknowndownstream 6V:lH

(6) Zoning: unknown 0

(7) Impervious core: unknown

(8) Cutoff: unknown

(9) Grout curtain: unknown

(10) Other: N/A

h. Diversion and Regulating Tunnel Not Applicable

i. Spillway

(1) Type: Narrow Crested Weir

(2) Length of weir: 76 feet

(3) Crest elevation with flashboards: 428.85 -without flashboards: 427.0

(4) Gates: N/A

(5) Upstream channel: floor of sand and gravel(6) Downstream channel: natural streambed 85 feet wide

channel flows beneath structure 25 feet downstreamof dam. Channel narrows to 26 feet approximately80 feet downstream of dam where it passes beneathbridge. At second structure the channel isobstructed by 3 feet wide pier.

(7) General: At center of spillway 6 ft. wide by 4 ft.deep notch in stone masonry wall with stop logs inplace.

J. Regulating Outlets

(1) Invert El: 422.9.

(2) Size: 2 1/2' x 2 1/2'


7 7 " " "'9

................. ~-O*

7 70

()Description: 2 1/2' square stone masonry boxsluice way opening into spillway channel

()Control mechanism: hand wheel operator for slidegate (inoperable)

()Other: N/A -

-%7-.:

SECTION 2

* ENGINEERING DATA

2.1 General. There was limited engineering data available forthis Phase I inspection. There are no drawings, speci-fications, or computations available from the Owner, State,

p or County agencies. A copy of' a previous inspection reportdated October 1969, prepared by Tighe and Bond ConsultingEngineers is included in Appendix B. The most recent

* inspection was conducted in 1972 by the MassachusettsDepartment of Public Works. A copy of that report is alsogiven in Appendix B.

We acknowledge the assistance and cooperation of personnelfrom the Massachusetts Department of Public Works; and theHampden County Engineers Office. In addition, we acknow-ledge the assistance of Mr. William Cormier, Zero Corpora-tion, who provided information on the history and operationof the dam. .

2.2 Construction Records. There are no construction records oras-built drawings available for the dam or appurtenances.

2.3 Operator Records. No operating records are available, andthere is no record kept of' the elevation of the pool orrainfall at the dam site.

*2.4 Evaluation

a. Availability. There is limited engineering dataU available for this dam.

b. Adequacy. The lack of detailed hydraulic, structural andconstruction data did not allow for a definitive review. *

Therefore, the evaluation of the adequacy of this dam isbased on the visual inspection, past performance history,and engineering judgment.

c. Validity. The information obtained during the fieldsurvey is valid for the Phase I inspection.


. * ~ .

SECTION 3

VISUAL INSPECTION

3.1 Findings

a. General. The Phase I Inspection of Zero ManufacturingCorporation Dam was performed on December 2, 1980. Acopy of the inspection checklist is included in AppendixA. Previous inspections were conducted in 1969 for theHampden County Board of County Commissioners, and by theMassachusetts Department of Public Works in 1972. Copiesof those reports are given in Appendix B. Selectedphotographs taken during our Visual Inspection are 0included in Appendix C.

b. Dam. The dam consists of a stone masonry spillway with aconcrete cap (see Photos No. 3, 4), a nearly verticaldownstream face, and four outlets contained within theintake area portion of the dam (see Photos No. 5 and 6). SThe intake area of the dam consists of vertical concretewalls on the upstream face, while the downstream wallsare stone masonry (see Photos No. 1, 3). The area -between the upstream and downstream walls is earthfilled . -. - -

and ranges in width between 9 feet and 22 feet. There isa low area within the intake area located directly abovethe low level outlet (see Photo No. 8). At the base ofthe wall, directly below the low level outlet, two clearseeps were flowing at approximate'y 4 and 8 gpm (seePhoto No. 7). The concrete along the splash zone of theupstream walls in the intake area was severely eroded andspalled (Photos No. 5, 6). .5

The spillway has a concrete cap over the stone masonryand is in good condition. At the base of the spillwayapproximately 8 of the masonry blocks used as erosionprotection have been displaced (see Photos No. 3, 4).

The stone masonry wall which is the downstream face ofthe spillway is in good condition. There is grass and -some small trees growing between the Joints of the stone .masonry at the right abutment of the spillway and alongboth the left and right downstream masonry training walls(Photos No. 3 and 4). Trees up to 12 inches in diameter -Sare growing near the left spillway abutment.

c. Appurtenant Structures. The spillway, which encompassesapproximately one-half of the dam is a narrow crestedweir 76 feet long and 11 feet high (see Photos No. 3 and4).-O


7. 7

Flashboards 1.85 feet high are located along the entirelength of the spillway crest. There is a notch in the

U flashboards, 6 feet long by 0.6 feet deep located at thecenter of the spillway. Directly below this notch is a 6foot wide by 4 foot deep opening in the stone masonry L--.with stop logs in place. There is no access walkway tothe flashboards or stoplogs which would permit theirremoval during periods of high flow. There is a majoraccumulation of soil and vegetation growth within thepond and along the spillway crest (see Photos No. 3 and4). The condition of the upstream face of the spillwaycould not be determined because of siltation.

At the time of the inspection, water was discharging overthe spillway, so the weir, stoplogs and flashboards anddownstream toe could not be examined.

There are four outlets along the intake portion of thedam (see Figure B-1 and Photos No. 5 and 6). None ofr the outlets have been operated since 1962 and areconsidered to be inoperable. Three of the outlets arecontrolled by hand wheel operators located along theupstream face of the intake area. The first hand wheeloperator (Outlet No. 1) controls flow to the low-leveloutlet located within the stone masonry. A thickaccumulation of silt is blocking the upstream end ofthe outlet and the surrounding area. It is unlikelythat this outlet could be opened and flow maiiltainedin an emergency. The discharge end of the outlet isclogged with debris.

Outlets Nos. 2 and 3 each control flow to 16 inch dia-* meter pipelines which were used to transmit water to

boilers at separate heating plants. The pipe controlledby the second hand wneel operator (Outlet No. 2) wasreportedly cut and sealed downstream of the dam. Thethird hand wheel operator (Outlet No. 3) is used toprovide water to boilers for Zero Corporation's MainStreet heating plant and is continuously open. OutletNo. 3 has a trash rack and screen at the upstream end.The rack consists of vertical steel slats that areheavily rusted and the steel screen, which is immediately downstream of the trash rack, is also heavilyrusted. The trash rack and screen at Outlet No. 3 arecleaned periodically.

A fourth outlet (Outlet No. 4 ), located to the right ofthe three hand wheel operators (see Photo No. 6), is awooden slide gate 5-1/2 feet wide which was used to . -

regulate flow to a water wheel to power machinery at theOld Ellis Mill. The height of the slide gate could notbe determined due to siltation in front of it.

ZERO MANUFACTURING COMPANY DAM11• 1

. . . . . . . . . .

The hand wheel operators and lifting mechanism for theslide gate have not been operated or maintained since£ Zero Corporation purchased the dam i!n 1962.

d. Pond Area. The pond area is lightly developed. The Townof Monson is located downstream of the Pond. Residen-tial development is located on the upstream side of thereservoir. Most of the land is wooded with gentle

* slopes. There is a slight potential that futuredevelopment will occur in the pond area.

e. Downstream Channel. Both the spillway and outletdischarge into the downstream channel. The stone masonryand concrete walls that form the walls of the channel arein good condition (see Photos No. 3 and 4). Portions ofthe left side of the channel are earth slopes which havebeen slightly eroded by runoff to the extent that thegrass cover has been removed. The floor of the channelis the natural streambed. There is a slight accumulationof debris in the floor of the channel (see Photos No. 2and 7). Several trees are growing on the sides of thechannel (see Photos No. 3 and 5). About 25 feetdownstream of the dam, the channel passes beneath afactory building (see Photo No. 2). The upstream openingis approximately 85 feet wide by 4.5 feet high. Thereare 10 building support columns founded on piers whichobstruct flow within the channel. The channel at thedownstream end of the building narrows to a width of 25feet and increases to a height of 8 feet. Approximately6 feet downstream of the building, the stream passesbeneath a bridge with a 29 foot wide by 9 foot highopening. Approximately 12 feet downstream of the bridge

* the channel is partially obstructed by a 3 foot wide pierfor support columns of a second factory building. Thechannel side walls adjacent to this building are 10 feethigh. Approximately 230 feet downstream of the dam thestream returns to the natural channel width of 80 feet.

There is a second discharge channel for Outlet No. 4.The channel passes beneath the two factory buildingsand joins the main discharge channel approximately 210feet downstream of the dam. The side walls of thechannel are vertical and constructed of stone masonry.Although Outlet No. 4 is kept closed, there was amoderate amount of flow in the channel. The source ofthis leakage is unknown. The floor of the channel isgravel with a moderate amount of debris.

3.2 Evaluation. The visual inspection indicates that the dam isin fair condition. The stated deficiencies which must becorrected to assure the continued performance of this damand measure to improve these conditions are outlined inSection 7.

ZERO MANUFACTURING COMPANY DAM -

12

The following conditions could affect the long term-performance of the dam.

5 1. Heavy siltation upstream of the dam resulting in

blocking the low-level outlet.

2. Displaced stone blocks at the toe of the spillway.

3. Inoperable outlets. -

4. Seepage at the base of the wall directly below the lowlevel outlet.

5. Leakage downstream of Outlet No. 4.

6. Severely spalled and eroded concrete along the upstream 9walls of the intake area.

7. A growth of saplings through the masonry walls at theabutments of the spillway.

r-.7

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*'

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-. -, S "

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-S

SECTION 4"

OPERATING AND MAINTENANCEPROCEDURES

4.1 Operating Procedures

* a. General. There are no operating facilities and noregular operating procedures for this dam.

b. Warning System. There is no warning system in effect at

this dam.

4.2 Maintenance Procedures

a. General. The dam is not adequately maintained. ZeroCorporation is responsible for maintenance of thefacility.

1. b. Operating Facilities. There is no maintenance of theoperating facilities at the dam.

4.3 Evaluation. There are no regular programs of maintenance ortechnical inspections at the dam. There are also no plansfor surveillance of the dam during periods of heavy rainfall,or for warning people in downstream areas in the event of anemergency at the dam. The lack of standard operating andmaintenance procedures is undesirable, considering that thedam is in the "high" hazard category. These programs shouldbe implemented as recommended in Section 7.3.

* 0


~ .

SECTION 5

EVALUATION OF HYDRAULIC!p HYDROLOG IC FEATURES

5.1 General. Zero Manufacturing Company Dam has a drainage areaof 114.?3 square miles of which 2.7 percent is ponds and swamps(see Figure D-1, Drainage Area Map). The land is gentlyrolling and lightly developed.

There is a flood control dam located on Conant Brook whichwas constructed to provide additional storage within thewatershed.

The pond has a surface area of approximately 13 acres, and amaximum storage capacity of 156 acre-feet at El 434.6.

The low-level outlet can discharge a flow of 58.5 cfs whenthe pond is at El 427 which is the crest of the spillway. Atthis pond elevation and with no additional inflow, the outletcan lower the pond by 1 foot in about 3 hours.

* 5.2 Design Data. There are no hydraulic or hydrologic com-putations available for the design of the spillway at ZeroManufacturing Company Dam.

* -05.3 Experience Data. A previous inspection report from 1972indicated the dam was overtopped during the 1955 hurricane.The flood waters were reported, in that inspection report, tohave been approximately 10.5 to 11.5 feet above the spillwaycrest. Water was reportedly flowing through the second floor

* windows of the factory 25 feet downstream of the dam.

5.14 Test Flood Analysis. Zero Manufacturing Company Dam has beenclassified in the "small" size and "high" hazard categories.According to the Corps of Engineers guidelines, a test floodranging from one-half the PMF (Probable Maximum Flood) to thefull PMF should be used to evaluate the capacity of thespillway. The one-half PMF was chosen on the basis of thesize of the dam and the small storage capacity.

The drainage area is made up of the watershed above theConant Brook Dam (7.8 square miles) and the watershed of theConant and Chicopee Brooks (7.0 square miles) below theConant Brook Dam. The PMF rate for the entire 114.8 squaremiles of drainage area for Zero Manufacturing Company Dam wascalculated to be 1,180 cfs per square mile. This calculationis based on an average slope of 2 percent in the drainagearea, the pond-plus-swamp area to drainage area ratio of 2.7percent, and the US Army Corps of Engineers'

ZERO MANUFACTURING COMPAN4Y DAM15

guide curves for Maximum Probable Flood Peak Flow Rates(dated December 1977). For this analysis the peak flow rate Vwas determined to be between the curves for rolling and flatand coastal topography. Applying the one-half PMF rate tothe 14.8 square mile drainage area (Conant Brook and ChicopeeBrook watersheds) resulted in a peak test flood inflow of8,730 cfs. Considering the storage effects of the Corps ofEngineers flood control dam on Conant Brook, the test flood 0

* inflow for Zero Manufacturing Company Dam was reduced.First, the PMF rate was calculated for the watershed belowConant Brook Dam (7.0 square miles) and was determined to be1,580 cfs per square mile of the drainage area. Applying theone-half PMF rate to the Chicopee Brook watershed aloneresulted in a peak test inflow of 5,530 cfs. Secondly, due 3.to storage effects at the Conant Brook Reservoir Dam, thecoincident flow from the Conant Brook watershed would be225 cfs. The resulting combined inflow was therefore apeak test flood inflow of 5,760 cfs. With the flashboardson the spillway, the peak test flood outflow was calculatedto be 5,730 cfs (387 cfs per square mile). With flashboards, .the pond level would rise to El 437.2. Without flashboards,the peak outflow would be 5,760 cfs and the pond would riseto El 436.7.

.- :

Hydraulic analyses indicate that the spillway with flash-boairds can discharge 3,600 cfs or 62 percent of the test Pflood outflow with the pond at El 434.6 which is the lowpoint on the top of the dam. Without flashboards, thespillway could discharge 4,250 cfs, or 74 percent of theoutflow before the dam is overtopped.

Approximately 25 feet downstream of the spillway, the channelpasses beneath a building with an opening 4.5 feet high. .-Beneath this structure the channel narrows from 85 feet to 26feet. This constriction would result in a tailwater at thetoe of the dam of El 434.7.

5.5 Dam Failure Analysis. Due to the high tailwater effectduring the test flood, the peak discharge rate due to fail-ure of the dam was calculated under "Dry Weather" conditionsto be 2,235 cfs with the pond at El 428.85. This calcula-tion is based on a maximum head of 12.5 feet and an assumed30-foot wide breach occurring in the center of the spill-way. Failure of the dam would produce a downstream floodwave 11 feet deep as compared to no channel flow prior tofailure. This would result in a flood 6.5 feet deep in thefirst floor of the building straddling the stream immediatelydownstream of the dam.

ZERO MANUFACTURING COMPAN4Y DAM16

J- -°2

TABLE 5-1.

Flashboards Flashboardsin place removed

Maximum height of waterabove dam, ft: 2.6 2.1

" Maximum height of waterabove low area (El 435,5)

- west of left abutment, ft: 1.7 1.2Discharge over spillwayand dam, cfs: 5,360 5,540Discharge over low areawest of left abutment cfs:cfs: 370 220

Depth at critical flow, ft: 1.5 1.2Velocity at critical flow, fps: 7.0 6.3

There are two factory buildings and a bridge located abovethe channel between 25 and 125 feet downstream of the dam.The support columns of these structures are founded on pierswhich are located within the floor of the channel andpartially obstruct the flow.. Due to the configuration of thechannel, little attenuation of the flood flow is expected.An assumed failure of the dam would result in a flood wavethat would rise above the channel opening beneath the factorycausing the flooding of the first floor. Severe damage tothe building could result in the possible loss of more than afew lives and an excessive amount of property damage. Accord-ingly, the dam has been placed in the "high" hazard category.

L


-.°

SECTION 6

* STRUCTURAL STABILITY

6.1 Visual Observations. The evaluation of the structuralstability of Zero Manufacturing Company Dam is based on areview of previous inspection reports and the visual inspec-tion conducted on December 2, 1980.

Based on the visual observation detailed in Section 3, ZeroManufacturing Company Dam is in fair condition. In the eventthe soil is removed upstream of the spillway, an unstablecondition could result. An analysis to determine the limitsof dredging should be performed so that the stability andimpermeability of the dam is unimpaired.

As was discussed in Section 3, seepage was observed along thebase of the spillway directly below the low level outlet(Outlet No. 1). There is a low area directly above thisoutlet within the intake area's vertical walls and there is agrowth of saplings. Also, there are several saplings growingout of the vertical masonry wall of the spillway in the areaof the low level outlet. Several of the stone blocks usedfor erosion protection at the downstream toe of the spillwayhave been displaced by water action creating a potential forundermining at the toe of the spillway. S

6.2 Design and Construction Data. Construction of Zero Manu-turing Company Dam was completed in 1900. Computations

for design of the dam, spillway and outlet are not available.

Drawings showing the proposed or as-built construction of the

dam are not available.

Specifications for construction of the dam are not available.

6.3 Post-Construction Changes. Since the original construc-tion of the dam, the only known repairs made in the past 20years were the replacing of the flashboards in 1975.

6.4 Seismic Stability. The dam is located in Seismic Zone No. 2,and in accordance with Corps of Engineers' guidelines doesnot warrant further seismic analysis at this time.

&A


. . .. . . .

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- - - -- - -

SECTION 7

ASSESSMENT, RECOMMENDATIONS, ANDREMEDIAL MEASURES

7.1 Dan Assessment

a. Condition. As a result of the visual inspection, the- review of available data, and limited information on

operation and maintenance, the dam is considered to be infair condition. The following deficiencies must becorrected to assure the continued performance of thisdam: heavy siltation upstream of the dam blocking thelow-level outlet; inoperable outlets; seepage at thebase of the spillway directly below the low leveloutlet; leakage downstream of Outlet No. 14; severelyspalled and eroded concrete along the upstream wal--3of the intake area; a growth of saplings through tl>-masonry walls at the abutments of the spillway; anddisplaced masonry blocks along the toe of the spillway.

The peak test flood (one-half PMF) outflow is estimatedto be 5,730 cfs with the pond at El 437.2 assuming theflashboards are in place. The test flood would overtopthe low point on the dam by 2.6 feet. Hydraulicanalyses indicate that the spillway (with flashboards)

I can discharge 3,600 cfs or 62 percent of the test floodoutflow before the dam (intake area) is overtopped.

b. Adequacy. The latk of detailed design and construc-tion data did not allow for a definitive review. There-fore, the evaluation of this dam is based on a review of

* the available data, the visual inspection, pastperformance and engineering judgment.

c. Urgency. The recommendations and remedial measuresoutlined below should be implemented by the Owner withinone year after receipt of this Phase I Inspection Report.

7.2 Recommendations. It is recommended that the Owner employ aqualified registered engineer to:

a. Determine the limits of dredging required upstream of the* dam in the vicinity of the low-level outlet. The stability

and impermeability of the dam and spillway should not beimpaired by the dredging operation. In lieu of dredging,consideration could be given to providing an alternate meansof lowering the reservoir.


b. Conduct an investigation of the source of water flowingin the discharge channel downstream of' Outlet No. ~4

it ~ and design repairs, if necessary, to control the leakage.

c. Conduct an investigation of the seepage at the base ofthe spillway directly below the low level outlet. Thiswould include an evaluation of the dam stability.

d. Determine the extent of the deterioration of the upstreamconcrete walls of the intake area and recommend necessaryremedial repairs.

e. Establish a procedure for removing trees, brush, androot systems from the stone masonry walls of the spill-way abutments. Make recommendations for backfillingwith suitable material.

f. Inspect the downstream face of the spillway, especiallythe center section, under a no-flow condition.

rThe Owner should implement the recommendations of theEngineer.

* 7.3 Remedial Measures

a. Operating and Maintenance Procedures. It is recommendedthat the Owner accomplish the following:

(1) Repair the operating mechanism on the low-leveloutlet and on Outlet No. 3 to restore them to

* working condition. Investigate a means of sealingOutlet No. 2 at the upstream end, so as to remove

* pressure in the conduit.

(2) Reset the dislodged stone blocks at the toe of thespillway to prevent overflowing water from washingout the downstream toe area.

(3) Remove all debris and loose stone in the floor ofthe spillway discharge channel.

(4) Institute a definite plan for surveillance of thedam and spillway during and after periods of heavyrainfall and a plan to warn people in downstreamareas in the event of an emergency at the dam.

(5) Implement a systematic program of maintenanceinspections. As a minimum, the inspection program*.-should consist of a monthly inspection of the damand appurtenances, and be supplemented by addition-al inspections during and after severe storms. All

ZERO MANUFACTURI1NG COMPANY DAM20

° .0

repairs and maintenance should be undertaken incompliance with all applicable State regulations.The maintenance program should include removal of'any debris caught on the spillway weir to prevent •clogging of the spillway.

(6) Institute a program of annual technical inspectionsof this dam.

7.4 Alternatives. There are no practical alternatives.

I -

* .


. . . . . . . . . . . . . .. . . .-.... ...'-' .-

APPENDIX A

*PERIODIC INSPECTION CHECKLIST .

ZER MAUATRN0OPN A

PERIODIC INSPECTION

PARTY ORGANIZATION

PROJECT ZERO MANUFACTURING 00. DAM DATEDec. 2. 1980

Abbreviations: TIME8 AM to 3 PM

* D/S -DownstreamU/S UpsreamWEATHER cloudy-cool

N/A -Not Applicable w.s. ELEV. 4 2 8 *8_U.S. 4 1 5 -8DN.S.

PARTY:

1. N. D'Agostino Metcalf &Eddy Geotechnical

2. S. Nagel Metcalf &Eddy Geotechnical

3. F. Gordon Metcalf &Eddy Geotechnical

* 4. S. Pierce Metcalt &Eddy Geotechnical

5. L. Branagan Metcalf &Eddy Hydraulics

16. M. Mass Bryant Associates, Inc. Hydraulics

*7. W. Cloutier Zero Corporation

8. E. Greco Metcalf &Eddy Geotechnical

10.

PROJECT FEATURE INSPECTED BY REMARKS

1. Dam D'Agostino, Nagel, Branagan, Greco

2. Outlet Works -Spillway D'Agostino, Nagel, Branagan, Greco

3. Outlet Works - Intake Area D'Agostino, Branagan

*4. Outlet Works -Low Level Outlets D'Agostino, Nagel

pageA-of 7..

PERIODIC INSPECTION CHECK LIST 0

PROJECT ZERO MANUFACTURING OD. DAM DATE Dec. 2, 1980

PROJECT FEATURE Dam NAME N. D'Agostino

DISCIPLINE Geotechnical NAME S. Nagel

AREA EVALUATED CONDITIONS

DAM EMBANKMENT34.6 at top of concrete wall intake

Crest Elevation irea

Current Pool Elevation i28.8Jnknown-reported by prevous inspections

Maximum Impoundment to Date o be 10.5 to 11.5' above top of spillway .S1955

Surface Cracks one visible-cut stone masonry dam-dry walluonstruction with conc. cap & vertical conc.-wall at inak ara

Pavement Condition /A

Movement or Settlement of Crest gone visible

Lateral Movement gone visible

Vertical Alignment "ood

Horizontal Alignment __ood_

itone wall with conc. cap at left abutmentCondition at Abutment and at )f spillway. Conc. wall (part of foundationConcrete Structures f brick building) at rt.abut. (training wallConcrete Structures:or o3A water wheel intak) .- °

Indications of Movement of

Structural Items on Slopes one visible

Trespassing on Slopes Minor along right abutment

Sloughing or Erosion of Slopes 3palling of concrete at abutments

or Abutments

Rock Slope Protection - Riprap ./A

Failures

Unusual Movement or Cracking at gone visibleor near Toes

or seeps along base at downstream rt. spillwayUrusual Embankment or Downstream butment directly below box sluiceway.Approx.Seepage low of 10 gpm.

Piping or Boils one visible

Foundation Drainage Features one visible 0

Toe Drains gone visible

Instrumentation System gone visibleFoundation walls & basement walls on Pond side of structures page.-2of 7.dry - reportedly never had seepage problem.

PERIODIC INSPECTION CHECK LIST

PROJECT ZERO MANUFACTURING CO. DAM DATE Dec. 2, 1980

PROJECT FEATURE Outlet Works - Spillway NAME N. D'Agostino

DISCIPLINE Geotechnical NAME S. Nagel

AREA EVALUATED CONDITIONU 0

OUTLET WORKS - SPILLWAY WEIR,APPROACH AND DISCHARGE CHANNELS

a. Approach Channel

General Condition Submerged - Silted in S

Loose Rock OverhangingChannel qone

Trees Overhanging Channel

Floor of Approach Channel Submerged

b. Weir and Training Walls Concrete wall on right

General Condition of Stone wall with concrete cap on leftConcrete fair.

Rust or Staining No

Spalling Severe-at angle point at juncture withtt Pt rnntrnla S "

m Any Visible Reinforcing _o

Any Seepage or Efflorescence fes-efflorescence on right wall

Drain Holes one

c. Discharge Channel tructure over channel

bebris in stream, downstream ofGeneral Condition 1Hampden Road

Loose Rock OverhangingChannel

Yes - downstream ot Hampden RoadTrees Overhanging Channel

Floor of Channel Gravel

Other Obstructions piers and floor of structure.I

page -_ of f7

PROJECT ZERO MANUFACTURING CO. DAM DATE Dec.2, 1981

PROJECT FEATURE Outlet Works Spillway NAME N. D'Agostino

* DISCPLINE Geotechnical/Hydraulics NAME L. Branagan

Spillway Weir (cont.)

Two inch thick flashboards in place on crest of spillway.

Approximately 1.85 feet high. Held in place by steel pipes.

At center of spillway one board removed to create six feet

wide by .62 feet deep notch. Directly below this notch is

a four feet deep by six feet wide opening in the stone masonry.

This opening has stop logs in place.

p A

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9

page A-4 of 7

PERIODIC INSPECTION CHECK LIST


PROJECT FEATURE Intake Area NAME N. D'Agostino

DISCIPLINE Geotechnical/Hydraulics NAME L. Branagan

AREA EVALUATED CONDITION

OUTLET WORKS - INTAKE CHANNEL AND

INTAKE STRUCTURE

a. Approach Channel 3ubmerged S

Slope Conditions Vertical concrete wall

Bottom Conditions ilted in

Rock Slides or Falls q/A

Log Boom F __s_________

Debris

Condition of Concrete Lining 4/A...._ _

Drains or Weep Holes None _ _____ _--_

b. Intake Structure _-_-__ _

Condition of Concrete Badly spalled at splash zone

None.--Stop Logs and Slots one

Intake Area-Pond Side vertical concrete walls. D/S portion stone masonry walls-

earth filled area - small trees growing in area.Outlet--l. Left gate valve controls flow to low level outlet (30"x30" box sluiceway at

D/S end) through 4'x4' gate inoperable--some movement of water observed in Sarea of gate.

Outlet--2. Middle gate valve which controls flow into a 16-inch diameter pipe which atone time flowed to structure (former power plant),downstream of Hampden Road.Pipe was cut and blocked at Hampden Road in 1979 during sewer line constructionnow, inoperable.

Outlet--3. Right gate valve - controls flow into 16-inch diameter pipe to boilers at apower plant (approx. mile D/S of dam) to produce steam for heating. Hastrash rack and screens. Only maintenance performed is to clean screens.Provides 10,000 gpd to boilers. Intake always left open. Pressure regulatedat Power Plant, excess water discharged back into Chicopee Brook.

Outlet--4. Slide Gate-lifting mechanism for control of flow to a water wheel (removed)is inoperable. Slide Gate is wooden with steel slats. Opening approximately5 ' wide. Height of gate could not be determined due to siltation ofapproach channel. Approach channel to outlet mechanisms for old water wheel(removed).

Right training wall spalled, cracked.Left training wall at corner spalling up to 6"deepat water line. (cont. on next page) p.1

- . . -- - - •- .- : • . . . . . . . . ... .- - , , ". _

. .•. -."- --


PROJECT FEATURE Intake Area (cont.) NAME N. ''AgOStino

DISCIPLINE Geotechnical/Hydraulics NAME L. Branagan

" Intake Area (Cont.)

Discharge Channel - Old channel from which discharge from water wheel flows -

3 beneath Zero Corporation structures and exits from Sstructure downstream of Hamden Road.

Water was observed to be flowing in this channel.

All outlet mechanisms have not been operated or maintained since ZeroCorporation purchased property in 1962 from Ellis Mills Company. (originalowners of dam.)

1p S

* S

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. . ... • ..

PERIODIC INSPECTION CHECK LIST 0


PROJECT FEATURE Outlet Works-Low Level NAME N. D'AgostinoOutlet-

DISCIPLINE Geotechnical NAME S. Nagel 6

AREA EVALUATED CONDITION

OUTLET WORKS - TRANSITION AND SCONDUIT

General Condition of Concrete N/A

Rust or Staining on Concrete N/A

Spalling N/A

Erosion or Cavitation N/A

Cracking N/A

Alignment of Monoliths N/A

Alignment of Joints N/A

5 Numbering of Monoliths N/A

16"-diameter ductile iron pipe follows stream channel to power plant on MainStreet. Runs above ground. Valves have been installed to blowoff water tog prevent freezing in pipe at critical points during low flows in pipe.

Sluiceway-Square 30" wide x 30" high opening in stone masonry portion of damat downstream right abutment of spillway controlled by left gatevalve has not been operated since 1962.

fS

pagsA-7of 7

................................. '..L. . . . .

6-

APPENDIX B

PLANS OF DAM AND PREVIOUSINSPECTION REPORTS

Page

U Figure B-1, Plan of Dam B-1

Figure B-2, Sections through Dam B-2

Previous Inspection ReportsDated 1969 for the Hampden CountyBoard of County Commissioners B-3Dated December 19, 1972 by MassachusettsDepartment of Public Works B-4

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.81EOqGE H.MCDONNELL.,. P*IiIP W. SHNRIDAN

EDWARD J. IAYON

CIIL.SAIARY AND ELECTRICAL ENGINEERING

INVESTIGATIONS. REPORTS.PLANS AND SPECIFICATIONSTIG H E SUPERVISION OF CONSTRUCTION AND OPERATION

_ _ CONSULTING ENGINEERS________BOWERS AND PEOUOT STREETS

HOLYOKE. MASSACH4USETTSTELJErftESON 3-3991

CD Monson 0October 22, 1969

The Honorable the Board of County Commissioners52 Statle StreetSpringfield, MassachusettsGentlemen:

During the year 1969 inspections have been made from time totime of the various dams situated within the Town of Monson.Inspections recently completed have now concluded the in-spection routine in Monson, and every dam located within thatN community, coming under County Jurisdiction, has now been in- :spected at least once during the present calendar year. Thefollowing is a report on the general condition of each of thedams and dam sites situated within the Towm of Monson.

D. Ellis Mills Upper Dam (Zero Manufacturing Dam)

The stone masonry forming this dam was found to be insatisfactory condition. The normal three flashboards

£ were on the crest of the dam and water level in storage .was at the top of the upper flashboard.

Abutment areas were okay. The flood training walls atboth abutments were in satisfactory condition.

The toe area of the dam, in the bed of the stream, issatisfactory. Some of the large stone masonry blocks

. . .have been moved from the toe area at the left of the damby flood flows. This condition does not appear to becausing any erosion in the bed of the stream. In theopinion of the undersigned this dam is safe.

p

: 5

... 5-3 . ZERO IQG'. CO. DAM. "'i:'

.9-

INSPECTION REPORT - DAL.S AND RESERVOIRS

* I. Locations City/Town IA4 SoA Dam No...-., 7%. .It-"w

Name of Dam ILLIS A18145 upPe , bA'.o Inspected by M,,rd.w

Date of Inspection I2. 7-.

2. Owner/ss per: Assessors . Prey. Inspection__________

Reg. of Deeds _ . _ Pers. Contact ,

Name St. & No. City/Town State Tel, No.

2. __Name St. & No. City/Town State Tell No.

3.Name St. & No. City/Town State Tel. Noe

3. Caretaker (if any) e.g. superintendentp plant manager, appointedby absentee ownerg appointed by multi owners.

Name: St. & No.

City/Towns States Tel.Novs

4. No. of Pictures taken oe re'C5. Degree of Hazards (if dam should fail completely)*

. 1 kinor 2. Moderate__________

3. Severe _ _ _ _ _ 4. Disastrous

* This rating may change as land use changes (future development)

6. Outlet Control: Automatic .... Manual .___,_._.________._o

Operative t' yes No.

S 7. Upstream Face of Dams Conditions

1. Good _.... 2. Mincr Repairs

3. Major Repairs 4. Urgent Repairs.-

A . Comment s -

4 , ZZAR MFG. CO. DAMI* ..... --.. -.-. . ..- ...--.. .-. . . . . -..- ..- '--,. .4.-*,

.......................... .t

..... . . . . .. '_t' t

-2- DAN. NO. N O..

8. Downstream Face of Dams

Conditions 1. Good A" 2. Minor Repairs __

3. Major Repairs - 4. Urgent Repairs

Commentss

9. Emergency Spillways I'--. - -

Conditions 1. Good _ 2. Minor Repairs

3. Major Repairs - 4. Urgent Repairs

Commentss . - ) 2.-

10. Water Level at time of inspections fte above _' below

top of dam - principal spillway24 of- chk Qre fLashibt.arlds :

other,p

11. Summary of Deficiencies Noted&

Growth (Trees and Brush) on Embankment ., _______"_"_"

Animal Burrows and Washouts . . .... __ _ _ _._ _..... ._ _

Damage to slopes or top of dam .A t CL-

Cracked or Damaged Masonry . . $

Evidence of Seepage -, At

Evidence of Piping Ivo__ r_

Eros ion Ye M/ re

Leaks . . /V ,r .S

Trash and/or debis impeding flow

Clogged or blocked spillway /Am V

Other e

ZERO MFG. CO. DAN"-. ': "' " ": - .- ' " ..-.' -. - - .°- .: . . . - " - . . "'-., . " . .: : .: : 2 :' : : - .. - . " " "

. . . . . . . . .". ." .- . . ..-. . . . ..-.-. .-. . . . . .._..._,'.','.'.'..' ._._.'-' .'_._' ." . -"-. . , .' . : . """. " - - - " "" -"'- "- "

12. Remarks & Reommeaions'~" (fualy p1f)

I~~~~~~ cowy 5~ X-r ooc,,rio wcYstj

"TWS \01 i5015 T'wr Wl'Me - .# 2' 1' n A OV.-r~~-E 2 " VLQc R OFvTVIVct4 V/wvows" C

Am GER k E17AClTcK WILL Nc-rC,~i~

~ ~ot) qWpdS1LT5 \H A V/ALLOF &IER ejNN

&s N icu-<y ~~\Y~ 9 &M \s IN Coop Com~p rrov AWTi

0KhS Ogd4IRQ 4 u~MOUT5T 'hiRGS1W~ OF CQNC. Pr. krAF

~ Q ~ ow'~ ~~oo-pAovise. &RZKOVALFCKEi.

13. overall Conlditions'

1, safe _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

2. minor repair$ needed

3. Conditionally safe -mjrrpisnee

4, Unsafe it epan

5. ReserVoi? impoundment no longer *xss(epan

ReCcfUommed removal from inspectionl list

ZERO 147G. CO. DAM4

1S

DESCRIPTION OF DAM

DISTRICT

Submitted by 9,k.= Dam No.

Das %O*'y/Town AC7~V

i"i

Name of Dam _.,. .ks ,

1. Locations Topo Sheet No- *

Provide X 11" in clear copy of topo map with location ofDam clearly indicated.

2. Year builts - Year/s of subsequent repairs

3. Purpose of Dams Water Supply- Recreational

Irrigation __ ._.. ..._ Other . . . ... ..

4. Drainage Areas -sq.,m-. __..-___ sqo _ __ acres

. 5. Normal Ponding Areas 7 acresl Ave. depth - .

Impoundtents gals.; _ _ acre ft,

K 6. No. and type of dwellings located adjacent to pond or reservoir

~ I*e. summer homes 3 sew YSAftLOND kAJRAS

7. Dimensions of Dams Length ASO' C ._ Max. Height

* Slopes, Upstream Face _ -\_ . .. ...__

Downstream Face V _zr .. -"

Width across top ViL VS aQ..... -0

S. Classification of Dam by Materials* Earth I Cone. Masonry Stone lasonry

* Timber Rockfill __ ._ __ Other

9. A. Description of present land usage downstream of dams

.i2 .. J rural$ l, urban.

Be Is there a storage area or flood plain downstream of dam whichcould accomodate the ipoundment in the event of a completedam failure? yes _-. no. _ ...-

-L 11-7ZZEO IFG, CO. DAM* . -- •.. -. ..-

I - . ...-

DAM NO. 3-7-1q" 4

10. Risk to life and property in event of complete failure.

go. of people t 4VNo. of homes __"___ ___-.,

Ho. of Businesses ____-_,_ .

- No. of industries _ _ _ _ Type Mtn.

No. of utilities ____ _ _ Type

Railroads .

Other dams _ _ _--

Other % 1 * .

11. Attach Sketch of dam to this form showing section and planon 8' x 11" sheet.

12. How to Locate s

* .- ~ o~if(Q ~t'?' Uss r.(&Vc fit20o IF .O&ISSr)

4. - ..D

I

, . R LG.C. DAM:G

- - . .- ' 10, * - - -*t.~ - *fl. fl. --

VE.%$lL UPERi PAM

I (Z610MCL.AM)

/~~~53S A-c ke

3cR MFG. C. Dft

.- A

FebtmWy 6*2ff3

Zero Naafaoturing Owpany2N Maik trelet

MUs XLU Manufacturing -e

* An engineer frwm the Wasacaeh tts Departmeunt of Fwblic Wortshas Inapected the above dam owed b7 the Zero %anfactuing ~Qany.

Mwe Inspection wasn made In aceordmnce with Chapter 253 of theMssaabusetts Osneral Java, an amended by Maqter 595 of the At* of 2970.

The results of the Inspection Indicate that this die Isasaffelhe'avw It appears that the capacity of the outlet obamiel wider thefactory does not haye the eapacity to acoowodete extraws flows tbasebiag local flooding prabims. 3sveral posaibiLities exist whichmay lesse this oocurzewsc; the most notable being the removal. of thetwo feat of fisboards along the west of the damn an part of an overallemrgency plan dowing peek flow periods. The outlet, controls shouldbe cheeked and made operative. Preventive siutalnence should be exeroisedregularly. Other Items which v noted that required your attentionare the erosion of coceenea the spilway and the aolatiou oftrash and debris at the bas of the apilway.

Iti oe ta you recognise your reeo sblt and act an

Very truly Y01rs

* ~6/~ve...-.-

pRKm C. 8Q!41M, I.Se> Deputy Waef Uwner

as GoL brand DL a9B013A. fr1olano LAst3

ZERO MPG. CO. DAMB-10

APPENDIX C

rk PHOTOGRAPHS

Note: Location and direction of photographs shown onFigure B-1 in Appendix B.


NO I O FDMA NAEAE

II of i I fi .

'[1W 171......

a vu lw fitI _ 7

c-it

ZERO NIANLFACTU RING CO. DAM

C ad

- S2

ZERONIANU ACTURIN CO DA

NO. 5 INTAKE AREA - HAND WHEEL OPERATORS FOR LOWLEVEL OUTLET AND WATER SUPPLY PIPES

NO. 6 INTAKE AREA - CONTROL MECHANISM FOR SLIDEGATE.

C-3b ZER0 NUNUFACTURING 0). 1)AN

Bc-4ZERO AJ4UACTURNG C. DA

APPENDIX D

HYDROLOGIC AND HYDRAULICCOMPUTATIONS

Page

*Figure D-l. Drainage Area Map D-1

Hydrologic and Hydraulic Computations D-2

ZEROMANUACTUING OMPAY DA

t US

- 0

~.14 ~ *Nx~EU.1

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Project "IA~ KCVuteA.J OtJWOO F,* rdM VA *%-I' Acct. No. ' I& J -A pa I s of..* Subject ro~aa u~iLbVW wk 0 A Comptd. ey V1 4-:*DOWNi Z i'Qim Mmr4 Ft'.1)AO Ck'd. ByMADae _

(,~ Onoa,4 roo Res. tmac oof TisI lod

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G- D

1L1 ZERO MFG. CO. DM

Pvoject I 'vC.1 IAw v~. IS w Z-- AcCt. No. * Page of t+LI..

7Subtoct IOA SL Jt 7 P if Cmtmyoat 'io5

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1K. - SIT30a~~~~~ 000________

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Project -944,tyev'i 001n-Fe--AfJ Acz'i o 7" PagSubec C. ~ "'.. S Date L.Detail Zev G k-4 F m Ckd.By U_ Date

4.~~~~ Co-&3 (3 3, 3'&(-) H-.r cveri 42", ,o:

--Q Q!o 3o0 3.o HAr~ocved 300 43i.o t

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a -4, 230 00 92U.60 3,0 2.0 2 1 (U o 6030 f103,Of 0 4,980 7,13o 9,'S30 93o

0 8- I-! e- x; ,e, ,. 44 '" l, bO.dr--

z CCd, p 12u 7 0'60t 4 29. sr-

per. U 430 A 3.r 44o 4_31 4 W5 7 4 5?. H8 tr.e . 61 I,.( 1Z .IJt' 4.IS" 8W~ ,o1" -r-.

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'esE', 43c , 437 438 Cre.r4 io,, dflowa, '-(s0 '3oo C0 arouMJ{t -C40o. 7 .r4;fw&4%.

-o 40 doer ,* 4 -a (ed ,i r,,--0 350 /00~0 ye4uef P"':4.,1, Aese 40(00= Go 5o /coo dgf,,,,ea Wei'; f(ot .

A ~ dro'~aa~e -4J , -.A abo') ve, . -Ada A

ResE. 430 43S- 440 ,437. 434 434; 438 421 4z7* q41 ---7 M2 /7 ,? 1-/ /4- f7 - -

___Q'230. 300 MCIo - G ze o. 140 --

- •. .-"-ZERO MFG. CO. DAN................... . ..-.

Project Wa~. revfw Or jli- adwDrl'~ N~ ~t o 7 T2 Pag 5 of 14Subject HOoa O~ .Mt. Comptd. By Lf D ate.1C

Dti iOMrt M Ck-d. By Date

A-~~~ ~ ~ ~ iaw I1 l.W

0 - - (

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* Hi34 F/o w:

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adr C4L g24A0fm(v- j cvm4o11e.4L a skes4py"~

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v 14.0 17.9 iq.(# Z..'t44 zif'r :'ufs- Z.rZVSO 311I0 4-3o -SI(O S6a

TWkFJ. 4744 431.4 ' 444 434. 43-7.41.4 r.4- &.

40 1.430 207e 2760

I ZERO MFG. CO. DA1

Project l0 Acct. o 72 - Page .of

* Subject ~ 1J 4 if~'I Comptd. By L Date F/CDetail M ''F~]A~ Ck-d By tAIA--Dt

. r US. fiCI

i@

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1-_ 6.3.. 5_.. -_. O r

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5+40 3, 9.730.'

l1 ,7 o .. R . ....7oSe o2 n , ::i47o7 .903

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4oo U .... .. ,~ 4 a- . '?6oz, , o. ,

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Project Ae'vi aC & lo m FitafPQ 0"D l Acct.o. 7 I L . _ Page__8 IfJoSubject -frn d a t,. A M f Comptd.By ".-at .ITDetail Zn6 Fa 0A m Ckhd. By _km ate r L

ii_ _-- -..- r-- ---T.

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Project AAl V; 42wgAoD -rd Dams, Acct. No. 72 Page q~t 4Subject HawptJtrr, Cejun7 Al ~1af comPtd. By A; Date

Detail 70 Vr? F 4O Ck'd. By MAMDate

F- '.i .e C-l 4 oF-SSA

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Corn, . /e 7 e4 4 5 Fles. Byev D. LAHA

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Ema Z99A MM~G 'QA Ck-d.B Date v-A%

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___ ___ ___ ___ ___ _ Road eel'__ __

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toi 0o+e,-e 427 4 7"W27 ocr ;

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* Project 7 . ' I i fAa e 7h, tp. 72 paw ofSubject Haimpelon r-Auflg Mass, Comptd. By .I .. D~ate A.IL....

®Fe II~r '08 DA4, Daft'

'1 i Faah re. Of'tIL d4%,. duva, 0-e fed foa 0, or w~ifA~_r~o-Ue~low poti.-+ +&&e -ri4 (. 4 3)

W(AL ppeb- 4-0 00co 4.. Si.If h&3*v4 dut. 4-0i.~7viovi IU4 u4+-P'w ~k i ck f..e411A. hav#e-

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f b e eo., davi II ,tf I* clr4E 0 W s ;I e~u. (7 W

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arc I Ar ,l acres 'C el. 1-4io '4rowe consi,

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Detail z. E C 4A Ckd. By A~L.............Date 1

@Failfur-e o-f Domn

I4- FciO' lr..i f41%e- duf At &0~ fed orsV440-. res, a*4e low .poi;, OKe e4n Creieoe-i*ArWJOW(A C ppgo_.- 4-o beo&1a1o Lpi( g_~uIt 4-. (if''o eW~~ai4jeCV% WAktck 4,jo have a ee16001de Ou{ I-At (ow-'er faa- 1 ftoov,

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ProjNoestoFk #.IA.AOFd D%.A~ .. - Pago of

Subiect Hdmopdam df^US 1 Mi dtCOMPtd. By ELZ..... Date i Fz~LDetail Z~ip WE. 124AI Ck'd. By Date

@~~ ~ ~ A"4 w-YYA110 spill

*~'r -_____ __.e fa.4i'i-4f V1O.0. .

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ke-4r4JS&4,IAJrv, 0' (dry) to 5'.)S( -

D31 ZERO MFG. CO. DAM

Project v , F k) ofm4Y.4rd 1 O00"f Act N, 72. S2. Page o

Subject Ma W9de 6 C~UMa Al Comptd. By Date IZQZI S

Detail kfiit AI& 'QAA Ci d. By Wd~l Date

5AsaE VS g~eSevor(fev-

A'es, arc 1 13 acv-es t4 et 1-4g3o krco.*~ CUIIdio-e& fon.~ efeu. 42.1 *.tAt kt3 A 4

00

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D-8ZR FG O A

APPENDIX E

* INFORMATION AS CONTAINED I1N THENATIONAL INVENTORY OF DAMS

ZER 0INFCUI4 OPN A

* S

S

* 0

S

& S

NOT AVAILABLE AT ThIS TIME

S

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