B08__A30_Specification_35_22_46_-_Radial_Gates_Rev20241029_0003.pdf

CRIP MC185/MC270 Check Rehabilitation SECTION 35 22 46 La Paz County, Arizona RADIAL GATES

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GENERAL

SECTION INCLUDES

This section includes designing, fabricating, delivering, and installing radial gates and associated equipment including, but not necessarily limited to the radial gate (e.g., leaf assembly, skin plate, radial arm assembly, trunnion, trunnion support bracket and seals), gate appurtenances, motors, post-installed concrete anchors, gate hoist assemblies, wire ropes, drums, sill plates, rubbing plates, lifting system yoke, and anodes. This section also includes furnishing miscellaneous materials including, but not necessarily limited to anchor adhesive and leveling grout required for, or incidental to, Contractor’s installation of radial gate and appurtenances.

The Contract Drawings are for the purpose of guidance and to show functional features and required external connections. They do not necessarily show all of the components described in this specification and necessary to accomplish the desired results nor do they necessarily show all components required to interface with the equipment. The Contractor shall provide all parts, equipment, and devices necessary to meet the functional requirements of the system.

RELATED SECTIONS

The following list of related specification sections is not intended to be all-inclusive.

Section 01 33 00 – Submittal Procedures

Section 03 60 00 – Grouting for anchor adhesive and leveling grout

Section 05 05 13 – Shop-Applied Coatings for Metal for radial gate coating requirements.

Section 05 50 01 – Miscellaneous Metal Fabrications

Section 05 52 13 – Pipe Railings

Section 40 63 13 – Hoist Control Panel for the radial gate control panel and wiring

Section 40 70 00 – Instrumentation for Process Systems gate position transmitters

REFERENCE CODES AND STANDARDS

Design Codes include:

1. USACE ETL 1110-2-584 Design of Hydraulic Steel Structures

2. AISC 360-16 Specifications for Structural Steel Buildings

ASTM International (ASTM)

1. ASTM A36 Standard Specification for Carbon Structural Steel

2. ASTM A48 Standard Specification for Gray Iron Castings

3. ASTM A108 Standard Specification for Steel Bar, Carbon and Alloy, Cold-Finished

4. ASTM A126 Standard Specification for Gray Iron Castings for Valves, Flanges, and Pipe Fittings

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5. ASTM A240 Standard Specification for Chromium and Chromium- Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and General Applications

6. ASTM A276-16 Standard Specification for Stainless Steel Bars and Shapes

7. ASTM A307 Standard Specification for Carbon Steel Bolts, Studs, and Threaded Rod 60 000 PSI Tensile Strength

8. ASTM A311 Standard Specification for Cold-Drawn, Stress-Relieved Carbon Steel Bars Subject to Mechanical Property Requirements

9. ASTM A493-16 Standard Specification for Stainless Steel Wire and Wire Rods for Cold Heading and Cold Forging

10. ASTM A575 Standard Specification for Steel Bars, Carbon, Merchant Quality, M-Grades

11. ATM B21 Standard Specification for Naval Brass Rod, Bar, and Shapes

12. ASTM B98 Standard Specification for Copper-Silicon Alloy Rod, Bar and Shapes

13. ASTM B843-13 Magnesium Alloy Anodes for Cathodic Protection

14. ASTM F593 Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs

15. ASTM F594 Standard Specification for Stainless Steel Nuts

NACE International (NACE) AMPP

1. NACE (AMPP) SP0169-13 Control of External Corrosion on Underground or Submerged Metallic Piping Systems

2. NACE (AMPP) TM0497-12 Measurement Techniques Related to Criteria for Cathodic Protection on Underground or Submerged Metallic Piping Systems

American Welding Society, Inc. (AWS)

1. AWS D1.1/D1.1M-10 Structural Welding Code – Steel

2. AWS D1.6/D1.6M-07 Structural Welding Code – Stainless Steel

DEFINITIONS

Cathodic Protection: A technique to reduce the corrosion of a metal surface by making that surface the cathode of an electrochemical cell.

Electrolyte: A chemical substance, such as soil or water, containing ions that migrate in an electric field. The terms for these specific conductive solutions may be substituted for the word “electrolyte” in these definitions.

Galvanic Anode Cathodic Protection: Reduction of corrosion of a metal in an electrolyte by electrically coupling it to a more anodic (or active) metal. This form of cathodic protection is also called sacrificial anode cathodic protection.

https://www.astm.org/Standards/A311.htm https://www.astm.org/Standards/A311.htm https://www.astm.org/Standards/A311.htm https://www.astm.org/Standards/B21.htm https://www.astm.org/Standards/B21.htm https://www.astm.org/Standards/B98.htm https://www.astm.org/Standards/B98.htm https://www.astm.org/Standards/B98.htm https://www.astm.org/Standards/F593.htm https://www.astm.org/Standards/F593.htm

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Gate Hoist Assembly: A modular assembly consisting of a hoist base, motor, gearing, control panel, wire rope drums, cross shaft, walkway grating, railings, and bearing bracket to operate the radial gates.

Fully Closed: Gate resting on the sill plate.

Fully Open: Gate raised such that the opening height equals the gate height.

CONTRACTOR’S SUBMITTALS

Submit the following in accordance with Section 01 33 00 – Submittals.

Action Submittals

1. 35 22 46-1, Radial Gate Designer and Manufacturer Qualifications

a. Provide Radial Gate Designer qualifications demonstrating compliance with the minimum qualifications.

b. Provide Radial Gate Manufacturer qualifications demonstrating compliance with the minimum qualifications.

c. Provide welder qualifications demonstrating compliance with the minimum qualifications.

d. Provide Cathodic Protection Designer qualifications demonstrating compliance with the minimum qualifications.

2. 35 22 46-2, Radial Gate Approval Drawings and Data

a. Prepared under the direction, and bearing the seal and signature, of a licensed Professional Engineer.

a. Complete description of all materials and gate appurtenances, including:

i. Material properties and thickness of all structural components of the frame, slide, gate leaf, and trunnions.

ii. Product data for all components of gate hoist assembly.

iii. All materials of the cathodic protection system including manufacturer’s data sheets for anodes, metallurgical bonding system (weld studs), and dielectric coating system for anode connections.

a. Shop drawings showing all details of construction; details required for installation; dimensions; and anchor bolt locations, arrangement, sizes, and types.

Drawings shall define the type, size, number, and location of all anodes for cathodic protection system and define any necessary requirements or typical details necessary for installation of cathodic protection system.

b. Radial gate design calculations demonstrating compliance with specification requirements and governing design code(s) showing that all components and anchorages were designed based upon the maximum heads and design loads described herein.

c. Cathodic protection design calculations: Prepared under the direction of an individual meeting the required minimum qualifications and bearing their

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i. Surface Area

ii. Current Calculations

iii. Coating Efficiency

iv. Electrolyte Resistivity Data

d. Motor

i. Supply a motor information data sheet listing the output torque or thrust, voltage, phase, frequency, motor amperage at running torque and locked motor, nominal motor HP, and output speed at travel time.

ii. Calculations showing seating and unseating torques versus the output torque of the motor.

iii. Wiring Diagrams: electric schematic and connection wiring diagrams with list of symbols in accordance with ANSI/IEEE or IEC.

iv. A one-line diagram illustrating internal motor wiring.

v. An interconnection diagram showing field terminations with unique terminal identification.

vi. Factory test reports, if normally provided by the manufacturer or vendor, prior to delivering the motor. Factory test reports shall include factory acceptance test checklists and pass/fail results certified by a trained factory representative.

vii. Motor manufacturer’s warranty information.

e. Radial gate manufacturer’s handling and installation procedures/requirements, including manufacturer’s standards of alignment required for installation.

f. Radial gate manufacturer’s warranty information.

3. 35 22 46-3, Wire Rope Prestressing Test Results

a. Test results from wire rope manufacturer certifying completion of industry-standard prestressing procedures and documenting the breaking strength.

b. Test results from the wire rope manufacturer for the wire rope spelter sockets, if applicable.

4. 35 22 46-4, Radial Gate Factory Acceptance Test Results

a. Complete and document all factory acceptance tests as required in Part 3 of this specification for the radial gate.

b. Tests submitted under other sections (e.g., 05 05 13 and 05 50 01) do not need to be resubmitted under this section.

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5. 35 22 46-5, Owner-witnessed Factory Acceptance Test Results

a. Complete and document all Owner-witnessed factory acceptance tests as required in Part 3 of this specification for the gate hoist assembly.

b. Include tests outlined in other sections (e.g., 40 63 13) and indicated as to be provided under this submittal.

6. 35 22 46-6, Gate Handling and Installation Plan. Include, at a minimum, the following information.

a. Demonstrate compliance with handling and installation requirements contained in manufacturer’s operation and maintenance manual.

b. Include a summary of Contractor’s equipment for handling, transporting, and installing radial gate and gate appurtenances.

Informational Submittals

1. 35 22 46-7, O&M Manuals

a. This submittal shall include the following manuals compiled in a single bookmarked pdf. Where manufacturer O&M manuals contain information for multiple models, sizes, or optional accessories, clearly indicate by using arrows or brackets precisely what has been provided.

b. Radial Gate Manufacturer’s Operation and Maintenance Manual

i. Including instructions for handling, storage, installation, and operation and maintenance.

ii. Include a list and frequency of specific maintenance activities.

c. Radial Gate Motor Operation and Maintenance Manual

i. Manufacturer’s instruction for handling, storage, installation, operation, and maintenance manuals. Include lists of major components, recommended spare parts, special tools for installation, and maintenance adjustments.

d. Anti-Backdrive Device Operation and Maintenance Manual

i. Including instructions for handling, storage, installation, and operation and maintenance.

ii. Include a list and frequency of specific maintenance activities.

e. Reduction Gearing Operation and Maintenance Manual

i. Including instructions for handling, storage, installation, and operation and maintenance.

ii. Include a list and frequency of specific maintenance activities.

f. Hoist Control Panel Operation and Maintenance Manual

i. See requirements described in 40 63 13 – Hoist Control Panel.

g. After approval, provide 4 physical copies of the final compiled manual. Each physical copy shall be enclosed in a 3-post, expandable metal hinge binder

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2. 35 22 46-8, Post-Installation Documentation

a. Complete and document all post-installation testing and alignment as required in Part 3 of this specification.

b. Erecting engineer’s certificate of installation with manufacturer’s standards of alignment.

c. Hoist Control Panel site acceptance test results as described in Section 40 63 13.

d. Cathodic protection testing data, including electrical continuity between the anode and the protected structure.

e. Final warranty information for the radial gate and radial gate motor, including the date of delivery.

f. Complete equipment inventory and bill of materials.

3. 35 22 46-9, Contractor’s Field Dimension Data (For Retrofit Applications)

a. Field measurements obtained during annual irrigation dry-up related to radial gate design and fabrication.

QUALIFICATIONS

Radial Gate Manufacturer: The manufacturer shall have manufactured radial gates of the type described herein on a minimum of 20 similar projects.

Radial Gate Designer: The designer shall have designed radial gates of the type described herein on a minimum of 20 similar projects. The Radial Gate Designer may be the Radial Gate Manufacturer.

Erecting Engineers: 5 years of experience installing similar equipment. Erecting engineer(s) may be an employee of the radial gate manufacturer.

Cathodic Protection Designer: Corrosion Specialist, Cathodic Protection Specialist or CP4 NACE (AMPP) International certification for personnel performing or directing the design of the cathodic protection system. Lead designer must possess a minimum of 5 years of experience designing similar projects.

Welder: Manual welding operators performing welding operations on these gates and accessories shall be qualified under the “Standard Qualification Procedure” of the American Welding Society.

Single Manufacturer: All equipment of a specific type (e.g., radial gates and magnesium anodes) specified under this Section shall be furnished by a single manufacturer.

QUALITY CONTROL

Unit Responsibility: To ensure compatibility of all components directly related to the radial gates, unit responsibility for the radial gates and accessories as described in this section shall be the responsibility of the radial gate manufacturer unless specified otherwise.

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Provide the services of one or more erecting engineers onsite during the installation and startup of each defined major piece of equipment and subassembly. The responsibilities of the erecting engineer(s) are to technically supervise and provide instruction on the proper installation of the equipment.

BIA REPRESENTATIVE’S QUALITY ASSURANCE INSPECTION AND TESTING

BIA Representative may choose to complete an inspection of radial gate and gate hoist equipment at the fabrication shop(s) prior to shipment. BIA Representative inspection may include independent quality assurance testing.

Following their inspection, BIA Representative will either:

1. Provide authorization to Contractor to proceed with shipment.

2. Provide a list of nonconformities requiring correction prior to shipment.

BIA Representative may elect to complete additional inspections at the plant(s) or at the point of delivery.

WARRANTY

Contractor shall provide a manufacturer’s warranty of radial gate and gate appurtenances extending for a period not less than 2 years from the date of substantial completion.

PRODUCTS

GENERAL

The radial gates and appurtenances shall be designed and fabricated in full conformity with the Drawings and requirements of this specification. Equipment specified under this section shall be supplied with all the necessary parts and accessories indicated on the drawings, specified, or otherwise required for a complete and properly operating installation.

The design shall be prepared under the direction, and bearing the seal and signature, of a Professional Engineer licensed in the state where the materials will be installed.

Applicable specifications listed below are for the alloy, grade, type or class of material and the condition and finish appropriate to the structural and operational requirements.

Materials shall be as indicated in Table 35 22 46-1.

Table 35 22 46-1

COMPONENTS/MATERIALS ALLOY/GRADE/TYPE/CLASS

Cast Iron ASTM A48 – Class 30 ASTM A126 Class B

Structural Steel Shapes, Plates and Bars ASTM A36, A500 or A992

Carbon Steel Bars ASTM A108, A575 or A311

Stainless Steel

ASTM A276

ASTM A240

Type 304, 304L, 316, 316L

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Bronze Bar, Rods, and Shapes ASTM B98 or B21, Permalube Bronze

Connection Bolts ASTM F3125 or SAE Grade 5

Stainless Steel Assembly Hardware ASTM F-593, F-594

Magnesium Anodes ASTM B843

Welding Studs ASTM A276 or ASTM A493

Hardware Stainless Steel

DESIGN CRITERIA

The radial gate and operator system shall be designed based on Contractor’s field dimensions, hydraulic information provided below and in the Construction Drawings, including all other related loads that will act on the gate through its operating range. Gate operating housings, supports, and wire rope connections to the gate shall be designed with a minimum safety factor of five based on the ultimate strength, or a safety factor of three based on yield strength of the materials used. Design head used for the structural analysis and design of the radial gate shall be as specified in Table 35 22 46-2, or assuming one foot of water is flowing over the gate when fully closed, whichever is greater.

1. Radial Gate key Elevations and dimensions are included below in Table 35 22 46-2.

Elevations included in Table 35 22 46-2 are based in U.S survey feet and are relative to the NAVD88 vertical datum.

Table 35 22 46-2

DESCRIPTION MC185 MC270

Replacement of an existing gate or new construction Replacement Replacement

Tag MC185 MC270

Gate Width (ft) 18.5 18.5

Gate Height (ft) 13.5 12.5

Gate Invert Elevation 349.8 348.0

Design Head (ft) 17.0 15.8

Overflow or Breastwall Overflow Overflow

2. All welds shall have complete fusion with the base metal and shall be free from cracks, oxides, slag inclusions, and gas pockets.

3. Design such that no field welding is required for assembly or installation.

4. Areas or crevices that could potentially pool water are not allowed. Provide drain holes and cope corners as necessary to facilitate drainage.

5. The radial gate controls shall feature a hoist control panel with devices, features, and appurtenances as outlined in Section 40 63 13 Hoist Control Panel.

Cathodic Protection

1. Galvanic anode cathodic protection systems shall be provided for the radial gate and associated metalwork.

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2. Materials shall provide a minimum service life of 20 years (system and components).

3. Provide corrosion-engineering services to furnish and install the galvanic anode cathodic protection systems.

a. Include galvanic anodes, accessory equipment, and features as directed in this specification.

b. Materials and installation shall be consistent with sound corrosion engineering principles and practice in accordance with NACE SP0169.

4. Maintain sufficient anode materials below the minimum normal operating water level.

5. Anodes must be fastened to the gate by means of a welded bolt or threaded rod through the center of the anode.

6. Provide and maintain electrical continuity between the anode and structure as per NACE

TM0497.

GATE LEAF ASSEMBLY

The gate leaf assembly shall consist of horizontal structural members, vertical stiffeners, and a curved skin plate. Horizontal structural members shall be of adequate size and so located to transmit the thrust from the face of the gate to the radial arms. Design loads placed on the structural reinforcing channels shall not induce stresses in excess of those specified in the design codes referenced herein. Minimum 0.25-in thick, curved skin plate shall be attached to the structure by welding. Sufficient holes shall be located around the perimeter of the assembly for attaching the seals. The gate leaf shall be fabricated in one piece.

Overflow gates shall be designed to withstand a water depth of 1 foot greater than the vertical height of the gate or the design head specified in Table 35 22 46-2, whichever is greater.

Breastwall gates shall be designed to withstand a water depth as shown in the gate schedule.

Maximum deflection of the face plate shall be limited to L/360 for overflow gates and to a maximum of 3/16-inch for breastwall gates at the upper reinforcing member.

Each gate shall be fitted with replaceable and adjustable rubber seals retained by stainless steel bars along the side and bottom edges of the gate face. The seals shall be of the belt type or “J” type, as specified, and shall be designed to bear on the walls and bottom of the structure or (if specified) on rubbing plates and sills to ensure a water-tight fit when the gate is closed. On breastwall gates, a rubber seal shall also be provided at the top edge of the gate.

RADIAL ARM ASSEMBLIES

The radial arm assemblies shall transmit the load from the radial arms to the pivot pin and shall be designed to include forces generated by pin friction. Radial arm assemblies shall consist of structural members. The slenderness ratio of the radial arms shall not exceed 120.

TRUNNIONS

The trunnion sleeve shall be fabricated steel and welded to the trunnion arms. The trunnion sleeve shall be equipped with self-lubricating bronze sleeve bearings. The trunnion pin assembly shall fit the existing anchor rods at MC185 and MC270.

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The trunnion pin shall be stainless steel and shall be designed to support the maximum transferred load.

SIDE SEAL RUBBING PLATES

Furnish a stainless-steel rubbing plate providing a smooth contact surface for the side seals throughout the full range of movement of the gate. The rubbing plates shall be adjustable on the anchor bolts to permit vertical alignment of the contact surfaces. Plates shall extend to top of wall or minimum one gate height above the gate top in the closed position. Rubbing plates shall have the minimum dimensions indicated in the Drawings or (if not indicated in the drawings) shall be a minimum of ¼ inch thick by 6 inches in width.

Side seal rubbing plates shall be suitable for mounting in a grouted channel such that finished surface of the plate is flush with the surface of the adjacent concrete walls of the structure, when installed in a new concrete structure. Surface/face mounted side seal rubbing plates are acceptable when installed on an existing concrete structure.

BOTTOM SILL PLATE

Furnish a stainless-steel bottom sill plate providing a smooth, level contact surface for the full width of the invert of each gate. The sill plate shall be adjustable on anchor bolts using a two-nut combination of anchor and leveling nuts to facilitate leveling and alignment.

New Construction: Bottom sill plates shall be suitable for mounting in a grouted channel such that the finished surface of the sill plate is flush with the surface of the concrete floor of the structure.

Retrofit Construction: Surface/face-mounted bottom sill plates are acceptable when installed on an existing structure.

GATE HOIST ASSEMBLY

Provide a single unit gate hoist assembly for each gate consisting of a hoist base weldment, hoist operator (i.e., motor and reduction gearing), control panel and associated electrical equipment, wire rope drums, cross shaft, and bearing bracket to operate the radial gates. The operators shall be adequate for opening radial gates to the fully open position for the operating head specified. The gate hoist weldment must span the gate bay width, supported by, and anchored to the concrete gate bay walls.

The assembly, including the motor, gearing, anti-backdrive device, wire rope drum, walkway grating, railings, Hoist Control Panel, cross shaft, etc., shall be fully assembled, tested, and aligned in the shop on a single steel base weldment to minimize field assembly and field alignment procedures. The manufacturer shall incorporate lift points on the base weldment to facilitate crane lift of the assembly to the installation location. The Contractor shall take responsibility for the gate hoist assembly design, including fit-up with walls, walkways, railings, and other elements of the check structure. The Gate Hoist Assembly shall be located immediately downstream of the concrete walkway platform, as indicated on the Drawings.

Motor

1. Multi-turn style actuators (e.g., Rotork and similar products) are not allowed.

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2. Provide a nominally 1800 rpm motor suitable for use with the 3 phase 208V, 60Hz power supply as indicated in the Construction Drawings. Motor manufacturer is to have a minimum of 10 years of experience manufacturing gate/valve motors.

3. Motor shall feature a metal nameplate, embossed or engraved with the following information at a minimum: Manufacturer, model number, horsepower, voltage, phase, hertz, RPM, full load amps, serial number, month and year of manufacture, and space heater data.

4. Identify wires for motors by unique numbers.

5. Design the motor and drive system, including gear reducers, for a gate operating speed of 6 inches per minute. Motor must maintain specified travel times during a plus or minus 10% fluctuation in voltage.

6. All calibration and set-up features shall be easily accessible and not require the use of specialized tools.

7. Provide motor with rated output torque sufficient to guarantee operation of the gate/valve at any position at the most severe operating conditions, including seating and unseating conditions, and accounting for maximum mechanical friction or other restrictive conditions inherent in the gate/valve assembly. Calculate motor maximum torque with the applied voltage 10% below the nominal motor voltage rating. The actuator motor must be capable of operating through one complete stroke (open or close) against the maximum differential pressure without overheating when voltage to the motor is within 10% of the specified voltage.

8. The motor must be suitable for service in an ambient temperature ranging from -20°F to 130°F, and up to 100% relative humidity. Provide actuator materials and coatings suitable for outdoor use in cold and hot weather.

9. The motor shall be a low inertia high torque design with minimum class H insulation and rated for a minimum of 70 starts per hour. Overload protection shall be limited by thermostats embedded in the motor end windings and integrated into its control.

10. The motor shall be totally enclosed, fan cooled and shall be furnished with a combination drain/breather for removal of moisture from the motor enclosure and shall be furnished with an automatically controlled space heater to minimize condensation, located within the motor frame.

11. Electrical and mechanical disconnection of the motor will not require draining the lubricant from the reduction gearcase.

12. Provide motor protection as follows:

a. Stall – de-energize the motor in the event of a stall when attempting to unseat a jammed gate/valve.

b. Over temperature – thermostat will cause tripping of the motor. Auto-reset on cooling.

c. Direction – phase rotation correction.

Anti-backdrive Device

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1. Provide an anti-backdrive device that maintains the radial gate open position when the motor is shut off or removed. The device shall be connected to the motor output shaft and shall engage automatically when the motor shuts off.

2. The device shall include an operating nut provided to manually operate the radial gate with an electric drill coupled with a Love Joy Inc., L-075 625 bit, or provided equal, in the event of power failure. The direction of rotation to open the gate shall be clearly marked.

3. Device shall feature a metal nameplate embossed or engraved with product information (e.g., manufacturer, model number, serial number, month and year of manufacture).

Reduction Gearing

1. Accomplish reduction by means of spur, helical, bevel, or worm gears. The use of nonmetallic or aluminum gears in the power train is unacceptable. Totally enclose the gearing in an oil-filled or grease-filled gearcase suitable for operation at any angle at low speed. All gearing and components must be of metal construction. The design should be such as to permit the opening of the gearcase for inspection or disassembly without taking the gate out of service.

2. A manufacturer-recommended synthetic gear oil to be used to lubricate the gearcase. The gearcase shall feature an oil level indicator. Provide an oil drain at the lowest point possible on the reducer housing designed to drain all the oil from the sump.

3. Gear housing in monobloc design, supporting all gears and bearings in one piece of solid casting (excluding the input shaft).

4. Gearcase shall feature a metal nameplate, embossed or engraved with the following information at a minimum: Manufacturer, model number, exact reducer ratio, output torque rating, input horsepower rating, input speed, serial number, month and year of manufacture, and lubrication quantity.

Controls

1. Provide a Hoist Control Panel per Section 40 63 13 to control hoist motor power and rotational direction. The Hoist Control Panel shall be affixed to the base weldment and shipped to the project site as a complete, integrated assembly after shop testing.

2. Include the following control and safety switches as part of the Gate Hoist Assembly:

a. Two individually adjustable position limit switches, one for each gate direction (up and down). The position limit switches shall be installed within the hoist gearbox, or externally coupled to the gearbox or hoist shaft via metal gears or shafts.

b. One torque switch in the open direction to break the hoist motor power circuit and engage the Anti-Backdrive Device to minimize damage caused by binding or an obstruction.

c. All switches shall be protected by an IP66 or equivalent enclosure and be positioned for easy access for maintenance and adjustment.

d. The switches shall be terminated within the Hoist Control Panel.

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3. Include redundant gate position transmitters, to provide analog gate position feedback signals to a remote programmable logic controller described in Section 40 67 16. The redundant gate position transmitters shall be installed within the hoist gearbox, or externally coupled to the gearbox or hoist shaft via metal gears or shafts. Refer to section 40 70 00 for additional gate position transmitter requirements.

4. Wiring and Terminals

a. All field terminations shall be permanently marked with unique designations. The terminal designations shall correspond with publicly available manufacturer’s wiring diagrams.

b. All field wiring shall be uniquely and permanently labeled.

c. Use tropical grade PVC insulated stranded cable of appropriate size for the control and single-phase power internal wiring. Clearly identify each wire at each end.

d. Separate the terminal compartment from the inner electrical components of the actuator by means of a watertight seal.

e. All wiring supplied as part of the actuator to be contained within the main enclosure for physical and environmental protection. External conduit connections between components are not acceptable.

f. Provide a durable identification card showing plan of terminals attached to the inside of the terminal box cover indicating:

i. Serial number.

ii. External voltage values.

iii. Wiring diagram number.

iv. Terminal layout.

Drum

1. Fabricated from welded steel, ASTM A36 or equal.

2. The minimum ratio of the drum diameter to wire rope diameter shall be 12:1.

3. The drum shall include helical grooves to receive hoisting ropes to ensure that they spool and unspool in an orderly and controlled manner. The grooved length shall be sufficient for full travel of the gate, without over winding, plus minimum 2 dead wraps.

4. Provide each drum with a removable safety cover.

a. Cover design will surround from above, the sides of, and the entire length and width of the drum, and cover the rope holes in the work platform without interfering with the motion of the ropes, shafts, bearings, or couplings.

b. Cover shall be anchor-bolted to the work platform or gate weldment.

c. Provide inspection openings with removable, bolted-on steel covers.

d. The cover shall be sloped or curved to drain precipitation.

e. Weld joints continuously to seal against intrusion of moisture or dust.

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f. Provide screens or barriers, as required, to prevent or minimize insect, bird, or animal intrusion.

Mechanical Gate Position Indicator

1. All gate operators shall be furnished with an integrated, mechanical gate position indicator. The indicator shall continuously display the vertical gate opening defined as the vertical distance between the concrete floor and the lowest protruding gate leaf edge across all gate positions within the specified gate operating range. Acceptable indicator types:

a. Moving graduated wheel with fixed needle indicator

b. Fixed graduated wheel with moving needle indicator

c. Mechanical counter

d. Geared vertical mechanical gate position indicator connected to the cross shaft of each Gate Hoist Assembly; totally enclosed in a galvanized gate position enclosure complete with a lexan lens graduated scale. Provide a small, screened vent at the top and bottom of the enclosure for ventilation. Provide all necessary gearing, cables, and supports for a complete system.

2. Locate the indicator within 24 inches to 52 inches vertically above the operating deck, and at least 36 inches horizontally away from deck edges, guard rails, and other obstructions.

3. The indicator shall display vertical gate opening in units of feet with graduations no greater than 0.1 ft.

4. Indicator number labels shall be 1 inch tall or larger, regardless of the indicator type.

5. Maximum indicator error across the full gate operating range (compared to field measurements of the vertical gate opening) shall be 0.05 ft.

Safety Features

1. The Construction Drawings indicate the gate hoist assembly will be installed immediately downstream of the concrete walkway deck but do not detail all handrail requirements for enclosing the gate hoist assembly – detailed design of handrails, guard chain, etc. to enclose the gate hoist assembly is the responsibility of the Contractor.

Owner’s expectation is that the handrails will be fabricated and attached to the gate hoist assembly.

2. Install walkway gratings on the hoist assembly in accordance with Section 05 50 01 – Miscellaneous Metal Fabrications. Hoist assembly walkway grating shall be designed to be level with the main walkway platform when installed.

3. Install chain railing or pipe railing around the perimeter of hoist assembly in accordance with Section 05 52 13 – Pipe Railings.

WIRE ROPES AND SOCKETS

The wire rope manufacturer shall prestress the wire rope according to standard industry practices.

Rope designation: independent wire rope core.

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Material: compatible with radial gate so as to not cause damage due to dissimilar metals.

Minimum breaking strength: based on uneven (60 percent) gate loading to one side of hoist with a safety factor of 5.

Length: For each rope, provide a rope length which is the sum of:

1. Full travel of the rope around the grooved drum, plus two dead wraps,

2. The distance from the drum pitch diameter tangent to the center of the gate lifting lug hole when the gate is fully lowered, and

3. Approximately 10 inches in addition to aid with anchoring the rope.

a. All but approximately 2 inches of this extra length are to be cut off after the rope is anchored to the drum.

Provide 2 extra wire ropes per radial gate, cut to the appropriate length.

Sockets:

1. Type: open spelter or swaged type.

2. Material: same as wire rope.

3. Provided with headed pines, drilled for and provided with stainless steel copper pins.

4. Dimensionally compatible with lugs on the gates and the rope diameter.

5. 100 percent termination efficiency, rated for minimum temperature operating range from -20 to 130 degrees F.

6. Socketing:

a. If used, speltering shall be zinc-poured or resin.

b. Tension tested to two-fifths of rope breaking strength.

GATE POSITION GAUGE

Each gate shall be furnished with an individual fixed plate gate position gauge. The gauge will be anchored to the concrete side wall at one gate leaf edge, above the typical upstream operating water level, to display a reading of the vertical gate opening defined as the vertical distance between the concrete floor and the lowest protruding gate leaf edge.

Each gauge shall use the top of the gate leaf as the indicator of the vertical gate opening.

Each gauge shall be designed so that, when installed, all ticks terminate within 1 inch of the gate leaf edge to minimize uncertainty.

Each gauge shall have labeled ticks with printed numbers at each whole foot with numbered labels corresponding to the distance. Number labels shall be no less than 3 inches tall.

Graduated ticks shall be provided at a 0.1 foot internal, no less than 1 inch long. The gauge shall be readable from 20 feet.

The gauges shall be designed with a supporting frame or other structure to maintain a maximum deflection of 0.125 inch when applying a 200-pound horizontal force parallel to the gate leaf at the top of the gauge.

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FASTENERS

All anchor bolts, assembly bolts, screws, nuts, etc. shall be of ample section to safely withstand the forces created by the operation of the gate under the specified pressures and loads. The quantity and size of fasteners shall be designed by the manufacturer.

Design of all anchorages to concrete shall be the responsibility of the manufacturer with the arrangement reviewed and accepted by the BIA Representative. As indicated above, wall face-mounted trunnion brackets must include a grout-embedded shear lug to resist primary thrust forces. The shear lug shall be augmented by post-installed anchor rods to resist secondary forces resulting from load vector directional changes and geometric eccentricities. All load combinations and all load effects arising from geometric eccentricities shall be considered in the anchorage design.

In the event anchorage to the structure triggers a potential design change to the supporting structure, contact the BIA Representative immediately.

COATINGS

Radial gates and associated equipment subject to submergence, including, but not necessarily limited to leaf assembly, radial arm assembly, trunnion, and trunnion support bracket, shall be coated in accordance with Section 05 05 13 – Shop-Applied Coating for Metal.

All other non-submerged exposed carbon steel surfaces shall be painted or finished suitable for outdoor exposure, with a color that generally matches the radial gate equipment coatings, and in accordance with paint manufacturer’s recommendations.

Handrails provided integral with walkway yoke equipment shall be hot-dip galvanized in accordance with Section 05 52 13 – Pipe Railings.

Do not paint:

1. Aluminum-brass, brass, and stainless-steel metalwork or bolt threads, seals, and machined surfaces where paint could interfere with proper operation or fit.

2. Galvanic anode sacrificial surfaces.

EXECUTION

DESIGN

Radial gate and cathodic protection design shall not commence until Radial Gate Designer and Manufacturer Qualifications are approved.

FABRICATION

Work shall not commence before Radial Gate Approval Drawings and Data are approved.

Locate the motor to be readily accessible for operation and maintenance without obstructing walkways.

The gearcase oil drain hole shall be easily accessible from the work platform.

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Do not mount motor and gearing where shock or vibrations will impair their operation, and do not attach the support systems to handrails, process piping, or mechanical equipment.

Install the gate hoists, wire ropes, lifting assemblies, and anchorages in accordance with the Manufacturer’s recommendations.

Locate the controls to be readily accessible for operation and maintenance without obstructing walkways.

All gates and equipment shall be inspected and approved by qualified shop inspector(s) (e.g., weld inspections and coatings) and BIA Representative prior to shipment.

FACTORY ACCEPTANCE TESTING

General

1. Factory acceptance testing shall not commence until fabrication of all related materials and individual units specified under this section is complete.

2. For Owner-witnessed testing, the BIA Representative shall be notified at least 14 days prior to testing.

3. The Erecting Engineer shall be present in the shop during factory acceptance testing.

4. Factory acceptance testing documentation shall include, but not be limited to:

a. The date the tests were conducted, as well as all manufacturer, Contractor, and Owner personnel that were involved in, or present for, the test.

b. Include model and serial number of any measuring equipment used.

c. Documented proof that the required inspections were successfully made during the tests.

d. Any abnormalities in operation such as excessive vibration, noise, or heat discovered during the testing.

e. List all deficiencies corrected and the method of correction.

Radial Gate – Prior to shipping the Radial Gate for field installation:

1. Skinplate welds shall be tested for water-tightness prior to painting and mounting of seals by coating one face of the skinplate with soapsuds and applying air pressure with a hose using a minimum air pressure of 60 psi at the nozzle to the opposite face, Disclosed leaks shall be sealed with light welds.

2. Complete other tests as may be required to demonstrate compliance with Manufacturer’s design and assembly requirements.

3. Refer to Section 05 05 13 – Shop Applied Coatings for Metal for coatings quality control testing and submittal requirements.

4. Refer to Section 05 50 01 – Miscellaneous Metal Fabrication for shop weld quality control, testing, and submittal requirements.

Gate Hoist Assembly – Prior to shipping the Gate Hoist Assembly for field installation:

1. Fully assemble the Gate Hoist Assembly, including anchoring and connecting the Hoist Control Panel as outlined in Section 40 63 13.

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2. Notify the BIA Representative and provide test protocols at least 10 days in advance of Site Acceptance Testing. Fully rehearse the Factory Acceptance Testing prior to the Owner-witnessed test to verify nothing identifiable is expected to inhibit the Contractor from fully performing the witnessed testing and demonstrations.

3. Conduct and document Owner-witnessed Factory Acceptance Testing.

a. Shop Testing shall be performed at 208V.

b. Testing Checklist. Operate the motor in both directions and conduct the following tests:

i. Inspect for evidence of misalignment, bending, warping, permanent deformation, cracking, or malfunction of structural components.

ii. Check for abnormal noise or vibration in machinery drive components including gearing, bearings, and couplings.

iii. Ensure the cross shaft and drums spin at the design operating speed.

iv. Use an electric drill and the square nut on the anti-backdrive device to spin the drive shaft and drums in both directions.

v. Covers shall be removed from drum for inspection after all testing.

vi. Correct all deficiencies noted and retest all components after corrections.

OWNER’S INSPECTION OF MATERIALS AND AUTHORIZATION FOR SHIPMENT

Contractor shall notify BIA Representative when materials specified under this section are ready for BIA Representative’s inspection at the fabrication shop prior to shipment.

Contractor shall provide access to the completed equipment at Contractor’s fabrication shop for BIA Representative, and/or BIA Representative’s testing personnel.

Contractor shall not ship materials until the Owner-witnessed Factory Acceptance Testing has been completed (Gate Hoist Assembly) and the BIA Representative has completed their independent inspection of the radial gate(s) and authorized shipment.

SHIPPING AND DELIVERY OF EQUIPMENT

Contractor shall not ship radial gate components to the site until the Handling and Installation Plan has been approved and Owner’s shipping authorizations have been received.

Contractor shall provide temporary bracing to maintain tolerances during shipping.

The Contractor shall have an Erecting Engineer on-site during off-loading to ensure proper picking, rigging, and delivery.

The Contractor shall take delivery and have the radial gate staged on the construction site no less than 28 calendar days prior to irrigation drawdown for on-site BIA Representative inspection.

INSTALLATION

An Erecting Engineer shall be present for the radial gate installation and provide technical support.

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It is the responsibility of the Contractor to handle, store, erect, and place in proper operating condition the equipment specified in this Section in strict accordance with the Manufacturer’s requirements outlined in the operations and maintenance manual and in accordance with standard industry practices.

Contractor shall install gates in a true vertical plane; square and plumb; and with no twist, convergence, or divergence in the radial arm or gate leaf assemblies.

Install necessary anodes for cathodic protection of the gate not previously affixed during shop fabrication.

GATE COMMISSIONING AND POST-INSTALLATION TESTING

After installation, the radial gate will be field-tested in the presence of the BIA Representative and the Erecting Engineer to ensure that all items of equipment are in full compliance with this Section. The gate will be cycled a minimum of 2 cycles to confirm that it operates without binding, scraping, or distorting in the gate or any gate appurtenances. Additionally, the gate and lifting assembly shall be tested by the Contractor at the discretion of the BIA Representative, to demonstrate and confirm the following:

1. The inspection will include verifying proper installation and correct operation of the motor and radial gate, including testing and documentation of all remote monitoring and control signals shown on the plans.

2. Start-up of the new gate control system will include setting open and closed position limits, setting opening and closing torque limits, configuring the open and close interlocks to both “Limit” or “Torque”, configuring, and verifying all other control and monitoring contacts and functionality, and testing remote control, and all other settings necessary to ensure proper operation of the radial gate and to prevent damage to the gate or appurtenances. Additional field-testing requirements for the integrated Radial Gate and Hoist Assembly are defined in Section 40 63 13 – Hoist Control Panel.

3. The gate position indicator and gauge match the vertical gate opening within +/- 0.05’

4. Testing shall include turning off the motor with the gate at a partially open position.

Ensure the Anti-Backdrive Device engages and maintains the gate position without fluttering, chattering, or slipping.

5. Move the gate by 1 foot in both directions using an electric drill and the square nut on the Anti-Backdrive Device.

6. The equipment has been properly installed in accordance with the manufacturer’s instructions and recommendations.

7. The equipment has been installed in the specified location and orientation or as shown on the Contract Drawings.

8. The equipment has been aligned.

9. There are no mechanical defects in any of the parts.

10. All installed equipment is fully operable.

11. Measure and record the current draw and voltage supplied to the motor at 1-foot intervals of gate opening.

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12. Measure and record the full load operating temperatures of the gearing.

13. Check trunnions for abnormal noises.

14. Check for excessive leakage.

a. The BIA Representative will visually inspect the seals for conformance.

b. Seals which do not operate easily or are otherwise defective shall be adjusted, repaired, or replaced at the Contractor’s expense.

15. Verify the gate position transmitter calibration by recording the measured vertical gate opening (in feet) as well as the mechanical gate position indicator reading and gate position gage at five different positions covering the full gate travel. Adjust and confirm that the vertical gate opening gauge and indicator properly indicate (as compared to physical measurements of the same) with an error of no more than 0.025’ across the full gate operating range. During witnessed testing, record physical measurements, gauge, and indicator readings at the following positions:

a. Fully closed position

b. Fully open position

c. Three intermediate positions (between fully open and fully closed).

16. An Erecting Engineer shall complete a Gate Commissioning Testing Report documenting the date of commissioning, Contractor’s personnel present, BIA Representative(s) present, and results of the tests described in this section.

Cathodic Protection

1. The BIA Representative shall witness all field testing performed by the Contractor’s corrosion specialist, Cathodic Protection specialist or CP4.

2. Perform all testing…