23Q0066 Solicitation_LD2 Strut Arms.pdf

SEE ADDENDUM

(No Collect Calls)

W912ES23Q0066 28-Jun-2023

b. TELEPHONE NUMBER

651-290-5375

8. OFFER DUE DATE/LOCAL TIME

05:00 PM 14 Jul 2023

5. SOLICITATION NUMBER 6. SOLICITATION ISSUE DATE

AUTHORIZED FOR LOCAL REPRODUCTION

PREVIOUS EDITION IS NOT USABLE

STANDARD FORM 1449 (REV. 2/2012)

Prescribed by GSA – FAR (48 CFR) 53.212

(TYPE OR PRINT)

(SIGNATURE OF CONTRACTING OFFICER)

ADDENDA X ARE

26. TOTAL AWARD AMOUNT (For Gov t. Use Only )

23.

CODE 10. THIS ACQUISITION IS

SUCH ADDRESS IN OFFER

17b. CHECK IF REMITTANCE IS DIFFERENT AND PUT

BELOW IS CHECKED

TELEPHONE NO.

W912ES9. ISSUED BY

18b. SUBMIT INVOICES TO ADDRESS SHOWN IN BLOCK 18a. UNLESS BLOCK

7. FOR SOLICITATION

INFORMATION CALL:

a. NAME

ROBERTA L JUST

2. CONTRACT NO. 3. AWARD/EFFECTIVE DATE 4. ORDER NUMBER

(TYPE OR PRINT)

30b. NAME AND TITLE OF SIGNER 30c. DATE SIGNED 31b. NAME OF CONTRACTING OFFICER

30a. SIGNATURE OF OFFEROR/CONTRACTOR 31a.UNITED STATES OF AMERICA

1 27a. SOLICITATION INCORPORATES BY REFERENCE FAR 52.212-1. 52.212-4. FAR 52.212-3. 52.212-5 ARE ATTACHED.X

25. ACCOUNTING AND APPROPRIATION DATA

1. REQUISITION NUMBER

20.

ADDITIONAL SHEETS SUBJECT TO THE TERMS AND CONDITIONS SPECIFIED.

OFFEROR TO COMPLETE BLOCKS 12, 17, 23, 24, AND 30

SOLICITATION/CONTRACT/ORDER FOR COMMERCIAL ITEMS

W81G6731387153

ARE NOT ATTACHED

27b. CONTRACT/PURCHASE ORDER INCORPORATES BY REFERENCE FAR 52.212-4. FAR 52.212-5 IS ATTACHED. ADDENDA ARE ARE NOT ATTACHED

(BLOCK 5), INCLUDING ANY ADDITIONS OR CHANGES WHICH ARE

SET FORTH HEREIN, IS ACCEPTED AS TO ITEMS:

. YOUR OFFER ON SOLICITATION

28. CONTRACTOR IS REQUIRED TO SIGN THIS DOCUMENT AND RETURN

% FOR:SET ASIDE:UNRESTRICTED OR X

SMALL BUSINESSX

17a.CONTRACTOR/ CODE FACILITY

OFFEROR CODE

CONTRACTING DIVISION

USACE, ST PAUL

332 MINNESOTA STREET

SUITE E1500

SAINT PAUL MN 55101-1323

18a. PAYMENT WILL BE MADE BY CODE

RATED ORDER UNDER

DPAS (15 CFR 700)

13a. THIS CONTRACT IS A

13b. RATING

CODE15. DELIVER TO CODE 965605 16. ADMINISTERED BY

12. DISCOUNT TERMS11. DELIVERY FOR FOB DESTINA-

TION UNLESS BLOCK IS

MARKED

SEE SCHEDULE

14. METHOD OF SOLICITATION

RFQ IFB RFPX

FOUNTAIN CITY SERVICE BASE

MIKE HOLZER

431 NORTH SHORE DRIVE

FOUNTAIN CITY WI 54629-0397

TEL: 651-290-5989 FAX:

FAX:

TEL: 651-290-5414 SERVICE-DISABLED

VETERAN-OWNED

SMALL BUSINESS

8(A)

HUBZONE SMALL

BUSINESS

SIZE STANDARD:

NAICS:

332312

X

OFFER DATED

29. AWARD OF CONTRACT: REF.

DELIVER ALL ITEMS SET FORTH OR OTHERWISE IDENTIFIED ABOVE AND ON ANY

COPIES TO ISSUING OFFICE. CONTRACTOR AGREES TO FURNISH AND

EMAIL:

TEL:

31c. DATE SIGNED

SEE SCHEDULE

SCHEDULE OF SUPPLIES/ SERVICESITEM NO. QUANTITY UNIT UNIT PRICE AMOUNT

24.22.21.19.

WOMEN-OWNED SMALL BUSINESS (WOSB)

ELIGIBLE UNDER THE WOMEN-OWNED

SMALL BUSINESS PROGRAM

EDWOSB

32g. E-MAIL OF AUTHORIZED GOVERNMENT REPRESENTATIVE

SOLICITATION/CONTRACT/ORDER FOR COMMERCIAL ITEMS

(CONTINUED)

PAGE 2 OF56

ACCEPTED, AND CONFORMS TO THE CONTRACT, EXCEPT AS NOTED: ______________________________________________________

32a. QUANTITY IN COLUMN 21 HAS BEEN

RECEIVED INSPECTED

32b. SIGNATURE OF AUTHORIZED GOVERNMENT

REPRESENTATIVE

32c. DATE 32d. PRINTED NAME AND TITLE OF AUTHORIZED GOVERNMENT

REPRESENTATIVE

32e. MAILING ADDRESS OF AUTHORIZED GOVERNMENT REPRESENTATIVE 32f . TELEPHONE NUMBER OF AUTHORIZED GOVERNMENT REPRESENTATIVE

37. CHECK NUMBER

FINALPARTIALCOMPLETE

36. PAYMENT35. AMOUNT VERIFIED

CORRECT FOR

34. VOUCHER NUMBER

FINAL

33. SHIP NUMBER

PARTIAL

38. S/R ACCOUNT NUMBER 39. S/R VOUCHER NUMBER 40. PAID BY

41a. I CERTIFY THIS ACCOUNT IS CORRECT AND PROPER FOR PAYMENT

41b. SIGNATURE AND TITLE OF CERTIFYING OFFICER 41c. DATE

42a. RECEIVED BY (Print)

42b. RECEIVED AT (Location)

42c. DATE REC'D (YY/MM/DD) 42d. TOTAL CONTAINERS

STANDARD FORM 1449 (REV. 2/2012) BACK

Prescribed by GSA – FAR (48 CFR) 53.212

AUTHORIZED FOR LOCAL REPRODUCTION

PREVIOUS EDITION IS NOT USABLE

SEE SCHEDULE

20.

SCHEDULE OF SUPPLIES/ SERVICES

21.

QUANTITY UNIT

22. 23.

UNIT PRICE

24.

AMOUNT

19.

ITEM NO.

Scope of Work Lock and Dam 2 Strut Arms 03 May 2023

Section SF 1449 - CONTINUATION SHEET

SCOPE OF WORK

Scope of Work

Strut Arm Fabrication

Lock and Dam 2, Hastings, MN

Contract Number:

Solicitation Number: W912ES23Q0066

Table of Contents 1 General

1.1 Project Description

1.2 References

1.3 Submittals

1.3.1 Preconstruction Submittals

1.3.2 Shop Drawings

1.3.3 Product Data Submittals

1.3.4 Welding Submittals

1.3.5 Samples

1.3.6 Test Reports

1.3.7 Manufacturer’s Field Reports

1.4 Structural Steel Fabricator Qualification

1.5 Shipping, Delivery, Storage, and Handling

1.5.1 Protection of Finished Work – Machined Surfaces

1.5.2 Lubrication after Assembly

1.6 Quality Assurance

1.6.1 Detail Drawings

1.7 Complete Inspection

1.7.1 Inspector Qualifications

1.7.2 Final Fabrication Acceptance Inspection

1.7.3 Painting Acceptance Inspection

2 Products

2.1 Materials

2.1.1 Fracture Critical Member Materials

2.2 Metals

2.3 Miscellaneous Metals and Standard Metal Articles

2.3.1 Structural Steel

2.3.2 Structural Steel Plates

2.3.3 Steel Forgings for General Industrial Use

2.3.4 Steel Castings

2.3.5 Aluminum Bronze Castings

2.3.6 Bolts, Nuts, and Washers

3 Fabrication

3.1 Structural Fabrication

3.1.1 Assembly Drawings

3.1.2 Dimensional Tolerances for Structural Work

3.1.3 Structural Steel Fabrication

3.1.4 Welding Procedure Specifications

3.1.5 Bolted Connections

3.1.6 Miscellaneous Provisions

3.1.7 Patterns

3.1.8 Castings

3.1.9 Forgings

3.1.10 Shop Assembly

3.1.11 Machine Work

3.1.12 Miscellaneous Provisions

3.1.13 Shop Assembly

3.2 Tests, Inspections, and Verifications

3.2.1 Nondestructive Testing for Quality Verification

3.2.2 Required Inspection of Steel Castings

3.2.3 Testing of Bolted Structural Steel Connections

3.2.4 Inspection of Structural Steel Welding

3.2.5 Welds Subject to Nondestructive Examination

3.2.6 Test Coupons

3.2.7 Supplemental Examination

3.2.8 Structural Steel Welding Repairs

3.2.9 Witness Points

3.2.10 Control Dimensions and Weight

4 Painting Hydraulic Structures

4.1 References

4.2 Work Performance

4.3 Submittals

5 Attachments

This page is left intentionally blank.

1 General

1.1 Project Description

Fabricate four (4) strut arm assemblies per the attached specifications and drawings.

1.2 References

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by their basic designations.

AMERICAN WELDING SOCIETY(AWS)

AWS D1.5M/D1.5 (2015) Bridge Welding Code ASME INTERNATIONAL

(ASME)

ASME B18.6.3 (2010; R 2013) Machine Screws, Tapping Screws, and Machine Drive Screws (Inch Series)

ASME B4.1 (1967; R 2020) Preferred Limits and Fits for Cylindrical Parts

ASME B46.1 (2009; R 2019) Surface Texture, Surface Roughness, Waviness and Lay

AMERICAN WELDING SOCIETY(AWS)

AWS D1.1/D1.1M (2015; Errata 1 2015; Errata 2 2016) Structural Welding Code - Steel

AWS D1.5M/D1.5 (2015) Bridge Welding Code ASTM INTERNATIONAL

(ASTM)

ASTM A123/A123M (2017) Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products

ASTM A148/A148M (2020) Standard Specification for Steel Castings, High Strength, for Structural Purposes

ASTM A193/A193M (2023) Standard Specification for Alloy-Steel and Stainless Steel Bolting for High Temperature or High Pressure Service and Other Special Purpose Applications

ASTM A275/A275M (2018; R 2023) Standard Practice for Magnetic Particle Examination of Steel Forgings

ASTM A36/A36M (2019) Standard Specification for Carbon Structural Steel

ASTM A325 (2014) Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength

ASTM A380/A380M (2017) Standard Practice for Cleaning, Descaling, and Passivation of Stainless Steel Parts, Equipment, and Systems

ASTM A388/A388M (2019) Standard Practice for Ultrasonic Examination of Steel Forgings

ASTM A490 (2014a) Standard Specification for Structural Bolts, Alloy Steel, Heat Treated, 150 ksi Minimum Tensile Strength

ASTM A572/A572M (2021) Standard Specification for High-Strength Low-Alloy Columbium-Vanadium Structural Steel

ASTM A588/A588M (2019) Standard Specification for High-Strength Low-Alloy Structural Steel with 50 ksi (345 MPa) Minimum Yield Point, with Atmospheric Corrosion Resistance

ASTM A609/A609M (2012; R 2018) Standard Practice for Castings, Carbon, Low-Alloy, and Martensitic Stainless Steel, Ultrasonic Examination Therof

ASTM A668/A668M (2023) Standard Specification for Steel Forgings, Carbon and Alloy, for General Industrial Use

ASTM A709/A709M (2021) Standard Specification for Structural Steel for Bridges

ASTM A780/A780M (2020) Standard Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings

ASTM A992/A992M (2022) Standard Specification for Structural Steel Shapes

ASTM B117 (2019) Standard Practice for Operating Salt Spray (Fog) Apparatus

ASTM B271/B271M (2018) Standard Specification for Copper-Base Alloy Centrifugal Castings

ASTM D1002 (2010; R 2019) Standard Test Method for Apparent Shear Strength of Single-Lap- Joint Adhesively Bonded Metal Specimens by Tension Loading (Metal-to-Metal)

ASTM D2240 (2015; R 2021) Standard Test Method for Rubber Property – Durometer Hardness

ASTM D695 (2015) Standard Test Method for Compressive Properties of Rigid Plastics

ASTM D790 (2017) Standard Test Methods for Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating Materials

ASTM E165/E165M (2018) Standard Practice for Liquid Penetrant Examination for General Industry ASTM E446 (2020) Radiographs for Steel Castings Up to 2 In. (51mm) in Thickness ASTM E709 (2021) Standard Guide for Magnetic Particle Examination

ASTM E94/E94M (2022) Standard Guide for Radiographic Examination Using Industrial Radiographic Film

ASTM F3125/F3125M (2022) Standard Specification for High Strength Structural Bolts and Assemblies, Steel and Alloy Steel, Heat Treated, Inch Dimensions 120 ksi and 150 ksi Minimum Tensile Strength, and Metric Dimensions 830 MPa and 1040 MPa Minimum Tensile Strength

1.3 Submittals

Submittals will be approved by either the point of contact (PoC) or technical point of contact (TPoC).

The PoC is:

Roberta Just roberta.l.just@usace.army.mil 651-290-5375

The TPoC is:

Mike Holzer Michael.a.holzer@usace.army.mil 651-290-5989

Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government.

Submit the following in accordance with UFGS 01 33 00 SUBMITTAL PROCEDURES:

1.3.1 Preconstruction Submittals

Work Plan; G The Contractor must provide a detailed plan for fabrication and related information prior to the Pre-fabrication Conference. The Work Plan must include the recommended measuring system for ensuring dimensional tolerances as required herein.

Bolted Connection Work Plan; G Submit a bolted connection work plan for approval 30 days prior to commencement of fabrication.

1.3.2 Shop Drawings

Detail Drawings; G, STR & MECH Assembly Drawings; G Revised Detail Models and Drawings; G Structural Steel Welding Repairs Castings; G, STR & MECH

1.3.3 Product Data Submittals

Material Orders; G

Submit copies of purchase orders, mill orders, shop orders and work orders for materials, prior to the use of the materials in the work.

For materials that are not in stock, substitute materials may be requested. Submit copies of purchase orders, mill orders, shop orders, and work orders for substitute materials for approval by USACE prior to the use of the materials in the work.

Materials List; G Submit materials lists for fabricated items, at the time of submittal of detail drawings.

1.3.4 Welding Submittals

Structural Steel Welding Repairs; G

Submit prior to making repairs. Address weld repairs within the weld as well as weld repairs for base metal discontinuities.

Fracture Critical Member Welding Repairs; G Submit welding repair plans for base metal and welds of fracture critical members prior to making repairs.

Welding Procedure Specifications (WPS); G A WPS must be submitted for all welds applicable to work under this contract. All WPS submitted must have the Procedure Qualification Records (PQR) attached.

Fracture Control Plan (FCP); G A FCP must be submitted for welding on all Fracture Critical Members (FCM) and must be in accordance with AWS D1.5M/D1.5, Section

12. Welding procedures, qualifications, and certifications must be submitted showing compliance with FCP requirements.

Welding Schedules for Structural Steel; G Schedules of welding procedures in accordance with approved WPS for steel structures must be submitted to and approved by USACE prior to commencing fabrication. Welding schedules must identify the order of each weld in an assembly or the structure as a whole.

Welding Log; G Develop, maintain, and submit a welding log that is capable of individually identifying and tracking every weld. Include the member to be welded, member type (FCM or not), welding position, type of weld, applicable WPS reference, AWS joint preparation designation, name or stamping designation of welder, welding operator or tracker, date and time of completion of welding, name and date of CWI visual inspection, nondestructive testing (NDT) performed on the weld, type of NDT inspection, date(s) of inspection, inspector name, NDT acceptance criteria used, description of any defects found and reason for non-compliance, and corrective action taken. Weld identification on the shop drawings must match the weld tracking log identification.

Qualification of Welders and Welding Operators; G Welder and welding operator qualification test records, certifications, and tracker qualifications must be submitted to and approved by the Contracting Officer prior to commencing fabrication. All welders performing welds must be qualified according to Section 12 of AWS D1.5M/D1.5. Welders that will not be performing any Fracture Critical Member welds must be qualified in accordance with AWS D1.5M/D1.5 Clause 5. All qualifications must be current prior to commencing any work. Submit a log for each welder showing that they are current in the process and procedures being proposed for this work. All welders will be limited to performing only those welding procedures for which they are qualified.

1.3.5 Samples

Bolts, Nuts, and Washers; G

Random samples of bolts, nuts, and washers as delivered to the fabrication shop. If requested, the random samples will be selected in the presence of the Contracting Officer and provided to the Contracting Officer for testing to establish compliance with specified requirements.

1.3.6 Test Reports

Tests, Inspections, and Verifications; G

Submit Certified tests, inspections, and verifications reports for all foreign materials used before incorporation into the structure. Test all foreign steel used by an approved U.S. laboratory to ensure that it meets the required standards. All materials require a Mill Test Report (MTR).

Bolts, Nuts, and Washers; G Supply the certified manufacturer's mill reports which clearly show the applicable ASTM mechanical and chemical requirements together with the actual test results for the supplied fasteners.

Radiographic Inspection Reports; G

Non-Conformance Report Form Template; G Non-Conformance Report; G

1.3.7 Manufacturer’s Field Reports

Bolt holes mislocated or misdrilled; G Control dimensions and weight; G

After fabrication of each structure but prior to painting, record and submit a “control dimensions” report.

1.4 Structural Steel Fabricator Qualification

The fabricating plant and fabricator must be certified as of the time the solicitation closes under the AISC (American Institute of Steel Construction) Quality Certification Program with one of the following certifications:

IBR: Certified Bridge Fabricator – Intermediate with fracture critical endorsement ABR:

Certified Bridge Fabricator – Advanced with fracture critical endorsement HYD: Certified Hydraulic Steel Structures Fabricator (includes fracture critical endorsement)

The fabricating plant and fabricator must also be certified under the AISC Quality Certification Program with an endorsement for applying sophisticated paint systems (SPS) in Category P1, P2, or P3.

Submit copies of the AISC certificate indicating that the fabrication plant meets the specified structural steelwork category. Maintain at least one of the listed certifications for the duration of fabrication and notify the Government upon any change or expiration of these certifications.

1.5 Shipping, Delivery, Storage, and Handling

The strut arms are required to be either crated or secured to a heavy-duty pallet prior to shipping and/or delivery. The crating containers or pallets must be constructed in a manner that allows for movement with a forklift. The contractor is responsible to repair any damage that may occur during shipping. The weight of the finished part must be displayed on the outside of the packaging or part.

The contractor will deliver two (2) finished strut arm assemblies (and all associated miscellaneous parts) by February 29, 2024 to the address below:

US Army Corps of Engineers Fountain City Service Bay 431 North Shore Drive Fountain City, WI 54629 PoC: Mike Holzer

Notify the PoC seven (7) days in advance of delivery of the finished assemblies.

The contractor will deliver the final two (2) finished strut arm assemblies (and all associated miscellaneous parts) by April 30, 2024 to the address below:

US Army Corps of Engineers Fountain City Service Bay 431 North Shore Drive Fountain City, WI 54629

POC: Mike Holzer

Notify the PoC seven (7) days in advance of delivery of the finished assemblies.

1.5.1 Protection of Finished Work – Machined Surfaces

Clean machined surfaces thoroughly of foreign matter and protect all finished surfaces by suitable means. Oil and wrap unassembled pins and bolts with moisture resistant paper or protected by other approved means. Finished surfaces of ferrous metals to be in bolted contact must be washed with an approved rust inhibitor and coated with an approved rust resisting compound for temporary protection during fabrication, shipping, and storage periods. Paint finished surfaces of metals which will be exposed after installation, except corrosion resisting steel or nonferrous metals, as specified in UFGS 09 97 02 - PAINTING: HYDRAULIC STRUCTURES.

1.5.2 Lubrication after Assembly

After assembly fill all lubricating systems with the lubricant specified and apply additional lubricant at intervals as required to maintain the equipment in satisfactory condition until acceptance of the work.

1.6 Quality Assurance

Maintain all records to certify compliance with all aspects of this contract. Records must be made available in a timely manner should the PoC request to see them.

Miscellaneous metalwork must be well formed to shape and size, with sharp lines and angles and true curves. Drilling must produce clean true lines and surfaces. Where tight fits are required, mill joints. Cope or miter corner joints, well formed, and in true alignment.

1.6.1 Detail Drawings

Prepare all shop drawings by a registered Professional Engineer or prepared under the direct supervision of a registered Professional Engineer. Prior to performing any fabrication of the miter gates, submit complete, detailed drawings to the Contracting Officer for approval. Detail drawings must show complete details of materials, tolerance, connections, and proposed welding sequences. Details drawings must include catalog cuts, templates, fabrication and assembly details, and type, grade, and class of materials, as appropriate.

Identify all FCM, including attachments that meet the FCM definition, on the detail drawings as well as all temporary and tack welds.

Each member must be identified following the numbering scheme as shown. A table must be provided containing a list of all members and a reference to each material certificate and test report that applies to that member. The table must maintain material identification to establish the heat of the material from which all components were fabricated. Detail drawings must identify weld procedures and Non-destructive Examination (NDE) required for each weld. Do not include splices in the structure unless specifically authorized by the Contracting Officer. Show all field welds on the shop drawings. Each weld required, both shop and field, to be provided a unique identifier to permit tracking on the weld tracking log. Return elements of fabricated items inadvertently omitted on Contract drawings to the Contracting Officer for detailing or detailed by the fabricator and so indicated on the shop drawings. Any and all details developed by the fabricator to be "clouded" on the shop drawings for separate approval by the Contracting Officer. Include any and all splices in the detail drawings and clouded for Contracting Officer approval.

1.6.1.1 Revised Detail Models and Drawings

As approved detail drawings are returned to the Contractor, the Contractor must incorporate the corrections in red and approved deletions/additions/revisions, including RFI, into their original electronic models and detail drawings. The revisions on the electronic detail drawings must be annotated using clouds and revision triangles with numbering associated to sequential revisions to a specific drawing. Within ten days after Government approval of all the detail drawings for a phase of work, the Contractor must submit the Revised Detail Models and Drawings - one set electronic in the original software format used to make the models and detail drawings and one set electronic Adobe Acrobat (.pdf) format full-size detail drawings - for Government review and approval.

1.6.1.2 As-Fabricated Models and Drawings

As-fabricated models and drawings must comply with the following:

1) When final revisions have been completed, the cover sheet drawing must show the wording "AS-FABRICATED DRAWING" followed by the name of the Contractor in letters at least 3/16 inch high. All other As-Fabricated drawings must be marked "AS-FABRICATED DRAWING" in the revision block.

2) Within thirty days after the Government approval of the Revised Detail Models and Drawings for a phase of work, the Contractor must submit the as-fabricated models and drawings - one electronic set in the original software format used to the make the models and detail drawings, one electronic set of the models and detail drawings translated from their original software format into AutoCAD (.dwg) or Microstation (.dgn) format and one set electronic full-size detail drawing set in Adobe Acrobat (.pdf) format. Model and drawing files, including the storage media, submitted will become the property of the Government upon final approval.

1.6.1.3 Non-Conformance Report

During each stage of fabrication of major structural components, provide and maintain material identification to establish the heat of the material from which the component is fabricated. Provide the Contracting Officer with a list showing heat numbers referenced to the material incorporated into each component. The Contracting Officer will reject material that loses its material identification unless the identity can be re-established to the satisfaction of the Contracting Officer. Submit Material Test Reports or Certified Test Reports for all material used in fabrication prior to incorporation into the structure. Provide fracture critical members with identification numbers placed on each individual piece of material that is referenced to the corresponding heat number. Properly document all nonconformances using a Non-Conformance Report Form. Submit a Non-Conformance Report Form Template prior to fabrication. The Non-Conformance Report Template is to be used during fabrication to record and submit all Nonconformances. Submit a Non- Conformance Report on the approved form to the Contracting Officer documenting any deviation from the QCP, approved shop drawings, code, Work Plan and/or specifications. Include the following in the Non-conformance Report form:

1) Company name and address

2) Report title

3) Non-Conformance Report number

4) Date

5) Company job number

6) Piece mark

7) Owner of structure

8) Fabricator

9) Owner’s project number

10) Location

11) Detailed description of the non-conformance

12) Photo, sketch, or drawing

13) Proposed repair/disposition of the non-conformance

14) Quality Control Manager’s signature and date

1.7 Complete Inspection

1.7.1 Inspector Qualifications

Qualify all inspectors performing structural steel inspection associated with this contract in accordance with AWS QC1. Provide an AWS Certified Welding Inspector (CWI) as the primary point of contact for quality control of welding. Qualify all personnel who perform NDT in accordance with ANSI/ASNT CP-189 NDT Level II or Level III. All personnel performing NDT are required to be supervised by an inspector who is Level III ASNT NDT certified in accordance with AWS D1.5M/D1.5 Clause 6 and Clause 12.

1.7.2 Final Fabrication Acceptance Inspection

Make the completed assemblies available for final inspection by the Government at the Contractor’s facility prior to painting or the application of any protective coatings. Notify the PoC at least fourteen (14) days in advance of when the assemblies will be available for inspection.

The final products must be free from imperfections which may impair serviceability. Any products which show tolerance errors, distortion, fissures, notches, cracks, cross threads, or variance from the specified condition may be cause for rejection and must be corrected at the Contractor’s expense.

1.7.3 Painting Acceptance Inspection

This inspection will be conducted after the assembly has been painted. The Contractor must notify the PoC at least seven

(7) days prior to when the painted assemblies will be available for inspection.

2 Products

2.1 Materials

Submit system of identification which shows the disposition of specific lots of approved materials and fabricated items in the work prior to completion of the contract.

2.1.1 Fracture Critical Member Materials

All materials used for the fabrication of Fracture Critical Members must meet the requirements of ASTM A709/A709M, Section 10. Do not use ASTM A588/A588M material as a substitute for any material specified. Mill repairs of base metal are prohibited. Cold bending is prohibited. Submit a rolling plan that includes provisions for providing constant heat during the rolling of all FCMs. Toughness must meet the requirements of ASTM A709/A709M for Zone 2 unless otherwise indicated or specified. All Fracture Critical materials to be welded must be ASTM A709/A709M Grade F2 as specified or as indicated, using killed fine-grain mill practice, unless otherwise shown or specified. Welding for fracture critical members must meet all requirements of AWS D1.5M/D1.5 Clause 12, including:

3) 12.5 Welding Processes. Only procedures in accordance with AWS D1.5M/D1.5, Section 12.5 are permitted.

4) 12.6 Consumable Requirements. All welding consumables to be heat or lot-tested by the manufacturer to determine conformance in accordance with the Fracture Control Plan (FCP). Exceptions are not allowed. Toughness test results must meet the values specified in Table 12.1 of AWS D1.5M/D1.5.

5) 12.7 Welding Procedure Specifications (WPS). All procedures, including repair welds, are prequalified or qualified by test as required and documented in the WPS and Procedure guidelines of AWS D1.5M/D1.5.

6) 12.8 Certification and Qualification. Welders and welding operators in accordance with AWS D1.5M/D1.5.

7) Material handling and preparation, including thermal cutting, preparation of base metal, and straightening, curving, cambering msut meet the applicable requirements.

8) 12.13 Tack Welds and Temporary Welds. Locate all welds within the joint and be in accordance with AWS

D1.5M/D1.5, Table 12.2. Temporary welds on FCM and castings are not permitted.

9) Welding processes, including preheat, interpass temperatures, and post weld thermal treatment must meet the applicable requirements.

10) 12.16 Weld Inspection. The Quality Control inspection program to be documented in the FCP. All inspectors and

NDT technicians are qualified as required. Test all butt welds with UT. Inspection procedures and documentation in accordance with AWS D1.5M/D1.5. Cooling times must be strictly adhered to.

11) 12.17 Repair Welding. Follow the repair procedures for minimum provisions unless specified otherwise. Repair procedures must be qualified and approved and subject to the same QA/QC inspection requirements as other welds. Minimum preheat for repair welding in accordance with AWS D1.5M/D1.5 section 12.17.6. All weld repairs to fracture critical members will be considered critical welds in accordance with AWS D1.5 Section 12.17.3.

2.2 Metals

Metal material with welds will not be accepted unless the welding is specified or indicated on the drawings or otherwise approved by

USACE.

2.3 Miscellaneous Metals and Standard Metal Articles

Conform to the respective specifications and other designated requirements for miscellaneous metal materials and standard metal articles. Sizes must be as specified or shown in the detail drawings. Where material requirements are not specified, submit for approval optional materials suitable for the intended use.

2.3.1 Structural Steel

ASTM A992/A992M.

2.3.2 Structural Steel Plates

ASTM A572/A572M Grade 50.

2.3.3 Steel Forgings for General Industrial Use

ASTM A668/A668M, Class E or F, as indicated on the drawings, carbon content not exceeding 0.35 percent, and an overall chemical composition which results in satisfactory weldability.

2.3.4 Steel Castings

ASTM A148/A148M, Grade 80-50.

2.3.5 Aluminum Bronze Castings

ASTM B271/B271M, Copper Alloy UNS No. C95400.

2.3.6 Bolts, Nuts, and Washers

Bolts, nuts, and washers must be of the material, grade, type, class, style and finish indicated or best suited for intended use.

2.3.6.1 High-Strength Bolts, Nuts, and Washers

ASTM A325, Type 1, plain or zinc coated, as indicated

2.3.6.2 Stainless Steel Bolts and Nuts

1) Bolts - Provide in accordance with ASTM A193/A193M Grade B8

2) Nuts - Provide in accordance with ASTM A193/A193M Grade B8

2.3.6.3 Machine Screws

ASME B18.6.3.

2.3.6.4 Anti-Seize Lubricant

Provide standard product designed for the intended use.

2.3.6.5 Metal Rebuilding Compounds

Physical characteristics of the metal rebuilding compounds must meet the following requirements:

1) Taber Abrasion resistance (loss per 1,000 cycles):

a. H10 Wheels (wet) 85 2mm^3

b. CS17 Wheels (dry) 24 mm^3

2) Adhesion to mild steel when tested in accordance with ASTM D1002, substrates prepared in accordance with the requirements noted above: 2,790 psi

3) Compressive strength when tested in accordance with ASTM D695: 12,525 psi at 68 degrees F

4) Flexural strength when tested in accordance ASTM D790: 9,140 psi at 68 degrees F

5) Hardness determined in accordance with ASTM D2240: Shore D 84

6) Shows no visible signs of corrosion after 5,000 hours exposure in the ASTM B117 salt spray cabinet

7) Reverse Notched impact strength: 0.69 ft-lb/in at 68 degrees F

3 Fabrication Furnish 1 (one) copy of mill certificates for all material used on this project prior to the use of the materials in the work.

3.1 Structural Fabrication

Material must be within tolerance as defined in paragraph 3.1.2 of this section before being laid off or worked. Perform straightening, if necessary, by heat straightening alone as defined by FHWA. Sharp kinks or bends will be cause for rejection of the material. Material with welds will not be accepted except where welding is specified, indicated, or otherwise approved. Bends must be made by approved dies, press brakes or bending rolls. Where heating is required, take precautions to avoid overheating the metal and allow to cool in a manner that will not impair the original properties of the metal. Proposed flame cutting of material other than structural steel will be subject to approval and must be indicated on the detail drawings. Shearing to be accurate and all portions of the work neatly finished.

Corners will be square and true unless otherwise shown. Re-entrant cuts to be filleted round to a minimum radius of 1 inch unless otherwise indicated or approved. Finished members will be free of twists, bends, and open joints. Bolts, nuts, and screws must be tight

3.1.1 Assembly Drawings

Submit assembly drawings indicating the sequence of fabrication, welding, and assembly and provide details for connecting the adjoining fabricated components in the shop. Assembly details to identify the required order of assembly and details of witness points as described in these specifications.

3.1.2 Dimensional Tolerances for Structural Work

Measure dimensions using an approved calibrated steel tape of approximately the same temperature as the material being measured.

The overall dimensions of an assembled structural unit must be within the tolerances indicated on the drawings or as specified in the particular section of these specifications for the item of work. Where tolerances are not specified in other sections of these specifications or shown, an allowable variation of 1/32 inch is permissible in the overall length of component members with both ends milled; component members without milled ends must not deviate from the dimensions shown by more than 1/16 inch for members 30 feet or less in length, and by more than 1/8 inch for members over 30 feet in length. Structural units must not deviate from the vertical plane by more than plus or minus 1/16th of an inch over the structural unit's overall length, for members 30 feet or shorter.

Structural units must not deviate from the horizontal plane by more than plus or minus 1/32nd of an inch over their entire length, for members 30 feet or shorter.

3.1.3 Structural Steel Fabrication

Structural steel may be cut by mechanically guided or hand-guided torches, provided an accurate profile with a surface that is smooth and free from cracks and notches is obtained. Prepare surfaces and edges in accordance with AWS D1.5M/D1.5, Subsection 3.2. Where structural steel is not to be welded, chipping or grinding will not be required except as necessary to remove slag and sharp edges of mechanically guided or hand-guided cuts not exposed to view. Chip, grind or machine to sound metal hand-guided cuts which are to be exposed or visible.

3.1.4 Welding Procedure Specifications

1) Welding Procedure

a. Weld in accordance with AWS D1.5M/D1.5. Prior to the start of production welding, submit a complete schedule of welding procedures for a typical structure; the schedule in accordance with AWS D1.5M/D1.5. Provide detailed procedure specifications and tables or diagrams showing the procedures to be used for each required joint.

b. Submit to the Contracting Officer, a WPS for each weld to be made. Prepare each WPS and qualify in accordance with AWS D1.5M/D1.5. Welding procedures to show types and locations of welds designated or specified to receive nondestructive examination and identify the weld as FCM when applicable. A WPS is always required, even if the procedure is considered prequalified in accordance with AWS D1.5M/D1.5. Each procedure to be clearly identified as being either prequalified or qualified by tests. If a WPS requires qualification by test, a representative of the Government to witness the test plate welding and the specimen testing. Approval of any procedure, however, will not relieve the Fabricator of the responsibility for producing a finished structure meeting all requirements of these specifications. Copies of the WPS to be made available for reference to the welders, welding operators and tack welders. A CWI meeting the specified qualifications to approve all WPSs and a Level II NDT inspector meeting the specified qualifications to approve all PQRs, unless otherwise indicated.

c. Welding Procedure Specifications include, at a minimum, the following; Indicate whether WPS is prequalified or qualified by testing, WPS ID No., Revision No., Date, Created by, Company Name, Supporting PQR No., Joint Design information (to include dimensional tolerances), Base Metal information, Shielding information, Preheat information, Type of operation, Position, Electrical Characteristics, Technique, PWHT, Joint Sketch including all code required essential variables. Include metal data sheets with WPS and PQR. Weld repair procedures are to be included on each WPS. All Welding Procedure Specifications for welding ASTM A709/A709M base metal to alternate base metal are required to be qualified through testing. Reduced section tensile tests and bend tests are always required when qualifying welding procedures.

2) Welder Performance Qualification of Welders and Welding Operators. Welding operators, welders, and tack welders to be qualified and requalified if necessary for the particular type of work to be done. Qualification to be in accordance with AWS D1.5M/D1.5. Certify by name to the Contracting Officer the welders and welding operators so qualified, including the date of qualification and code and procedures under which qualified. Copies of the Performance Qualification records to be submitted to the Contracting Officer and approved before fabrication is commenced. Require the welder and welding operators to repeat the qualifying tests when, in the opinion of the Contracting Officer, the work indicates a reasonable doubt as to proficiency. In such cases, the welder and welding operator to be recertified, as above, if they successfully pass the retest; otherwise, they are to be disqualified until they have successfully passed a retest. The period of effectiveness for all welder and welding operator performance qualifications must be in accordance with AWS D1.5M/D1.5. All expenses in connection with qualification and requalification will be borne by the Fabricator. The Government reserves the right to require requalification of welders if performance is suspect. A Government representative must be present during such prequalification.

3) Welding Process. Welding of structural steel to be by an electric arc welding process using a method which excludes the atmosphere from the molten metal and to conform to the applicable provisions of AWS D1.5M/D1.5 for all welds. Welding to be such as to minimize residual stresses, distortion, and shrinkage.

4) Welding Technique

a. Filler Metal: The electrode, electrode-flux combination and grade of weld metal must conform to the appropriate

AWS specification for the base metal and welding process being used or as shown where a specific choice of AWS specification is required. Weld metal toughness must meet the requirements of AWS D1.5M/D1.5, Tables, 4.1, 4.2, or 12.1, as applicable. The AWS designation of the electrodes to be used must be included in the schedule of welding procedures. Only low hydrogen electrodes to be used for manual shielded metal-arc welding regardless of the thickness of the steel. A controlled temperature storage oven must be used as prescribed by AWS D1.5M/D1.5, Subsection 12.6 to maintain low moisture of low hydrogen electrodes. Ovens to be powered full time. FCAW filler metal to be subjected to the storage and handling requirements defined in AWS D1.5M/D1.5 section 12.6.6. Filler metals and processes to not be combined in the same joint or weld.

b. Preheat and Interpass Temperature: Preheat in accordance with AWS D1.5M/D1.5 for all welds. Preheat for fracture critical welds to be as defined in Tables 12.3 and 12.4 and in accordance with the PQR/WPs. The weldments required to be preheated must be slowly and uniformly heated by approved means to the prescribed temperature, held at that temperature until the welding is completed and then permitted to cool slowly in still air. Any interruptions that require additional weld sequences for a component must follow the specified preheat and cool down processes for each welding segment.

Cutting attachments for heating purposes are prohibited.

5) Workmanship: Workmanship for welding must be in accordance with AWS D1.5M/D1.5, Section 3 for all welds and other applicable requirements of these specifications.

a. Preparation of Base Metal. Prior to welding, the Contractor must inspect surfaces to be welded to ensure compliance with the applicable sections of AWS D1.5M/D1.5.

b. Tack and Temporary Welds. Tack and temporary welds required for fabrication and erection must be made in accordance with AWS D1.5M/D1.5 under the controlled conditions prescribed herein for permanent work and to be remelted in accordance with AWS D1.5M/D1.5. Tacks welds that are to be incorporated into the permanent work are subject to the same quality requirements as the permanent welds and must not exceed 1/8-inch fillet welds, 1-inch long at 6-inch centers. Such tack welds are to be cleaned and completely remelted by subsequent welds made by SAW. Multiple-pass tack welds must have cascaded ends. Defective tack welds must be removed before permanent welding. All welds to be made using low-hydrogen welding electrodes and by welders qualified for permanent work as specified elsewhere in these specifications. Preheat as required by AWS D1.5M/D1.5 for permanent tack welds. In making temporary welds arcs are not to be struck in other than weld locations. Each temporary weld must be removed as required by AWS D1.5M/D1.5, Subsection 3.3.8. All arc strikes struck outside the weld zone must be ground out, filled (if material loss exceeds limits set for by AWS D1.5M/D1.5), and inspected with MT.

c. Weld Access Holes. Weld access holes must be provided as shown on the shop drawings. If the oversight of intersecting out-of-plane welds is encountered, the fabricator must notify the Contracting Officer for the approval of weld access hole additions in such locations. Payment for the addition of weld access holes not shown on plans will be the Contractor's responsibility.

d. Weld Backing Removal. Unless otherwise indicated, all steel weld backing material must be removed from welded joints prior to testing. All weld backing material that cannot be removed must be identified on the shop drawings.

e. Weld Backing. All weld backing material other than steel must be qualified by testing and must be included in submitted PQR/WPS. Variation from approved weld backing material will not be permitted, unless tested and a new procedure is submitted and approved for its use.

3.1.5 Bolted Connections

3.1.5.1 Bolted Structural Steel Connections

Provide bolts, nuts, and washers of the type specified or indicated. Equip all nuts with washers except for high strength bolts. Use beveled washers where bearing faces have a slope of more than 1:20 with respect to a plane normal to the bolt axis. Where the use of high strength bolts is specified or indicated, the materials, workmanship, and installation must conform to the applicable provisions of ASTM A325 or ASTM A490. Bolt holes must be accurately located, smooth, perpendicular to the member, and cylindrical. All holes must be drilled and must have diameters more than 1/16-inch larger than bolt diameters. Bolt holes mislocated or misdrilled by more than 1/16 inch from the hole locations shown on the plans must be promptly reported to the Contracting Officer. Submit the proposed corrective action for approval before the commencing with any repairs to mislocated holes.

1) Drill or subdrill holes for regular bolts and ream in the shop. Must not be more than 1/16 inch larger than the diameter of the bolt, unless otherwise indicated.

2) Match-ream or drill holes for fitted bolts in the shop. Remove burrs resulting from reaming. Burrs that extend 1/16 inch or less above the surface are permitted to remain on the faying surfaces of pretensioned joints. Burrs that extend over 1/16 inch above the surface must be removed from all joints. Keep bolt threads entirely outside of the holes. The body diameter of bolts to have tolerances as recommended by ASME B4.1 for the class of fit specified. Place fitted bolts in reamed holes by selective assembly to provide an LN-2 fit.

3) Except as otherwise indicated on the drawings, holes for high strength bolts must not have diameters more than 1/16 inch larger than bolt diameters. Any oversized bolt holes to have larger diameter bolts of the same grade installed to meet 1/16-inch maximum oversized dimension. If the thickness of the material is not greater than the diameter of the bolts, the holes may be punched. If the thickness of the material is greater than the diameter of the bolts the holes may be drilled full size or sub-punched or subdrilled at least 1/8 inch smaller than the diameter of the bolts and then reamed to full size. Poor matching of holes will be cause for rejection. Drifting occurring during assembly must not distort the metal or enlarge the holes. Reaming to a larger diameter of the next standard size bolt will be allowed for slight mismatching.

4) All high strength connections must be tightened to a tension not less than that given below. Tighten by turn-of- nut method only. Do not use washer-type indicating devices. Progress tensioning systematically from the most rigid part of the joint to its free edges.

Table 1: Bolt Tension Chart

Bolt Size ASTM F3125/F3215M, Grade A325

½ inch 12 kips 5/8 inch 19 kips ¾ inch 28 kips

7/8 inch 39 kips 1 inch 51 kips

1-1/8 inch 56 kips 1-1/4 inch 71 kips 1-3/8 inch 85 kips 1-1/2 inch 103 kips

5) Tighten all connections to the pretensioned condition. The pretensioned condition is defined as the tightness attained by tensioning the bolt to a tension not less than that given in the previous paragraph. Snug-tight condition will not be permitted.

6) Three weeks after initial bolt tensioning, all bolts must be re-tensioned by match marking and rotating the nut 1/6th turn.

7) Fastener components must be protected from dirt and moisture in closed containers at the site of installation. Remove only as many fastener components as are anticipated to be installed during the work shift from protected storage. Fastener components that are not incorporated into the work must be returned to protected storage at the end of the work shift.

Fastener components must not be cleaned or modified from the as- delivered condition.

8) Do not reuse galvanized ASTM F3125/F3125M Grade A325 bolts. When approved by the Contracting Officer, black ASTM F3125/F3125M Grade A325 bolts are permitted to be reused. Touching up or re-tightening bolts that may have been loosened by the installation of adjacent bolts is not considered to be a reuse.

3.1.5.2 Bolted Connection Work Plan

Submit a bolted connection work plan that includes, at a minimum, a description of the equipment used to calibrate, tension and measure bolt pretension, bolt group tensioning sequences, method of matchmarking and tracking of pretensioned and re-tensioned bolts, and quality control measures to ensure that bolts are pretensioned and re-tensioned in accordance with the specifications.

3.1.6 Miscellaneous Provisions

1) Weldments. Portions of the structure include thick weldments where locked in thermal stresses may make final dimensions unstable. The Contractor is required to sequence the work and thermally stress relieve subassemblies of thick weldments such that final machining achieves stable specified dimensions and tolerances.

2) Drain Holes. Position drain holes as shown on the drawings, unless otherwise noted. Drill drain holes. Flame cutting of holes is not permitted.

3) Seal Welds. Seal welds, as shown on drawings, are required to maintain water tightness. All seal welds must be made as shown on the drawings and made as such. Seal welds, when called for on the drawings, must be made the minimum size fillet weld as required in AWS D1.5M/D1.5. In addition, seal welds may require weld wrapping around reentrant corners that is specifically prohibited in AWS D1.5M/D1.5. All seal welds on fracture critical members must be subjected to the minimum preheat requirements of AWS D1.5 Table 12.3 as applicable. All seal welds must be subjected to the same testing requirements required for a fillet weld made to any fracture critical member according to AWS D1.5M/D1.5, Chapter 12.

3.1.7 Patterns

Take care to avoid sharp corners or abrupt changes in cross section; ample fillets are to be used in the fabrication of patterns. Add, as required, draft and increases in pattern thicknesses to conform to the standard foundry practice applied and as necessary to ensure that all metal thicknesses of the finished castings conform to the dimensions shown and are within the tolerances specified in paragraph

3.2.2 REQUIRED INSPECTION OF STEEL CASTINGS. Patterns for those parts listed below must be furnished by the Contractor, become the property of the Government, and not be used for work under any other Contract unless specifically authorized.

3.1.7.1.1 Fabrication of Patterns and Core Boxes

Patterns and core boxes must be substantially made from thoroughly seasoned Grade B or better sugar pine, northern white pine, or an approved equal. Built-up patterns and core boxes must be securely glued and screwed together. Use approved high-grade, water-resistant glue that is suitably treated for resistance to fungus and insect infestation. Only light sections are permitted to be nailed.

Counterbore and neatly fill screw holes with wood plugs. Dovetail or fasten with pull-out dowels loose pieces. Split patterns and core boxes must have metal dowels at partings. Skeleton or sweep patterns will not be accepted unless specifically authorized. Fill all nail and tool marks on molding surfaces with beeswax and sand all surfaces with No.

0 grade sandpaper. Finish patterns with a minimum of three coats of an approved phenolic- resin sealer colored in accordance with the standard trade practices for pattern colors. Each pattern, core box and loose piece must be stamped with the part mark shown. Furnish patterns complete with necessary core boxes and templates.

3.1.7.2 Disposition of Patterns, Core Boxes, and Templates

Casting pattern boxes and crates must be fabricated of all wood construction and corrosion resistant screws for long term storage of casting patterns. Boxes and crates must have removable lids for easy inspection of casting patterns. Each box and crate must be plainly marked to indicate the contents of that box.