Attachment_3_02500_Boarding_Floats_and_Gangplanks.pdf

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SECTION 02500 - BOARDING FLOATS AND GANGPLANKS

PART 1- GENERAL

1.1 DESCRIPTION: The contract work is located at five locations within the Lake Isabella recreational facility and includes:

a) Furnishing all material, equipment, and labor necessary to manufacture, deliver, and install the boarding floats, gangplanks, wire rope cable, concrete vaults, anchoring systems and all necessary hardware required to provide functional boarding float systems as shown on the plans and described within these specifications.

b) Furnishing all material, equipment, and labor necessary to remove and dispose of the existing boarding float systems; and demolition of the existing concrete vaults as shown on the plans and described herein.

PART 2 - NEW BOARDING FLOAT LOCATIONS AND DETAILS

2.1 PROJECT LOCATIONS

a. OLD ISABELLA HIGH WATER RAMP FLOATS (8’X80’):

Note: The new boarding floats and anchoring system shall be installed in the center of the boat ramp as shown on the plans.

b. OLD ISABELLA LOW WATER RAMP FLOATS (8’X60’):

8’ x 80’ Hot Dipped

Galv. Steel Frame

Float w/concrete decking

5/8” dia.

Cable

(Length)

Concrete

Anchor

(Deadman)

4100 lbs. EA

(Two Required)

16’-10”

Tapered

Aluminum

Gangplank

New Recessed

Cable Vault with Eyebolt

1 ea. 400 lf 8200 lbs (Min) 1 ea. 1 ea.

8’ x 60’ Hot Dipped

Galv. Steel Frame

5/8”dia.

(Length)

Concrete

Anchor

(Deadman)

4100 lbs. EA

(Two Required)

16’-10”

Tapered

Aluminum sandblasted

Gangplank

New Recessed

Cable Vault with Eyebolt

1 ea. 400 lf 8200 lbs (Min) 1 ea. 1 ea.

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Note: The new boarding floats and anchoring system shall be installed in the center of the boat ramp as shown on the plans.

c. SOUTH FORK RAMP FLOATS (8’X60’):

Note: The new boarding floats and anchoring system shall be installed in the center of the boat ramp as shown on the plans.

d. LAUNCH 19 FLOATS (8’X80’):

Note: The new boarding floats and anchoring system shall be installed in the center of the boat ramp as shown on the plans.

e. CAMP 9 RAMP FLOATS (8’X80’):

The new boarding floats and anchoring system shall be installed along the right side of the boat ramp as shown on the plans.

8’ x 60’ Hot Dipped

Galv. Steel Frame

(Length)

Concrete

Anchor

(Deadman)

4100 lbs. EA

(Two Required)

16’-10”

Tapered

Aluminum

Gangplank

New Recessed

1 ea. 450 lf 8200 lbs (Min) 1 ea. 1 ea.

8’ x 80’ Hot Dipped

Galv. Steel Frame

(Length)

Concrete

Anchor

(Deadman)

4100 lbs. EA

(Two Required)

16’-10”

Tapered

Aluminum

Gangplank

New Recessed

Cable Vault with Eyebolt

1 ea. 400 lf 8200 lbs (Min) 1 ea. 1 ea.

8’ x 80’ Hot Dipped

Galv. Steel Frame

(Length)

Concrete

Anchor

(Deadman)

4100 lbs. EA

(Two Required)

16’-10”

Tapered

Aluminum

Gangplank

New Recessed

1 ea. 450 lf 8200 lbs (Min) 1 ea. 1 ea.

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f. TILLY CREEK HIGH WATER RAMP FLOATS (8’X20’):

The new boarding floats and anchoring system shall be installed along the left side of the boat ramp as shown on the plans.

g. TILLY CREEK LOW WATER RAMP:

The new boarding floats and anchoring system shall be installed in the center of the boat ramp as shown on the plans.

h. DEMOLITION OF EXISTING BOARDING FLOATS

The contractor shall remove and dispose of all existing boarding floats and accessories in accordance with specification 02100 Demolition.

2.2 EXPERIENCE

The boarding float fabricator must be currently in the business of commercial steel and aluminum boarding float fabrication and be able to furnish adequate evidence of a minimum of 5 years of experience in commercial steel and aluminum boarding float fabrication.

2.3 SUBMITTALS

a. Shop drawings and design and freeboard calculations for the boarding floats shall be submitted for approval prior to purchase, fabrication, or installation; and shall bear the seal of a California Registered Professional Engineer (Stamped drawings are

8’ x 20’ Hot Dipped

Galv. Steel Frame

(Length)

Concrete

Anchor

(Deadman)

4100 lbs. EA

(Two Required)

16’-10”

Tapered

Aluminum

Gangplank

New Recessed

1 ea. 260 lf 8200 lbs. (Min) 1 ea. 1 ea.

8’ x 20’ Hot Dipped

Galv. Steel Frame

(Length)

Concrete

Anchor

(Deadman)

4100 lbs. EA

(Two Required)

16’-10”

Tapered

Aluminum

Gangplank

New Recessed

NA 200 lf 8200 lbs. (Min) NA 1 ea.

02500 - 4 required since flotation and counterweights are to be sized by the contractor as part of the contract). All work shall conform to the approved Shop Drawings. Construction details and finishing details of the boarding float shall be consistent throughout.

b. In additional, the Contractor shall provide the following submittals to the Project

Engineer for approval prior to purchase, fabrication, or installation:

1. Flotation tub and floatation foam source and technical data

2. Concrete deck panel construction details and design calculations

3. Mooring cleats

4. Boarding float wheels

5. Gangplank wheels / rollers

6. Fender board material and color

7. Corner bumpers

8. Wire Rope and Hardware

9. Welder certifications for both steel and aluminum welding, in accordance with

American Welding Society (AWS) D1.1 and D1.2 procedures.

10. Request to the project engineer, in writing, for approval of proposed substitutions or equals.

11. Fabrication and installation schedule

2.4 DESIGN CRITERIA

Boarding Floats are to be designed to meet the following criteria:

a. Dead Load Only (DL): Boarding floats are to float level in the water within the following limits:

1. Length: 1/8 inch per foot over the length of an individual boarding float section, not to exceed 1” in 10’.

2. Width: 1 inch maximum over the width of the boarding float.

3. Uniform Live Load (ULL) shall be 20#/ft

4. Live Point Load (LPL) shall be 450#, applied 12 inches from the edge of the boarding float.

b. Freeboard

1. Dead Load Only (DL): 14 inch minimum / 20 inch maximum to the top of deck.

2. DL + ULL: 10 inch minimum to top of deck.

3. DL + LPL: 13 inch minimum to top of deck.

4. DL + ULL + LPL: 8 inch minimum to top of deck.

Due to the variances in concrete deck panel construction, the contractor shall furnish freeboard calculations for the boarding floats for approval. The calculations shall bear the seal of a Registered Professional Engineer.

2.5 HEIGHT REQUIREMENTS

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Maximum overall height of the boarding floats shall not exceed 29.5” measured from the top of deck surface to the level ground surface.

PART 3 – MATERIALS

3.1 STRUCTURAL ALUMINUM

a. Shapes and Plates shall conform to ASTM designation 6061 T-6 & 6063T. All minimum edge distances for aluminum plates and shapes shall be in accordance with the “Aluminum Association, Inc., Aluminum Design Manual”, latest edition.

b. Aluminum gangplank shall be tapered (wedge shape) as shown in the contract plans. Gangplanks shall have a light sandblasted finish to reduce glare.

Gangplank and transition plate slopes shall not exceed 5.0% in the direction of travel and cross slopes shall not exceed 2.0%.

3.2 STRUCTURAL STEEL

a. Shapes and Plates shall conform to ASTM designation A-36 and shall be double hot-dipped galvanized after fabrication in accordance with ASTM Designation A-

123. All minimum edge distances for steel plates and shapes shall be in accordance with the “AISC Manual of Steel Construction”, latest edition.

b. Pipe shall be steel pipe, galvanized in accordance with ASTM A-153. Pipes shall be of the size and grade as shown on the plans.

3.3 CONCRETE DECK PANELS

a. Concrete Deck Panels should be light weight concrete with fiber and steel reinforcement. The lightweight concrete should have a dry density of 92#/CF minimum to 98#/CF maximum. Panel sizes may range from 24” x 36” minimum to

48” x 120” maximum in size. Panels should be of the same size thru-out deck layout. Panel depth shall be approximately 1” - 2” thick per manufacturers design.

Panels shall be finished with a “non-skid” finish. Panel design may vary per manufacturer. Manufacturer to submit concrete panel design for approval.

b. Deck panels shall be installed with a 1½” x 1/8” neoprene foam tape cushion between the steel frame and the concrete panels (Use two 1 ½” strips, side by side on 3” joists). Panels shall be installed with the long edge supported on framing at

24” on centers. Broom pattern to run in the 24” direction.

c. Deck panels shall be cast with block outs at the locations required for grab bars and cleats as shown on the plans.

d. Deck panels shall be designed to support the following criteria:

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1. Dead load plus uniform vertical live load of 20 pounds per square foot.

2. Concentrated vertical load of 400 pounds located at the center of the deck panel.

3. Due to the variances in concrete deck panel construction, the contractor shall furnish deck panel design details and calculations for approval. The calculations shall bear the seal of a Registered Professional Engineer.

3.4 FLOATATION PONTOONS

a. Pontoons/tubs shall be manufactured from linear virgin polyethylene resin containing

UV ray inhibitors and carbon black, with the finished product being a high-density polyethylene Type III or IV. The pontoons/tubs shall be without any organic filler.

Pontoons shall be rotationally molded, one-piece construction. The pontoons/tubs minimum wall thickness shall be 0.150 inches (Nominal). Pontoons shall be Ace

Roto-Mold manufactured by Den Hartog Industries, or approved equal. Henderson

Marine Supply, phone (707) 781-7142 is one known distributor of this product in

California.

b. Pontoons/tubs shall be completely filled with expanded polystyrene (EPS). The expanded polystyrene shall have a density of 1.0 - 1.5 lbs. per cubic foot with water absorption not to exceed 3 lbs per cubic foot in accordance with the Hunt Water

Absorption Test. EPS contents shall conform to the ASTM C-578. The pontoon/tub polystyrene shall be produced by a manufacturer who has been continuously engaged in production of polystyrene for marine flotation for at least three years.

c. Flotation material shall be distributed as widely as possible under the floats for maximum stability and to meet the requirements of the design criteria.

d. Tubs shall be bolted to the steel frame with ½” diameter HDG machine bolts with flat washers and lock nuts. All bolt locations provided by the float manufacturer shall be utilized (Exp: a 4’x8’ pontoon requires 12 bolts per pontoon).

e. If upon installation of the docks in the water any design criteria is not achieved, the

Contractor shall repair or replace at no extra cost to the Government. Contractor shall submit repair procedures or replacement information for approval in conformance to that recommended by the float manufacturer.

3.5 FENDER BOARDS

The fender boards shall be high density polyethylene lumber. The size shall be 2” x 12”

(nominal), color yellow. Fender boards shall be in lengths of 60” +/- with ½” gap between board ends for thermal expansion. Planks shall be bolted to the frame with pairs of 3/8” diameter HDG machine bolts with washers and elastic locknuts. Counter sink bolt heads 1/8” below the face of the boards. Install flat washer under bolt head and a

02500 - 7 washer under the locknut. Do not over tighten, to allow slight movement as board expands and contracts due to temperature changes.

Fender boards shall be installed per the following guidelines:

a. Store fender board material in the shade, in as cool a place a possible, for at least 24 hours prior to pre-drilling of the bolt holes. This is very important as the boards may crack if installed in a warm, expanded condition.

b. Pre-drill holes for all bolts at least 1/8” larger than the diameter of the bolt. Drill hole all the way through the lumber.

c. Pre-drill counter bore hole for washer at least 1/4” larger than the diameter of the washer. Counter-bore hole so bolt head will be below the surface of the lumber 1/8”

– 3/16”.

d. Tighten bolts only to snug tightness, without torque resistance. If impact wrenches are used to install, back-off bolt to snug tightness.

3.6 CORNER DOCK BUMPERS

Corners of fender boards at end dock at top and bottom shall be covered with Henderson

Universal 10” Corner Dock Bumper, Item # 03-06B, or approved equal.

Fender corner bumpers shall be fastened to the fender boards with #10 x 1” S.S. wood screws @ 2” o.c. with a 1/8” x 1/2” wide aluminum backing strips.

3.7 MOORING CLEATS

Mooring cleats shall be installed as shown on the plans. Cleats shall be 10” overall length heavy ship or dock cleats of gray ductile iron, hot-dipped galvanized; Henderson 504H item # 05-08N, or approved equal. Cleats are to be fastened to the steel frame with 1/2” diameter HDG machine bolts with double nuts and lock washers. Any fasteners for cleats supplied without double nuts will be rejected by the project engineer.

3.8 GRAB RAILS

The grab rails shall be welded steel construction and hot dipped galvanized after fabrication. The grab rail base shall be attached to the boarding float frame and flush with the concrete decking as shown on the plans.

3.9 HINGES AND MISCELLANEOUS HARDWARE

a. Boarding float hinges shall be 2”Ф Sch80 hot dipped galvanized, A-53 steel pipe unless otherwise stated herein or shown on the plans. All hardware such as bolts and washers shall be hot-dipped galvanized in accordance with the Caltrans

Specification 75-1.05 Galvanizing, unless otherwise stated on the plans. All bolts

02500 - 8 shall have washers and elastic lock nuts unless otherwise shown or specified herein.

Elastic locknuts shall be zinc plated steel, heavy weight, standard height.

b. Silent Hinges: Silent hinges are required and shall utilize 2” Ф sch.80 hinge barrel, 1”Ф solid stainless steel hinge pin and UV resistant, Ultra High Molecular Weight polyethylene (UHMW - UV resistant) bushings in each hinge barrel.

3.10 WHEELS AND ROLLERS

a. Boarding float wheels shall be 3” x 10” aluminum wheels with polyurethane tread and 3¼” Delrin bearings for 1” S.S. axle, 2500# capacity; R&K Loadmaster wheels or approved equal. The manufacturer shall provide a 1 year minimum warranty on the wheels, with documentation furnished to the Government not later than the project final inspection.

b. Gangplank rollers shall be 3”Ф, UV resistant, Ultra High Molecular Weight polyethylene (UHMW - UV resistant).

3.11 WIRE ROPE AND HARDWARE

a. Wire Rope shall be 6 x 19 IWRC, 5/8” diameter, hot dipped galvanized improved plow steel with a minimum breaking strength of 30,000 lbs. Wire rope shall include all wire rope thimbles, forged steel wire rope clips, shackles, eye bolts, chain, etc., to connect the cable to the concrete anchors. All materials to be US made. Length:

Supply 400 – 450 feet (+/-) per location (See Specifications, Part 2 – New Boarding

Float Locations). Supply 8 ea. – 5/8” forged steel wire rope clips at each location.

Contractor to field verify all lengths required.

b. Chain shall be galvanized grade 30 general purpose proof coil steel chain, US made.

Chain shall be ½” size and have a safe working load of 4500 lbs. Length: Supply

30 feet per float location.

c. Shackles shall be galvanized, US made, forged alloy steel anchor shackles.

Shackles shall be 1/2” in size and have a safe working load of 6,600 lbs. Shackles shall have a screw pin with safety pin. Supply 6 each – ½” shackles at each new boarding float.

d. Turnbuckles shall be galvanized steel with jaw and jaw end fittings. Jaw and jaw end fittings shall be 1”- 8 thread size, and turnbuckle shall have 24” take up.

Turnbuckle shall have a safe working load of 10,000 lbs. Supply 1 turnbuckle at each boarding float location.

e. Eye Bolts shall be US made, forged galvanized steel, shoulder pattern, minimum

1”- 8 thread size, with 2” ID. Eye bolts shall have a minimum safe working load of

10,000lbs.

f. Secondary Wire Rope: Wire rope shall be 5/16” diameter, US made, galvanized plow steel with minimum breaking strength of 8,500 lbs. Wire rope shall include

02500 - 9 all wire rope, thimbles, shackles, and saddles to connect the rope cable to the boarding float and anchor guide cables. Supply one cable, 30 feet long with one swaged loop end at each boarding float location. Supply 2 ea. – 5/8” forged steel wire rope clips and one 3/8” shackle at each boarding float location.

3.12 CABLE VAULTS AND CONCRETE ANCHORS:

a. Install new concrete cable vaults at the locations shown on the plans or as determined by the Engineer. Concrete for the vaults shall be minimum 3500 psi concrete.

b. The contractor shall demolish seven existing cable vaults with wire rope, concrete anchors, and accessories in accordance with specification 02100 Demolition.

c. All hardware such as anchor frames/cover plates, bolts and washers shall be hot-dipped galvanized in accordance with the Cal-Trans Specification 75-1.05

Galvanizing, unless otherwise shown on the plans.

d. Concrete Anchors (deadman anchors) shall be minimum 3500 psi concrete. Where multiple anchors are required to be placed at the same location the contractor shall cable the multiple anchors together using 5/8” galvanized wire rope and cable clamps. The anchors shall be placed in a side by side configuration; do not stack the anchors on top of each other.

PART 4 - FABRICATION

4.1 FABRICATION

a. Connections between members shall be tight, accurate and secure. All fasteners shall be placed without splitting the HDPE fender member, and shall be squarely drawn up to a flush flat seat. Holes for fasteners shall be pre-drilled to avoid splitting or other damage to the member.

b. All bolts and screws shall be placed square or plumb and securely tightened at installation.

4.2 WELDING

a. All welding, welding procedures, testing and inspection shall be done in accordance with the requirements of the AWS Structural Welding Codes D1.2 & D1.1 (latest edition) aluminum and steel respectively. All segments shall be subject to testing according to the above specifications. The Engineer has the right to request test results on any part of the gangplank and boarding float he determines necessary to ensure that it meets the requirements of the plans and specifications. The cost of welder certification, welding procedure approvals, and welding testing per AWS

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D1.1 and D1.2 will be paid for by the welding contractors. Retesting, if required, will be paid for by the Contractor/fabricator.

b. Aluminum sections shall be fabricated only by AWS certified welders. Welder certifications shall be submitted to the Engineer prior to the start of fabrication. The contractor shall submit a certificate that all boarding float and gangplank welding was performed by a welder certified per AWS D1.2.

c. The steel boarding floats shall be fabricated only by AWS certified welders. Welder certifications shall be submitted to the Engineer prior to the start of fabrication. The contractor shall submit a certificate that all boarding float and gangway welding was performed by a welder certified per AWS D1.1.

PART 5 – INSTALLATION

5.1 DELIVERY

a. The contractor shall be responsible for obtaining and paying for all transportation permits.

b. The contractor shall be responsible for transportation and storage of his/her material and equipment.

c. The contractor shall be responsible for delivery, unloading, floating and installing the boarding floats, gangplanks, and accessories at the project sites for complete and operational boarding float systems.

d. The contractor shall notify the Contracting Officer’s Representative (COR) at least

5 days in advance of delivery to enable scheduling of inspections at the manufacturer prior to shipping the boarding floats. The expected project completion schedule shall be supplied to the engineer at time of float shipment from manufacturer.

e. The boarding floats and gangplanks shall be assembled, placed in water, flotation tested and left in water ready for use. The contractor shall, if necessary, adjust pontoons or add floatation/counterweights to produce a level float deck under a

“dead load” condition of components as required by the design criteria herein.

PART 6 - PAYMENT

Payment for the costs incurred under this section shall be at the contract bid prices for the following items, as shown on the Schedule of Items for: BOARDING FLOATS, GANGPLANKS, CONRETE VAULTS, WIRE ROPE AND HARDWARE, and

CONCRETE ANCHORS.

END OF SECTION