Attachment 1_Reference Specs.pdf

FOR REFERENCE ONLY

Ed 11-139

RFP NO. NOV05B-11-H-0028

US Army Corps of Engineers Vicksburg District

NEW ORLEANS TO VENICE

NOV-NF-W-05b, WEST BANK NON-

FEDERAL LEVEE

WILKINSON PUMP STATION

Plaquemines Parish, Louisiana

Construction Solicitation and Specifications

May 2013

NOV05B-11-H-0028

SECTION TABLE OF CONTENTS

DIVISION 05 - METALS

SECTION 05 50 03.00 12

METALWORK FABRICATION, MACHINE WORK, AND MISCELLANEOUS PROVISIONS

PART 1 GENERAL

1.1 SCOPE

1.2 REFERENCES

1.3 MEASUREMENT AND PAYMENT

1.4 SUBMITTALS

1.5 QUALITY CONTROL

1.5.1 Tests of Materials

1.5.2 Special Test Requirements

1.5.2.1 Government Nondestructive Testing

1.5.2.2 Contractor Nondestructive Testing

1.5.2.3 Tests of Machinery and Structural Units

1.5.3 Workmanship

1.5.4 Quality Control

1.6 DELIVERY, STORAGE, AND PROTECTION

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 General

2.1.2 Bolts, Nuts, Screws, and Washers

2.1.2.1 Bolts

2.1.2.2 Nuts

2.1.2.3 Screws

2.1.2.4 Washers

2.1.2.5 Galvanizing

2.1.3 Expansion Anchors

2.2 FLOOR GRATINGS

2.3 MANHOLE COVER AND FRAME

2.4 HEAVY DUTY FLOOR/TRENCH COVER

PART 3 EXECUTION

3.1 STRUCTURAL FABRICATION

3.1.1 Material

3.1.2 Dimensional Tolerances for Structural Work

3.1.3 Structural Steel Fabrication

3.2 WELDING

3.2.1 Structural Steel

3.2.1.1 General

3.2.1.2 Welding Equipment

3.2.1.3 Welding Procedures

3.2.1.4 Qualifications of Welders and Welding Operators

3.2.1.5 Technique

3.2.1.6 Workmanship

3.2.1.7 Inspection

SECTION 05 50 03.00 12 Page 1

3.3 STUD WELDING

3.3.1 Stud Materials

3.3.2 Stud Base Application Qualification

3.3.3 Workmanship

3.3.4 Inspection

3.3.5 Testing

3.4 BOLTED CONNECTIONS

3.4.1 Structural Steel Connections

3.4.1.1 Bolt Holes

3.5 SHOP ASSEMBLY

3.6 MACHINE WORK

3.6.1 General

3.6.2 Finished Surfaces

3.6.2.1 Finishes, Indicated

3.6.2.2 Finishes, Not Indicated

3.6.3 Unfinished Surfaces

3.6.4 Dissimilar Materials

3.6.5 Pin Holes

3.6.6 Shafting

3.6.7 Bearings

3.7 MISCELLANEOUS PROVISIONS

3.7.1 Metallic Coatings

3.7.1.1 Zinc Coatings

3.7.2 Cleaning of Corrosion-Resisting Steel

3.7.3 Protection of Finished Work

3.7.3.1 Machined Surfaces

3.7.3.2 Lubrication

3.8 INSTALLATION

3.8.1 General

3.8.2 Alignment and Setting

3.8.3 Blocking and Wedges

3.8.4 Foundations and Grouting

3.8.5 Expansion Joint Covers

3.8.6 Pipe Sleeves

3.8.7 COVER PLATES AND FRAMES

3.8.8 SETTLEMENT REFERENCE BOLTS

-- End of Section Table of Contents --

SECTION 05 50 03.00 12 Page 2

SECTION 05 50 03.00 12

METALWORK FABRICATION, MACHINE WORK, AND MISCELLANEOUS PROVISIONS

PART 1 GENERAL

1.1 SCOPE

This section specifies general workmanship requirements, applicable to the fabrication, assembly and testing of various items of metalwork and machine work to insure conformance with the specifications, and furnishing and installing the miscellaneous metalwork as shown on the drawings and specified herein. These requirements are in addition to those contained in the specification sections covering the specific items of work or indicated on the 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 the basic designation only.

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

AISC 303 (2010) Code of Standard Practice for Steel Buildings and Bridges

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI B4.1 (1967) Preferred Limits and Fits for Cylindrical Parts

ANSI B46.1 (1995) Surface Texture (Surface Roughness, Waviness and Lay)

ASTM INTERNATIONAL (ASTM)

ASTM A153/A153M (2009) Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware

ASTM A307 (2010) Standard Specification for Carbon Steel Bolts and Studs, 60 000 PSI Tensile Strength

ASTM A 123/A 123M (2002) Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products

ASTM A 325 (2006) Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength

ASTM A 380 (2006) Standard Practice for Cleaning, Descaling, and Passivation of Stainless Steel Parts, Equipment, and Systems

SECTION 05 50 03.00 12 Page 3

ASTM A 514/A 514M (2005) Standard Specification for High-Yield-Strength, Quenched and Tempered Alloy Steel Plate, Suitable for Welding

ASTM A780/A780M (2009) Standard Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings

ASTM C1513 (2012) Standard Specification for Steel Tapping Screws for Cold-Formed Steel Framing Connections

ASTM D1187/D1187M (1997; R 2011e1) Asphalt-Base Emulsions for Use as Protective Coatings for Metal

ASTM E488 (1996; R 2003) Standard Test Methods for Strength of Anchors in Concrete and Masonry Elements

ASTM F436 (2011) Hardened Steel Washers

ASME INTERNATIONAL (ASME)

ASME B18.2.1 (2010) Square and Hex Bolts and Screws (Inch Series)

ASME B18.6.2 (1998; R 2010) Slotted Head Cap Screws, Square Head Set Screws, and Slotted Headless Set Screws: Inch Series

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

ASME BPVC SEC IX (2004; 2005 Addenda; 2006 Addenda) Boiler and Pressure Vessel Code; Section IX, Welding and Brazing Qualifications

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2006; Errata 2006) Structural Welding Code - Steel

U.S. GENERAL SERVICES ADMINISTRATION (GSA)

FS FF-S-325 (Basic; Int Amd 3; Notices 3, 4) Shield, Expansion; Nail, Expansion; and Nail, Drive Screw (Devices, Anchoring, Masonry)

CID A-A-1923 (Rev A; Notice 2) Shield, Expansion (Lag, Machine and Externally Threaded Wedge Bolt Anchors)

MASTER PAINTERS INSTITUTE (MPI)

MPI 79 (Oct 2009) Alkyd Anti-Corrosive Metal Primer

SECTION 05 50 03.00 12 Page 4

NATIONAL ASSOCIATION OF ARCHITECTURAL METAL MANUFACTURERS (NAAMM)

NAAMM MBG 531 (2009) Metal Bar Grating Manual

RESEARCH COUNCIL ON STRUCTURAL CONNECTIONS (RCSC)

RCSCA.1 Specification for Structural Joints Using ASTM A 325 or ASTM A 490 Bolts

1.3 MEASUREMENT AND PAYMENT

Unless otherwise specified herein, any materials or operations used in conjunction with installation or as part of metalwork which is not included in the cost of other items of work listed in the bidding schedule shall not be measured for payment. Payment for metalwork fabrication, machine work, and miscellaneous provisions will be made at the contract lump sum prices for "Miscellaneous Metalwork". Price and payment shall constitute full compensation for furnishing and installing all metalwork fabrication, machine work, and miscellaneous provisions indicated on the drawings and/or herein specified which is not specified to be paid for under other items of work listed on the bidding schedule.

1.4 SUBMITTALS

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 Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Shop Drawings; G

Shop drawings shall be submitted for approval in accordance with the Contract Clauses. Drawings shall include catalog cuts, templates, fabrication and assembly details and type, grade and class of materials as appropriate. Elements of fabricated items inadvertently omitted on contract drawings shall be detailed by the fabricator and indicated on the shop drawings. Shop drawings shall indicate computed weights of structural steel items.

Submit fabrication drawings showing layout(s), connections to structural system, and anchoring details as specified in AISC 303.

Schedule of Welding Procedures; G

A complete schedule of welding procedures as described in paragraph "Welding Procedures" shall be submitted to the Contracting Officer and approved before fabrication commences.

SD-03 Product Data

Materials

The Contractor shall furnish the Contracting Officer 5 copies of all purchase and mill orders, shop orders for materials and work orders, including all new orders placed by Contractors and old orders extended by each supplier. The Contractor, at the time of

SECTION 05 50 03.00 12 Page 5 submittal of shop drawings, shall furnish a list designating the material to be used for each item. Where mill tests are required, purchase orders shall contain the test site address and the name of the testing agency. The Contractor shall also furnish a shipping bill or memorandum of each shipment of finished pieces or members to the project site, giving the designation mark and weight of each piece, the number of pieces, the total weight, and if shipped by rail in carload lots, the car initial and number.

Copies of certified shipping bills, in duplicate, shall be mailed promptly to District Engineer, U.S. Army Corps of Engineers, New Orleans, Louisiana 70160-0267.

Welding Procedure Specifications (WPS); G

A Welding Procedure Specification for each AWS Joint Designation, welding process and, as appropriate, each material, including prequalified welds, shall be submitted to the Contracting Officer and approved before fabrication is commenced. The WPS shall be submitted with the shop drawings. A CWI or NDT inspector meeting the qualifications stated in herein shall approve all WPS's. The CWI's or NDT inspector's signature, certification number(s) and, if applicable, stamp shall be on all WPS's.

Welder, Welding Operator and Tacker Qualification Certification; G

Welder, welding operator and tacker qualification certification for each welder, welding operator or tack welder shall be submitted to the Contracting Officer and approved before fabrication is commenced. A CWI or NDT inspector meeting the qualifications stated herein shall approve all welder qualifications. The CWI's or NDT inspector's signature, certification number(s) and, if applicable, stamp shall be on all welder qualifications.

Procedure Qualification Report (PQR); G

Procedure Qualification Reports (PQR's) if needed shall be submitted to the Contracting Officer for approval before fabrication is commenced. A CWI or NDT inspector meeting the qualifications stated herein shall approve all PQR's. The CWI's or NDT inspector's signature, certification number(s) and, if applicable, stamp shall be on all PQR's.

Inspector Qualification Certification; G

Copies of the certifications, including the Level III NDT Technician that certified the Level I and Level II Technicians shall be included in the submittal. Included with the Level III NDT certification shall be letter signed by the Level III Technicians stating that they are either full time employees or under retention for the NDT process they are certified for.

Nondestructive Testing Procedure; G

A copy of the weld testing firm's nondestructive testing procedures for each procedure used for weld testing shall be submitted to the Government Representative for approval prior to commencement of fabrication. Each

SECTION 05 50 03.00 12 Page 6

SD-07 Certificates

Certificates ; G

Certificates for material tests, examinations, and welding procedure and operator qualifications shall be submitted for approval as specified.

1.5 QUALITY CONTROL

1.5.1 Tests of Materials

The Contractor shall, at his expense, perform analyses and tests to demonstrate that all materials are in conformity with the specifications.

Should the Contractor desire to use stock materials not manufactured specifically for the work covered by these specifications, he shall submit evidence, satisfactory to the Contracting Officer, that such material conforms to the requirements of the specifications. Detailed tests of these materials will then not be required, if so approved by the Contracting Officer. Tests, except where modified, shall be made as indicated in the respective detailed specifications or on the drawings and, unless otherwise authorized, in the presence of the Contracting Officer.

The Contractor shall furnish specimens and samples for additional independent tests and analyses upon request by the Contracting Officer.

Specimens and samples shall be properly labeled and prepared for shipment.

1.5.2 Special Test Requirements

1.5.2.1 Government Nondestructive Testing

When doubt exists as to the soundness of any material part such part may be subjected to any form of nondestructive testing determined by the Contracting Officer. This may include ultrasonic, magnaflux, dye penetrant, x-ray, gamma ray or any other test that will thoroughly investigate the part in question. The cost of such investigation will be borne by the Government. Any defects will be cause for rejection and rejected parts shall be replaced and retested at the Contractor's expense.

1.5.2.2 Contractor Nondestructive Testing

The Contractor shall perform the nondestructive testing as specified herein. The cost of such investigation will be borne by the Contractor.

Any defects will be cause for rejection and rejected welds shall be repaired and retested at the Contractor's expense.

1.5.2.3 Tests of Machinery and Structural Units

Each complete machinery and structural unit, as required by other sections of these specifications, shall be erected and tested in the shop in the presence of the Contracting Officer, unless otherwise directed by the Contracting Officer. Waiving of tests, however, will not relieve the Contractor of responsibility for any fault in operation, workmanship or material that occurs before the completion of the contract or guarantee.

After being installed at the site each complete machinery or structural unit shall be operated through a sufficient number of complete cycles to demonstrate to the satisfaction of the Contracting Officer that it meets the specified operational requirements in all respects. The details for tests on the various machinery and structural units shall conform to the requirements of the applicable sections of these specifications.

SECTION 05 50 03.00 12 Page 7

1.5.3 Workmanship

Workmanship shall be of the highest grade and in accordance with the best modern practices to conform with the specifications for the item of work being furnished.

1.5.4 Quality Control

The Contractor shall establish and maintain a quality control system to assure compliance with the contract requirements and shall maintain records of all quality control operations covered by these specifications.

1.6 DELIVERY, STORAGE, AND PROTECTION

Protect from corrosion, deformation, and other types of damage. Store items in an enclosed area free from contact with soil and weather. Remove and replace damaged items with new items.

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 General

All nuts shall be equipped with washers where indicated on the shop drawings.

Beveled washers shall be used where bearing faces have a slope of more than 1:20 with respect to a plane normal to the bolt axis.

2.1.2 Bolts, Nuts, Screws, and Washers

The finished shank of each bolt shall be long enough to provide full bearing and washers shall be used to provide full grip when the nut is tightened.

2.1.2.1 Bolts

Bolts shall conform to ASTM A 325 and anchor bolts shall conform to ASTM A307, unless noted otherwise in the specifications for a particular item of work, or on the contract drawings. Where exposed, bolts shall be of the same material, color, and finish as the metal to which applied.

2.1.2.2 Nuts

Nuts shall conform to ASTM A 325, unless noted otherwise in the specifications for a particular item of work, or on the contract drawings.

2.1.2.3 Screws

ASME B18.2.1, ASME B18.6.2, ASME B18.6.3 and ASTM C1513.

2.1.2.4 Washers

Washers shall conform to the applicable provisions of ASTM F436, unless noted otherwise in the specifications for a particular item of work, or on the contract drawings.

SECTION 05 50 03.00 12 Page 8

2.1.2.5 Galvanizing

Bolts, nuts and washers shall be hot-dipped galvanized in accordance with ASTM A153/A153M. Embedded portion of anchor bolts shall not be galvanized.

2.1.3 Expansion Anchors

Expansion anchors shall meet the requirements of FS FF-S-325, Group II, Type 4, Class 1, CID A-A-1923. Nail driven types will not be acceptable.

Anchors shall be galvanized unless otherwise indicated. Provide 1/2 in.

diameter expansion anchors. Minimum concrete embedment shall be 2 1/4 in.

Design values listed shall be as tested according to ASTM E488.

a. Minimum ultimate pullout value shall be 3,500 lb.

b. Minimum ultimate shear value shall be 5,000 lb.

2.2 FLOOR GRATINGS

Provide galvanized steel floor grating as shown on the contract drawings and in accordance with NAAMM MBG 531.

a. NAAMM MBG 531, band edges of grating with bars of the same size as the bearing bars. Weld banding in accordance with the manufacturer's standard for trim unless otherwise indicated. Design tops of bearing bars, cross or intermediate bars to be in the same plane and match grating finish.

b. Attach gratings to structural members with saddle clips, or fasteners of the type recommended by the manufacturer and approved, unless noted otherwise. Anchors shall allow gratings to be removed for maintenance purposes.

c. Slip resistance requirements must exceed both wet and dry a static coefficient of friction of 0.6.

2.3 MANHOLE COVER AND FRAME

Provide a heavy duty type made of ductile cast-iron. Provide frame with a 30 inch diameter clear opening. The cover shall be vented. Maximum weight of frame and cover together to be 530 pounds.

2.4 HEAVY DUTY FLOOR/TRENCH COVER

Provide heavy duty type Floor/Trench covers and frames as shown on the drawings and manufactured by Neenah Foundry (model R-4990-MX, class 35B, type G lift handle) or an approved equal. Covers shall be designed for a 16,000 pound wheel load.

PART 3 EXECUTION

3.1 STRUCTURAL FABRICATION

3.1.1 Material

Material must be straight before being laid off or worked. If straightening is necessary it shall be done by methods that will not impair the metal. Sharp kinks or bends shall be cause for rejection of the material. Material with welds will not be accepted except, where welding

SECTION 05 50 03.00 12 Page 9 is definitely specified, indicated on the drawings, or otherwise approved.

Bends, except for minor details, shall be made by approved dies, press brakes or bending rolls. Where heating is required precautions shall be taken to avoid overheating the metal and it shall be allowed to cool in a manner as not to destroy the original properties of the metal. Flame cutting of material other than structural steel shall be subject to approval and, where proposed, shall be indicated on shop drawings submitted to the Contracting Officer. Shearing shall be accurately done and all portions of the work shall be neatly finished. Corners shall be square and true unless otherwise shown on the drawings. Re-entrant cuts shall be filleted to a minimum radius of 3/4-inch unless otherwise approved.

Finished members shall be free from twists, bends and open joints. Bolts, nuts and screws shall be tight.

3.1.2 Dimensional Tolerances for Structural Work

Dimensions shall be measured by means of an approved calibrated steel tape of approximately the same temperature as the material being measured at the time of measurement. The overall dimensions of an assembled structural unit shall be within the tolerances indicated on the drawings or as specified for the item of work. Except as required to meet the requirements above, an allowable variation of 1/32-inch is permissible in the overall length of component members with both ends milled; individual component members without milled ends shall not deviate from the dimensions shown on the drawings 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.

3.1.3 Structural Steel Fabrication

Structural steel may be cut by mechanically guided or hand guided torches provided an accurate profile with a smooth surface which is free from cracks and notches is obtained. Surfaces and edges to be welded shall be prepared in accordance with AWS D1.1/D1.1M, Subsections 5.15 through 5.17, and 5.19. 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. Hand guided cuts which are to be exposed or visible shall be chipped, ground or machined to sound metal.

3.2 WELDING

3.2.1 Structural Steel

3.2.1.1 General

Unless otherwise authorized or specified, welding of structural steel shall be by an electric arc welding process using a method which excludes the atmosphere from the molten metal. Welding, unless otherwise specified or authorized shall conform to the applicable provisions of AWS D1.1/D1.1M, Cyclically Loaded Structures.

3.2.1.2 Welding Equipment

All items of welding equipment shall conform to the requirements of

AWS D1.1/D1.1M.

3.2.1.3 Welding Procedures

The Contractor shall prepare for submission to the Contracting Officer a

SECTION 05 50 03.00 12 Page 10 complete schedule of welding procedures which shall consist of detailed procedure specifications for each structure to be welded and tables or diagrams showing the procedure to be used for each required joint. The schedule shall conform to the provisions of AWS D1.1/D1.1M, Sections 2, 3, 4.1, 4.12 through 4.17, 5, 6.7 through 6.13, 6.18, 6.27, and , 7 as applicable to Cyclically Loaded Structures, include filler metal requirements, preheat and interpass temperature requirements and any stress relief heat treatment, and show types and locations of welds designated on the drawings and/or in the specifications to receive nondestructive examination. The procedures shall be such as to minimize residual stresses and distortion of the completed weldment. Procedures shall be qualified by tests as prescribed in AWS D1.1/D1.1M, Section 4, Part B except for prequalified procedures described in AWS D1.1/D1.1M, Section 3. Properly documented evidence of compliance with all requirements of these specifications for previous qualification tests shall establish the joint welding procedure as prequalified. Each procedure shall be clearly identified as being either prequalified or qualified by tests. The test welding and specimen testing must be witnessed and the test report document signed by a representative of the Contracting Officer. The Contractor will be directed or authorized to make any changes in previously approved welding procedures that are deemed necessary or desirable by the Contracting Officer. Approval of any procedure, however, will not relieve the Contractor of the responsibility for producing a finished structure meeting all requirements of these specifications.

3.2.1.4 Qualifications of Welders and Welding Operators

Welding operators, welders, and tack welders shall be qualified and requalified if necessary for the particular type of work to be done.

Qualification shall be in accordance with AWS D1.1/D1.1M, Section 4, Part C or ASME BPVC SEC IX.

The Contractor shall certify by name to the Contracting Officer the welders and welding operators so qualified, including the date of qualification, certificates, and code and procedures under which qualified. Prior qualification may be accepted if welders have performed satisfactory work under the code for which qualified within the preceding three months. The Contractor shall require the welder and welding operators to repeat the qualifying tests when, in the opinion of the Contracting Officer, his work indicates a reasonable doubt as to proficiency. In such cases, he shall be recertified, as above, if he successfully passes the retest; otherwise, he shall be disqualified until he has successfully passed a retest. All expenses in connection with qualification and requalification shall be borne by the Contractor.

3.2.1.5 Technique

a. Filler Metal - The electrode, electrode-flux combination and grade of weld metal shall conform to the appropriate AWS specification for the base metal and welding process being used. Only low hydrogen electrodes shall be used for manual shielded metal-arc welding regardless of the thickness of the steel. The AWS designation of the electrodes to be used shall be included in the schedule of welding procedures to be furnished by the Contractor.

To maintain low moisture of low hydrogen electrodes, a controlled temperature storage oven shall be used at the job site as prescribed by AWS D1.1/D1.1M, Subsection 5.3.2.

b. Preheat and Interpass Temperature - Preheating shall be performed

SECTION 05 50 03.00 12 Page 11 as required by AWS D1.1/D1.1M, Subsection 3.5 and 5.7 or as otherwise specified except that the temperature of the base metal shall be at least 70 degrees F. The weldments to be preheated shall 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.

c. Stress-Relief Heat Treatment - Where stress relief heat treatment is specified or shown on the drawings, it shall be in accordance with the requirements of AWS D1.1/D1.1M, Subsection 5.8, unless otherwise authorized or directed by the Contracting Officer.

3.2.1.6 Workmanship

a. Preparation of Base Metal - Prior to welding, the Contractor shall inspect surfaces to be welded to assure compliance with AWS D1.1/D1.1M, Subsection 5.15 through 5.17, and 5.19.

b. Temporary Welds - Temporary welds required for fabrication and erection shall be made under the controlled conditions prescribed herein for permanent work. All temporary welds shall be made using low-hydrogen welding electrodes and by welders qualified for permanent work as specified elsewhere in these specifications.

Preheat furnished for temporary welds shall be as required by AWS D1.1/D1.1M for permanent welds except that the minimum temperature shall be 120 degrees F in any case. In making temporary welds, arcs shall not be struck in other than weld locations. Each temporary weld shall be removed after serving its purpose and ground flush with adjacent surfaces.

c. Tack Welds - Tacks welds that are to be incorporated into the permanent work shall be subject to the same quality requirements as the permanent welds. Preheating shall be performed as specified above for temporary welds. Such tack welds shall be cleaned and fused thoroughly with the permanent welds.

Multiple-pass tack welds shall have cascaded ends. Defective tack welds shall be removed before permanent welding.

3.2.1.7 Inspection

Welding shall be subject to inspection by the Contracting Officer to determine conformance with the requirements of AWS D1.1/D1.1M, and the approved welding procedures and provisions stated elsewhere in these specifications. The Contracting Officer will require nondestructive examination of designated welds and may require supplemental examination of any joint or coupon cut from any location in any joint. The Contractor shall maintain an approved inspection system and perform required inspections in accordance with the Contract Clause entitled "INSPECTION OF

CONSTRUCTION" (FAR 52.246-12).

a. Visual Examination - Prior to any welding, the Contractor shall visually inspect the preparation of material for welding to assure compliance with Subsections 5.1, 5.2, 5.10 through 5.13, 5.15 through 5.23, and 5.30 of AWS D1.1/D1.1M. All completed welds shall be cleaned and carefully examined for insufficient throat or leg sizes, cracks, undercutting, overlap, excessive convexity or reinforcement, and other surface defects to insure compliance with the requirements of AWS D1.1/D1.1M, Section 5 and Section 6, Part C. Defects shall be corrected as provided in paragraph

SECTION 05 50 03.00 12 Page 12

"Inspection" (d)

b. Test Coupons - The Government reserves the right to require the Contractor to remove coupons from completed work when doubt as to soundness cannot be resolved by nondestructive examination.

Should any two coupons cut from the work of any welder show strengths under test, less than that specified for the base metal it will be considered evidence of negligence or incompetence and such welder shall be removed from the work. When coupons are removed from any part of a structure, the members cut shall be repaired in a neat workman like manner with joints of the proper type to develop the full strength of the members, with peening as approved or directed to relieve residual stress. The expense for removal and testing of the coupons, repair of cut members and the performance of nondestructive examination of repairs shall be assigned to the Government or the Contractor in accordance with the Contract Clause entitled "INSPECTION OF CONSTRUCTION" (FAR 52.246-12).

c. Supplemental Examination - The Government reserves the right to perform supplemental nondestruction examinations as deemed necessary when the soundness of any weld is in doubt and to detect cracking or similar defects that might occur during shipment or erection and before final acceptance by the Government. The cost of such inspection will be borne by the Government. The repairs and the reexamination of repairs will be performed by the Contractor at no additional cost to the Government.

d. Repairs - Defective weld metal shall be removed by air carbon-arc or oxygen gouging to sound metal. Oxygen gouging shall not be used on ASTM A 514/A 514M steel. The surfaces shall be thoroughly cleaned before welding. The resulting cavities shall be rewelded in compliance with Article 6.6 of AWS D1.1/D1.1M. When deemed necessary by the Contracting Officer, the Contractor shall submit a welding repair plan for approval before repairs are made. Welds that have been repaired shall be retested by the same methods used in the original inspection. All costs of repairs and testing shall be borne by the Contractor, except for repair of members cut to remove test coupons which were found to contain acceptable welds.

e. Oxygen Cutting - In all oxygen cutting, flame shall be so adjusted and manipulated as to avoid cutting beyond the prescribed lines.

Cut surfaces and edges shall be left free of slag.

3.3 STUD WELDING

Stud welding, unless otherwise specified shall conform to the applicable provisions of Section 7 of AWS D1.1/D1.1M.

3.3.1 Stud Materials

The type, size and length of studs shall be as indicated on the drawings.

The Contractor shall furnish for approval the manufacturer's certified test reports and certification that the studs conform to the applicable requirements of AWS D1.1/D1.1M, Subsections 7.2 and 7.3.

SECTION 05 50 03.00 12 Page 13

3.3.2 Stud Base Application Qualification

As a condition of approval, the Contractor shall furnish, a certified report giving data, procedures and results of tests performed in accordance with the provisions of Article 7.4 of AWS D1.1/D1.1M. The test specimens shall be prepared using suitable specimen plates of the same base metal to which the studs are to be welded.

3.3.3 Workmanship

The studs shall be welded in accordance with the provisions of Article 7.4 of AWS D1.1/D1.1M. Studs on which a full 360 degree weld fillet is not obtained may, at the option of the Contractor, be repaired by adding a 3/16-inch fillet, using shielded metal arc process with low-hydrogen welding electrodes. If the reduction of the length of studs becomes less than normal as they are welded, welding shall be stopped immediately and not resumed until the cause has been corrected.

3.3.4 Inspection

The welding of stud connectors will be subject to visual inspection by the Government's Inspector. Each stud connector that does not show a full 360 degree weld fillet, that has been repaired by welding, or the reduction in length due to welding is less than normal shall be tested in accordance with the requirements for testing of one in every 100 stated in paragraph "Testing."

3.3.5 Testing

Prior to starting welding operation and at the beginning of each day's operation, two stud connectors shall be welded in the same general position (flat, vertical, overhead, sloping) to a separate piece of material of similar thickness and composition as the member to which the studs are to be welded. After being allowed to cool, these studs shall be tested by bending to an angle of 30 degree by striking the stud with a hammer. If failure occurs in the weld zone of either stud, the procedure shall be corrected and two successive studs successfully welded and tested before any studs are welded to the member. The foregoing testing shall be performed after any change in the welding procedure. If failure occurs in the stud shank, an investigation shall be made to ascertain and correct the cause before further welds are made. In addition to the foregoing tests at least one stud in every 100 shall be struck with a hammer and bent to an angle of 15 degree or if threaded shall be torque tested with a calibrated torque wrench as indicated in Figure 7.3 of AWS D1.1/D1.1M. If the stud fails, two more of the existing studs shall be bent or torque tested. If either of these two studs fails, all of the studs represented by the tests shall be rejected. Studs under testing that crack either in the weld, the base metal, or the shank shall be rejected and replaced by the Contractor at no additional cost to the Government.

3.4 BOLTED CONNECTIONS

3.4.1 Structural Steel Connections

Bolts, nuts and washers shall be of the type specified or indicated on the drawings. All nuts shall be equipped with washers except for high strength bolts. Beveled washers shall be used 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 on the drawings, the

SECTION 05 50 03.00 12 Page 14 materials, workmanship and installation shall conform to the applicable provisions of RCSCA.1.

3.4.1.1 Bolt Holes

Bolt holes shall be accurately located, smooth, perpendicular to the member and cylindrical.

a. Regular Bolt Holes - Holes for regular bolts shall be drilled or subdrilled and reamed in the shop and shall not be more than 1/16-inch larger than the diameter of the bolt.

b. Fitted Bolt Holes - Holes for fitted bolts shall be match-reamed or drilled in the shop. Burrs resulting from reaming shall be removed. The threads of bolts shall be entirely outside of the holes. The body diameter of bolts shall have tolerances as recommended by ANSI B4.1 for the class of fit specified. Fitted bolts shall be fitted in reamed holes by selective assembly to provide an LN-2 fit.

c. High Strength Bolt Holes - Holes for high strength bolts shall have diameters of not more than 1/16-inch larger than the bolt diameters. 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 bolt, the holes may be drilled full size or subpunched 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 done during assembly shall not distort the metal or enlarge the holes. For slight mismatching, reaming to a larger diameter of the next standard size bolt will be allowed.

3.5 SHOP ASSEMBLY

Unless otherwise specified, each machinery and structural unit furnished shall be assembled in the shop to determine the correctness of the fabrication and matching of the component parts. The tolerances shall not exceed those shown on the drawings and each unit assembled shall be closely checked to insure that all necessary clearances have been provided and that binding does not occur in any moving part. Assembly in the shop shall be in the same position as final installation (closed position) in the field unless otherwise specified. Assembly and disassembly work shall be performed in the presence of the Government Inspector, unless waived in writing by the Contracting Officer. Errors or defects disclosed shall be immediately remedied by the Contractor without cost to the Government.

Before disassembly for shipment, each piece of a machine or structure shall be match-marked to facilitate erection in the field. The location of match-marks shall be indicated by circling with a ring of white paint after the shop coat of paint has been applied, or as otherwise directed.

3.6 MACHINE WORK

3.6.1 General

Unless otherwise shown on the shop drawings, all tolerances, allowances and gages for metal fits between plain, non-threaded, cylindrical parts shall conform to ANSI B4.1 for the class of fit as shown or otherwise required.

Where fits are not shown they shall be suitable as approved by the

SECTION 05 50 03.00 12 Page 15

Contracting Officer. Tolerances for machine-finished surfaces designated by non-decimal dimensions shall be within 1/64-inch. Sufficient machining stock shall be allowed on placing pads to insure true surfaces of solid material. Finished contact or bearing surfaces shall be true and exact to secure full contact. Journal surfaces shall be polished and all surfaces shall be finished with sufficient smoothness and accuracy to insure proper operation when assembled. Parts entering any machine shall be carefully and accurately machined and all like parts shall be interchangeable, except that parts assembled together for drilling or reaming of holes or machining will not be required to be interchangeable with like parts. All drilled holes shall be accurately located.

3.6.2 Finished Surfaces

3.6.2.1 Finishes, Indicated

Where surface finishes are indicated on the drawings or specified herein, the symbols used or finishes specified shall be in accordance with ANSI B46.1. Values of required roughness height specified are arithmetical average deviations expressed in micro inches. Roughness specified is the maximum value and any lesser degree will be satisfactory unless otherwise indicated on the drawings. Compliance with surface requirements shall be determined by sense of feel and visual inspection of the work compared to Roughness Comparison Specimens, in accordance with the provisions of ANSI B46.1. Values of roughness width and waviness height are not specified, but shall be consistent with the general type of finish specified by roughness height. Flaws such as scratches, ridges, holes, peaks, cracks or checks which will make the part unsuitable for the intended use will be cause for rejection.

3.6.2.2 Finishes, Not Indicated

Where the finish is not indicated or specified, the type of finish shall be that which is most suitable for the surface to which it applies and shall be consistent with the class of fit required. Surfaces to be machine finished shall be indicated on the shop drawings by symbols which conform to ANSI B46.1.

3.6.3 Unfinished Surfaces

So far as practical, all work shall be laid out to secure proper matching of adjoining unfinished surfaces. Where there is a large discrepancy between adjoining unfinished surfaces, they shall be chipped and ground smooth, or machined, to secure proper alignment. Unfinished surfaces shall be true to the lines and dimensions shown on the drawings and shall be chipped or ground free of all projections and rough spots. Depressions or holes not affecting the strength or usefulness of the parts shall be filled in a manner approved by the Contracting Officer.

3.6.4 Dissimilar Materials

Where dissimilar metals are in contact, protect surfaces with a coat conforming to MPI 79 to prevent galvanic or corrosive action. Where aluminum is in contact with concrete, plaster, mortar, masonry, wood, or absorptive materials subject to wetting, protect with ASTM D1187/D1187M, asphalt-base emulsion.

SECTION 05 50 03.00 12 Page 16

3.6.5 Pin Holes

Pin holes shall be bored true to gages, smooth, straight and at right angles to the axis of the member. The boring shall be done after the member is securely fastened in position.

3.6.6 Shafting

Unless otherwise specified or authorized, all shafting shall be turned or ground hot-rolled or cold-rolled steel as required. Fillets shall be provided where changes in section occur. Cold-finished shafting may be used where keyseating is the only machine work required.

3.6.7 Bearings

Unless otherwise specified or shown on the drawings, bearings may be lined with babbit or bronze. Where the bearing pressure is in excess of 200 pounds per square inch, bearings shall be lined with bronze. Unless otherwise required or authorized, pressures on lined bearings shall not exceed 1000 pounds per square inch of projected area. Anti-friction bearings of approved types and of sizes not less than those recommended by the bearing manufacturer for the duty intended will be permitted subject to approval. All bearings shall be properly aligned and provided with a suitable means of lubrication. Anti-friction bearings shall be so installed as to provide for retention of the lubricant and to exclude dirt and grit.

3.7 MISCELLANEOUS PROVISIONS

3.7.1 Metallic Coatings

3.7.1.1 Zinc Coatings

Zinc coatings shall be applied in a manner and of a thickness and quality conforming to ASTM A 123/A 123M. In all cases where zinc coatings are destroyed by cutting, welding or other causes, the affected areas shall be regalvanized by the following methods. Coatings 2 ounces or heavier shall be regalvanized with a suitable low-melting zinc base alloy similar to the recommendations of the American Hot-Dip Galvanizers Association to the thickness and quality specified for the original zinc coating. Coatings less than 2 ounces shall be regalvanized by a repair compound conforming to

ASTM A780/A780M.

3.7.2 Cleaning of Corrosion-Resisting Steel

After fabrication, oil, paint and other foreign substances shall be removed from corrosion-resisting steel surfaces. Cleaning shall be done by vapor degreasing or by the use of cleaners of the alkaline, emulsion or solvent type. After the surfaces have been cleaned, they shall be given a final rinsing with clean water followed by a 24-hour period during which the surfaces are intermittently wet with clean water and then allowed to dry for the purpose of inspecting the clean surfaces. The surfaces shall be visually inspected for evidence of paint, oil, grease, welding slag, heat treatment scale, iron rust or other forms of contamination. If evidence of foreign substance exist, the surface shall be cleaned in accordance with the applicable provisions of Section 6 of ASTM A 380. The proposed method of treatment shall be furnished for approval. After treatment the surfaces shall be visually reinspected. Brushes used to remove foreign substances shall utilize only stainless steel or nonmetallic bristles. Any

SECTION 05 50 03.00 12 Page 17 contamination occurring subsequent to the initial cleaning shall be removed by one or more of the methods indicated above.

3.7.3 Protection of Finished Work

3.7.3.1 Machined Surfaces

Machined Surfaces shall be thoroughly cleaned of foreign matter. All finished surfaces shall be protected by suitable means. Unassembled pins and bolts shall be oiled and wrapped with moisture resistant paper or protected by other approved means. Finished surfaces of ferrous metals to be in bolted contact shall be washed with a rust inhibitor and coated with an approved rust resisting compound for temporary protection during fabrication, shipping and storage periods. Finished surfaces of metals which will be exposed after installation shall be painted as specified in Section 09 97 02.01 12 PAINTING: COAL TAR EPOXY SYSTEM, except that painting of corrosion resisting steel or nonferrous metals will not be permitted unless specifically authorized or specified.

3.7.3.2 Lubrication

The arrangement and details for lubrication shall be as shown on the drawings. Before erection or assembly, all bearing surfaces shall be thoroughly cleaned and lubricated with an approved lubricant. After assembly, all lubricating systems shall be filled with the lubricant specified and, additional lubricant shall be applied at regular intervals to maintain the equipment in satisfactory condition until acceptance of the work by the Contracting Officer.

a. Thread Lubrication - Threads on screw jacks and gate latches, shall be lubricated as specified above and maintained in satisfactory condition until acceptance of the work by the Government.

3.8 INSTALLATION

3.8.1 General

All parts to be installed shall be thoroughly cleaned. Packing compounds, rust, dirt, grit and other foreign matter shall be removed. Holes and grooves for lubrication shall be cleaned. Enclosed chambers or passages shall be examined to make sure that they are free from damaging materials.

Where units or items are shipped as assemblies they will be inspected by a representative of the Contracting Officer prior to installation.

Disassembly, cleaning and lubrication will not be required except where there is indication that such work is necessary to place the assembly in a clean and properly lubricated condition. Pipe wrenches, cold chisels, or other tools likely to cause damage to the surfaces of rods, nuts or other parts shall not be used for assembling and tightening parts. Bolts and screws shall be tightened firmly and uniformly, but care shall be taken not to over stress the threads. When a half nut is used for the purpose of locking a full nut, the half nut shall be placed first and followed by the full nut. Threads of all bolts, except high strength bolts, nuts and screws shall be lubricated by graphite and oil before assembly. Threads of corrosion-resisting steel bolts and nuts shall be coated with an approved anti-galling compound. Driving and drifting bolts or keys will not be permitted.

SECTION 05 50 03.00 12 Page 18

3.8.2 Alignment and Setting

Each machinery or structural unit shall be accurately aligned by the use of steel shims or other approved methods so that no binding in any moving parts or distortion of any member occurs before it is fastened in place.

The alignment of all parts with respect to each other shall be true within the respective tolerances required. Machines shall be set true to the elevations shown on the drawings.

3.8.3 Blocking and Wedges

All blocking and wedges used during installation for the support of parts to be grouted in foundations shall be removed before final grouting unless otherwise directed by the Contracting Officer. Blocking and wedges left in the foundations with the approval of the Contracting Officer shall be of steel or iron.

3.8.4 Foundations and Grouting

Concreting of sub-bases and frames and the final grouting under parts of machines shall be in accordance with good construction procedures.

3.8.5 Expansion Joint Covers

Expansion joint covers shall be set in formwork before pouring concrete and protected from damage and soil.

3.8.6 Pipe Sleeves

Pipe sleeves shall be set in formwork before pouring concrete. Align and space as indicated on the drawings.

3.8.7 COVER PLATES AND FRAMES

Install the tops of cover plates and frames flush with floor.

3.8.8 SETTLEMENT REFERENCE BOLTS

Upon installation of the settlement reference bolts the Contractor shall determine elevations of each bolt and submit his results to the Contracting Officer.

-- End of Section --

SECTION 05 50 03.00 12 Page 19

SECTION TABLE OF CONTENTS

DIVISION 22 - PLUMBING

SECTION 22 10 00.00 10

VERTICAL PUMPS, AXIAL-FLOW AND MIXED-FLOW IMPELLER-TYPE

PART 1 GENERAL

1.1 REFERENCES

1.2 SYSTEM DESCRIPTION

1.2.1 Design Requirements

1.2.2 Capacities

1.3 MEASUREMENT AND PAYMENT

1.3.1 Verticle Pumps

1.3.2 Formed Suction Intakes

1.4 SUBMITTALS

1.5 QUALITY ASSURANCE

1.5.1 Freeze Protection

1.5.2 Detail Drawings

1.6 DELIVERY, STORAGE, AND HANDLING

1.6.1 General

1.6.2 Processing for Storage

1.7 PROJECT/SITE CONDITIONS

1.7.1 Datum

1.7.2 Static Head

1.8 MAINTENANCE

1.8.1 Special Tools

1.8.2 Extra Materials

1.9 WARRANTY

PART 2 PRODUCTS

2.1 MATERIALS

2.2 METALWORK FABRICATION

2.2.1 Designated Materials

2.2.2 Bolted Connections

2.2.2.1 Bolts, Nuts, and Washers

2.2.2.2 Materials Not Specifically Described

2.2.3 Metalwork

2.2.3.1 Flame Cutting of Material

2.2.3.2 Alignment of Wetted Surfaces

2.2.3.3 Stress-Relieving Procedure

2.2.4 Examination of Castings

2.2.4.1 Examination Procedures

2.2.4.2 Acceptance and Repair Criteria

2.3 VERTICAL PUMPS

2.3.1 Speed

2.3.2 Reverse Flow

2.3.3 Efficiency

2.3.4 Impeller Bowl

2.3.5 Diffuser Bowl

2.3.6 Pump Column and Discharge Elbow

SECTION 22 10 00.00 10 Page 1 Revised By Amendment 0003

2.3.6.1 Column and Discharge Elbow

2.3.6.2 Column and Discharge Elbow Support

2.3.6.3 Pumps Discharge Diameter

2.3.6.4 Formed Suction Intake

2.3.6.5 Flanges

2.3.6.6 Flanged Joints

2.3.6.7 Nuts and Bolts

2.3.6.8 Galvanic Protection

2.3.6.9 Harnessed Coupling

2.3.7 Impeller

2.3.7.1 Removal and Prior To Finishing

2.3.7.2 Balance

2.3.8 Shafting

2.3.8.1 Shaft

2.3.8.2 Couplings

2.3.8.3 Journals

2.3.8.4 Circumferential Line

2.3.9 Shaft Enclosure

2.3.10 Guide Bearings and Seals

2.3.10.1 Guide Bearings

2.3.10.2 Oil Lubrication Shaft Seals

2.3.11 Bearing Heat Sensors

2.3.12 Thrust Bearing

2.3.13 Packing Gland

2.4 LUBRICATION SYSTEM

2.4.1 Lubrication System Accessories

2.4.1.1 Grease Gun

2.5 PAINTING

2.6 TESTS, INSPECTIONS, AND VERIFICATIONS

2.6.1 Dynamic Analysis

2.6.1.1 Torsional Analysis

2.6.1.2 Lateral Frequency Analysis

2.6.2 Factory Test

2.6.2.1 General

2.6.2.2 Test Setup

2.6.2.3 Instrumentation and Procedures

2.6.2.4 Pump Test

2.6.2.5 Test Procedure

2.6.2.6 Cavitation Tests

2.6.2.7 Witness Test

2.6.2.8 Test Report

2.7 BASEPLATE AND SUPPORTS

2.8 FACTORY ASSEMBLY

PART 3 EXECUTION

3.1 INSTALLATION

3.1.1 Setting and Aligning

3.2 FIELD TESTS

3.2.1 Dry Tests

3.2.2 Wet Tests

3.2.3 Completion and Acceptance

3.3 PUMP SYSTEM OPERATION TRAINING

ATTACHMENTS:

FIGURE 2

FIGURE 3

SECTION 22 10 00.00 10 Page 2

-- End of Section Table of Contents --

SECTION 22 10 00.00 10 Page 3

SECTION 22 10 00.00 10

VERTICAL PUMPS, AXIAL-FLOW AND MIXED-FLOW IMPELLER-TYPE

PART 1 GENERAL

1.1 REFERENCES

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

ACOUSTICAL SOCIETY OF AMERICA (ASA)

ASA S2.19 (1999; R 2004) Mechanical Vibration - Balance Quality Requirements of Rigid Rotors, Part 1: Determination of Permissible Residual Unbalance, Including Marine Applications

AMERICAN PETROLEUM INSTITUTE (API)

API RP 686 (2009) Recommended Practice for Machinery Installation and Installation Design

AMERICAN WATER WORKS ASSOCIATION (AWWA)

AWWA C200 (2005) Steel Water Pipe - 6 In. (150 mm) and Larger

AWWA C203 (2008) Coal-Tar Protective Coatings and Linings for Steel Water Pipelines - Enamel and Tape - Hot-Applied

AWWA C207 (2007) Standard for…