B01-Atch 1 PWS Attachment_1c Steel Structures Maintenance Instruction.pdf

ACTIVITY ID DATE

CONTRACT NO CONTRACT TITLE SUBMI NO

SUBM ITEM DESCRIPTION

SPEC SECTION SPEC PARAGRAPH SPEC PAGE NO

CONTRACTOR/QUALITY CONTROL MANAGER DATE

COMMENTS FOR DETAILED REVIEWER:

DETAILED REVIEWER 1 COMMENTS:

DETAILED REVIEWER 1 NAME/SIGNATURE: TITLE RESPONSE DATE

DETAILED REVIEWER 2 COMMENTS:

DETAILED REVIEWER 2 NAME/SIGNATURE: TITLE RESPONSE DATE

APPROVER'S COMMENTS:

SUBM STATUS GOVERNMENT CONSTRUCTION MANAGER DATE

4296/2C (9/98) SHEET 1 of

20/12/2023

Improve Weapons Storage Facility at Camp Darby, Livorno, Italy

SUBMITTAL TRANSMITTAL

2-

20/12/2023

N62470-17C-5002 231A

(SD-10) Steel Structure Maintenance Instruction

Contractor submits to GOV Cast in place Concrete Structure Maintenance Instruction.

1.3 - Operation and Maintenance Data

Improve Weapons Storage Facility (WSF)

Camp Darby, Pisa, Italy

Contract No. N62470-17-C-5002

Cimolai Internal Project Number: 2017.034

U.S. ARMY GARRISON VICENZA - CAMP DARBY

IMPROVE WEAPONS STORAGE FACILITY

Contract N62470-17-C-5002

Steel Structure Maintenance Instruction

REV. DATE Descritpion

0 20th December 2023 Steel structure maintenance manual

Table of Contents:

INTRODUCTION

1.0 SCOPE AND APPLICATION

2.0 TYPES OF CONCRETE STRUCTURES

3.0 IMPORTANCE OF REGULAR MAINTENANCE

4.0 SAFETY PRECAUTIONS

5.0 PERSONNEL

6.0 METHOD OF INSPECTION

7.0 TOOLS AND EQUIPMENT

INTRODUCTION

This guide is designed to assist you in ensuring the longevity and structural integrity of the steel structures composing the project.

The primary purpose of this manual is to provide an approach to steel structure maintenance. Please note that steel structures inspection is a specialized work which requires great level of expertise.

Please ensure that inspection are carried out by adequately trained personnel.

This manual is only intended for structural steel elements. Please refer to specific maintenance manual for mechanical components and painting system (i.e. Painting Maintenance Plan sub.#216, Swing bridge Mechanical system sub. #214B, Vossloh Bridge Joint, sub. #221A).

Additionally, for every detailed information regarding specific issues highlighted or necessary during the inspections (i.e. allowed tolerances, preferred method of inspection, allowed deformation) please refer to project designer.

NOTE:

The maintenance needs for steel structures, particularly with regard to bridges subject to railway traffic, can vary based on the level of utilization of the structures. Phenomena such as deformation, damage, and wear of the structure can be attributed to intense usage and fatigue phenomena.

At the moment, the actual extent of traffic to which the structures will be subjected is unknown to the constructor. The reference point is the design assumption of approximately 6 transits per year on average. Therefore, the manual does not consider states of wear caused by intense and regular usage of the structures, which were not anticipated in the project.

Please refer to project designer for additional details on the matter.

1.0 SCOPE AND APPLICATION

This manual is specifically tailored to the unique steel structures within ERI expansion project, which include:

- ASA AREA 9: Locomotive shed

- ASA AREA 6: Fixed Bridge

- ASA AREA 3: Swing Bridge.

To ensure these structures continue to serve their intended purposes effectively and safely, this manual provides you with a structured approach to maintenance, including safety precautions, types of steel structures, and the importance of regular maintenance.

Please refer also to other maintenance manual submitted for the project, which are to be red in conjunction with the present.

2.0 IMPORTANCE OF REGULAR MAINTENANCE

Regular maintenance is a critical component of preserving the functionality and longevity of steel structures within any project. The establishment of scheduled maintenance practices is fundamental to prevent deterioration, extend their lifespan, and ensure their continued reliability.

3.0 SAFETY PRECAUTIONS

Safety is of the upmost importance when performing maintenance on steel structures. Please ensure the well-being of all individuals working with or near these structures in accordance with safety rules and regulations.

CAREFULLY READ THE ENTIRE MANUAL BEFORE PROCEEDING WITH THE USE AND

MAINTENANCE OF THE RELEVANT STRUCTURES.

RISKS AND CRITICALITIES TO BE EVALUATED IN WORK PHASES (more common)

Falls from Heights

During the preparation and ground assembly phase of individual pieces of machinery, equipment, structures (cranes, concrete mixing plants, barracks, and the like), and during the inspection phase at height, safety measures against the risk of falling from heights must be considered. Mobile bridges on wheels, extension ladders, or scaffolding can be used for this purpose. If technically not possible, personal fall protection devices must be used.

Punctures, Cuts, Abrasions

Contact between the operator's body and sharp or pointed elements capable of causing injuries must be avoided. Where the need to handle potentially dangerous materials is foreseen, workers must use

PPE suitable for the task. All working parts of the equipment must be protected against accidental contact. Special attention must be paid during the marking of construction areas and the installation of temporary fences, especially when using sections of reinforced concrete bars.

Slips, Falls at Ground Level

Internal pedestrian paths within the construction site must be created and always kept clear of equipment, materials, or other items that could obstruct the workers' path. Areas for stacking materials to be disposed of or materials needed for installation must be identified in separate areas and separated from pedestrian paths. In the presence of slippery terrain, inert granular material must be applied to make work or passage areas safely usable.

Fall of Material from Above

All operators must use protective helmets. During the assembly of lifting equipment or other operations at height, the passage of people in the area that could be affected by a possible fall of elements, tools, or other items must be prevented. Hand tools and equipment must be kept in stable conditions (e.g., stored in containers or secured to the worker's body).

Manual Handling of Loads

Manual handling of loads must be minimized and rationalized to avoid excessive physical exertion of the personnel involved. The supply of materials and equipment must be carried out as much as possible with transportation and/or lifting means. Depending on the characteristics and size of the loads, manual handling activities must be preceded and accompanied by adequate information and training, subject to verification, for non-sporadic activities, of the health conditions of the workers.

4.0 PERSONNEL

This manual is intended exclusively to personnel assigned to operation and maintenance operations (inspection, preventive and corrective maintenance). The operations of use and maintenance must be entrusted to suitable and qualified persons. The machines can only be used by specialized personnel. Such persons must always have the instructions and must carefully observe their contents.

Please refer also to other manual such as: 2017034 ODP - MDP 10001A 3 (MOVABLE BRIDGE

OPERATING SYSTEM - USE AND MAINTENANCE MANUAL) .

5.0 METHOD OF INSPECTION

Visual inspection to detect possible anomalies preceding structural failure phenomena.

Visual inspection is a fundamental component of assessing the condition of steel structures, providing valuable insights into the surface integrity and identifying potential issues that may compromise structural integrity or aesthetics. To ensure the efficacy of visual inspections, it is imperative to follow systematic guidelines that encompass a comprehensive approach.

Inspectors should systematically cover the entire surface of the steel structure, considering both macroscopic and microscopic details.

Proper lighting conditions are essential for detecting subtle imperfections and ensuring accurate assessments. Inspections should ideally be conducted during daylight hours, and supplementary lighting may be necessary, especially for areas with limited natural light. Adequate lighting not only facilitates the identification of surface irregularities but also aids in capturing detailed documentation for further analysis.

Consider use of man basket, boom lift, scaffolds (fixed and mobile) where necessary to ensure correct reaching and visual clearance on all structural elements.

Trough visual inspection it is possible to control resistance and adequacy of the structures for the following parameters:

Resistance to Aggressive Agents

Requirement Class: Protection from chemical and organic agents

Demand Class: Safety

Elevating structures must not dissolve, disintegrate, or undergo changes in appearance due to the action of chemical aggressive agents.

Performance:

Elevating structures should maintain their functional characteristics over time, even in the presence of chemical agents (carbon dioxide, sulfates, etc.) in the environment.

Please also refer to already submitted Steel Paints and Coatings Maintenance Instruction (submission

216A)

Minimum Performance Level:

Refer to current legal and regulatory requirements, specifically D.M. 14.1.2008 (Technical Standards for Constructions) and Circular 2.2.2009, n.617 (Instructions for the application of the "New technical standards for constructions" as per the ministerial decree 14.1.2008).

Regulatory References:

D.Lgs. 9.4.2008, n. 81; D.M. Infrastructures and Transport 14.1.2008; C.M. Infrastructures and

Transport 2.2.2009, n. 617; UNI 7699; UNI 8290-2; UNI 9944; UNI 10322.

(Attitude to) Control of Electrical Leaks

Requirement Class: Electrical protection

Demand Class: Safety

Elevating structures must effectively prevent possible electrical leaks.

Performance:

All metallic parts of the elevating structures must be connected to grounding systems through dispersers. This ensures they are at the same electrical potential as the ground.

Ground connection should be present and fixed in position.

Minimum Performance Level: Varies depending on the design methods.

Regulatory References:

Law 1.3.1968, n. 186; D.M. Economic Development 22.1.2008, n. 37; D.Lgs. 9.4.2008, n. 81; UNI 8290-

2; CEI EN 50522; CEI EN 61936-1; CEI 64-8; CEI 81-10/1; CEI S.423.

Mechanical Resistance

Requirement Class: Stability

Demand Class: Safety

Elevating structures must withstand potential manifestations of deformations and significant settlements due to certain stresses (loads, seismic forces, etc.).

Performance:

Elevating structures, under the effect of static, dynamic, and accidental loads, must ensure stability and resistance.

Minimum Performance Level:

Refer to current legal and regulatory requirements, especially D.M. 14.1.2008.

Frequency and periodicity: 5 years. Extra inspections should be planned during potential extraordinary natural events which may impact integrity of the structures (earthquake, flooding, etc.)

5.1.1 DETECTABLE AND MORE COMMONS ANOMALIES

Attention should be given to the following more common issues:

Corrosion

Decay of metallic elements due to the combination with substances present in the environment (oxygen, water, carbon dioxide, etc.).

Deformations and Displacements

Deformations and displacements caused by external factors that alter the normal configuration of the element.

Bulging

Deformation of the element localized near the wing and/or the core of a structural steel element/profile.

Yielding

Deformation of the element that can occur when, with increasing load, the perfectly elastic behavior of steel diminishes.

Low Recyclability

Use in maintenance phases of materials, elements, and components with a low degree of recyclability.

Use of Non-Durable Materials

Use of non-durable materials in the maintenance phases of the elements.

5.1.2 COMMON CHECKS CARRIED OUT BY SPECIALISED PERSONNEL

Deformations and/or Displacements Control

Frequency: Every 5 months

Type: Visual Inspection

Check for any deformations and/or displacements of the structural element caused by external factors altering its normal configuration.

- Requirements to Verify: 1) Resistance to aggressive agents; 2) Mechanical resistance.

- Identifiable Anomalies: 1) Corrosion; 2) Deformations and displacements.

- Specialized Companies: Higher-level technicians.

Recyclability Degree Control

Frequency: As needed (during maintenance works, if any)

Type: Control

Verify that materials, elements, and components with a high degree of recyclability are used in maintenance phases.

- Identifiable Anomalies: 1) Low recyclability.

Control of Durable Materials Usage

Frequency: As needed

Type: Verification

Ensure that components characterized by high durability are used in the maintenance phases of elements.

- Identifiable Anomalies: 1) Use of non-durable materials.

MAINTENANCE PERFORMABLE BY SPECIALIZED PERSONNEL

Interventions on Structures

Frequency: As needed following results of visual inspection and sharing of information with the designer and involved stakeholders.

Repair interventions should be carried out according to the type of identified anomaly and following a diagnosis of the causes of the detected defect.

Specialized Companies: Various specialists.

Restoration of Coating Protection

Frequency: as prescribed in Steel Paints and Coatings Maintenance Instruction

Restoration of exposed parts for anti-corrosion protection after cleaning surfaces, removing dust, and other deposits. Anti-corrosion treatment on exposed parts using spray or brush application of corrosion protection.

Please also refer to already submitted Steel Paints and Coatings Maintenance Instruction

(submission 216A)

Inspection of Bolts and Fasteners

Frequency: Every 5 years

- All bolted joints the bolts must be cleaned from dust and visually inspected.

- Screws with signs of rust on the shank or in the thread, as well as nuts with rusted threads, should be cleaned and coating protection should be applied.

- Screws or nuts with visible damage or deformations should be immediately removed and should not be reused.

- Bolts that have loosened and the first two bolts following on the left and right should not be reused. When in doubt, replace them!

- Discarded screws, nuts, and washers should be disposed of in the scrap and not placed back in the "bolt collection box."

- Loosening or the absence of bolts can be visually confirmed or checked using a fork or polygonal wrench.

- Movements among the threaded elements can be visually confirmed by looking for signs of friction, scratches, or, with due attention, during the machine's operation.

- Cracks and deformations in the structure can often be detected with the naked eye. An experienced and trained operator can make these observations during their daily work. Any necessary repairs should be carried out by a specialist!

Replacement of Metal Structures

Frequency: If needed

Description: Partial or total replacement of structural elements degraded due to excessive corrosion, deformation, and/or reduction in section. Restoration of covering elements.

Specialized Firms: Higher-level technicians, Various specialists. This activity is not a standard maintenance activity and should be performed only in case of serious damages to the structure integrity.

WARNING: The suggested controls above adhere to standard practices and widely accepted industry standards and expertise. In the event that repairs are deemed necessary according to qualified inspector, it is imperative to coordinate and customize any interventions following a thorough inspection and the involvement of specialized companies possessing the requisite expertise and knowledge.

6.0 TOOLS AND EQUIPMENT

Please find below a list of necessary or auxiliary tools which may be needed for concrete inspections, depending on results of visual inspection and status of the structures:

- Flashlight: Essential for illuminating dark or hard-to-reach areas during inspections.

- Tape Measure: Used for measuring dimensions, crack widths, and other critical distances.

- Magnifying Glass: Aids in detailed examination of small cracks, surface imperfections, or material conditions.

- Total Station: Optical instrument for precise measurement of angles, distances, and elevations during structural surveys.

- High-Resolution Camera: Captures detailed images of surface conditions for documentation and analysis.

- Safety Gear: Includes personal protective equipment (PPE) such as hard hats, safety glasses, gloves, and appropriate footwear.

- Binoculars: Useful for inspecting hard-to-reach or elevated areas from a distance.

- Notebook and Pen: Essential for recording observations, measurements, and other pertinent information during inspections.

- Safety Barriers and Signage: Used to secure inspection areas and communicate potential hazards to others on the site.

Always ensure that personnel conducting inspections are trained and competent in the use of the equipment, and that safety measures are strictly adhered to during all inspection activities.