C-1245D_Summitville_Dam_Impoundment_-_Specifications_2015-01-14.pdf

SPECIFICATIONS FOR THE

SUMMITVILLE DAM IMPOUNDMENT

HEAD GATE AND CONTROLS

DESIGN PROJECT NO. SV-102

DAMID: 210103

C-1245D

Section 30, T. 37 N., R. 3 1/2 E., N.M.P.M., Rio Grande County, Colorado

Water Division No. 3 Water District No. 20

January 14, 2015

By

Davis Engineering Service, Inc.

P.O. Box 1208 - 188 S. 8th Street

Pagosa Springs, Colorado 81147

CERTIFICATES

I hereby certify that these specifications for the Summitville Dam Impoundment Head Gate and Controls Design Project No. SV-102 project which is located in Rio Grande County, Colorado, Water Division No. 3, Water District No. 20, were prepared by me or under my direct supervision, for the Owner thereof.

Michael M. Davis

Colorado PE 32583

Colorado Department of Public Health and Environment, Owner, whose mailing address is 4300 Cherry Creek South Drive, Denver, Colorado 80246, does hereby accept and approve these specifications for the Summitville Dam Impoundment Head Gate and

Control Design Project No. SV-102.

OWNER:

By: Title:

Approved on the day of , 2015.

State Engineer of Colorado

By:

William T. McCormick III

Chief – Dam Safety Branch

Colorado PE 29127

PRELIMINARY COPY

FOR BIDDING PURPOSES ONLY

TABLE OF CONTENTS

Title Page

Certificates

Table of Contents

General Requirements

List of Quantities

Detailed Technical Specifications

Item No. Description

1 Removal of Material

2 Galvanized Pipe and Oil Seal

3 Head Gate Installation

4 Anchor Bolts

5 Galvanized Pipe Clamp(s)

6 Bronze Nut(s) and Stainless Steel Washer(s)

7 Valve Stem

Appendices

Appendix Description

A Inspection

B Hydrogate Head Gate 561 Installation, Operation, & Maintenance Manual

C Hydrogate Drawing Package – Head Gate 501 Series

GENERAL REQUIREMENTS

A. SCOPE OF WORK: The work to be performed under this project shall be the kind-for-kind replacement of deteriorating head gate assemblies of the Summitville Dam Impoundment. The work consists of removing heavily corroded steel head gate assemblies, oil seal packing assemblies, galvanized piping, pipe couplings, and grout base pads, inspection of existing anchors bolts, bronze nuts, stainless steel washers and steel valve stem material, and installation of stainless steel head gate assemblies with grout base pad, galvanized piping, and oil seal packing assemblies.

The Contractor, unless otherwise specified, shall furnish all materials, equipment, tools, labor, supervision and transportation necessary to complete the work in accordance with the following specifications and accompanying drawings and to provide a complete and functional project.

The contractor shall also collect and properly dispose of lubrication oil, corroded steel components and clean up the work site.

B. DEVIATIONS NECESSITATED BY OTHER STRUCTURES: Whenever obstructions or unseen damage not shown on the drawings are encountered during the progress of the work and interfere to such an extent that an alteration to the structure or components is required, the Engineer shall have the authority to change the structure or components. If the change to the structure or components results in an increase in the amount of work performed by the Contractor, such additional work shall be paid for on the basis of unit price bid for that item of work.

C. HANDLING OF MATERIALS: All materials furnished by the Contractor shall be delivered and distributed at the construction site by the Contractor.

Pipe and head gate assemblies shall be loaded and unloaded by lifting with hoists, or skidding, so as to avoid shock or damage to materials as well as to coatings. Under no circumstances shall such materials be dropped. Pipe or head gate assemblies handled on skid ways shall not be skidded or rolled against pipe already on the ground.

D. SANITARY FACILITIES: The Contractor shall provide and properly maintain acceptable sanitary facilities for all construction personnel and shall enforce the use thereof, unless otherwise directed.

E. POWER: All power for lighting, operation of the Contractor's plant or equipment, or for other use by the

Contractor, shall be provided by the Contractor at his sole expense, unless otherwise directed.

F. WATER: The Contractor will furnish all water required in connection with the work at his sole expense, unless otherwise directed.

G. ENGINEER'S AUTHORITY: The design engineer shall be referred to as the Engineer hereinafter. The

Engineer shall act as the Owner's representative during the construction period. He shall decide questions which may arise as to quality and acceptability of materials furnished and work performed. He shall interpret the intent of the plans and specifications in a fair and unbiased manner.

H. INSPECTION: The Engineer and his representatives will at all times have access to the work. In addition, authorized representatives of the Colorado Division of Water Resources (DWR) shall be permitted to inspect all work and materials without escort and at their own risk.

I. CHANGE ORDERS: All work shall be done in accordance with the plans and specifications unless altered by an approved change order. No change order will be considered approved until written approval of such change is received from the Owner and the Engineer.

No substantive change in the approved plans and specifications shall be made without prior written approval of the State Engineer, or his authorized representative.

J. FINAL CLEANUP: Before the work shall be considered complete, all rubbish, waste and unused materials due to or connected with the Contractor's activities shall be removed from the site of the work and the premises left in a condition satisfactory to the Owner and the Engineer. Final acceptance will be withheld until all cleanup and restoration work is completed and acceptance of the cleanup operation is evidenced in writing by a representative of the Owner.

K. DETAILED TECHNICAL SPECIFICATIONS: The detailed technical specifications which follow are identified by item number which refers to the items of work in the List of Quantities. Item numbers on the List of Quantities which are followed by a letter refer to the same item but a different material, size, class or division of work.

Items with numbers under 100 are items for which payments are typically made. Items with numbers over

100 are items of work for which payment will not made, but are included for the direction of the Contractor in performing such items of work which are subsidiary to and necessary for the satisfactory completion of the pay item to which they refer.

L. PROJECT COMPLETION: Construction on the project shall not be considered complete until written approval is obtained from the State Engineer, or his representative, and from an authorized Representative of the Owner. These approvals shall be requested by the Engineer only after his final acceptance of the work by the Contractor. After approval by all parties, the Project Engineer shall prepare and submit "As-

Built" drawings to the Owner and the State Engineer.

M. RED LINE DRAWINGS: The Contractor shall be responsible for maintaining a set of current as-built drawings on the project site reflecting up-to-date changes, site conditions and approved change orders.

LIST OF QUANTITIES

Item Description Quant. Unit

1 Removal of Material 1 l.s.

2a Galvanized Schedule 40 Pipe, 2 1/2” Diameter 64 l.f.

2b Galvanized Schedule 40 Pipe, 2 1/2” Coupling 2 ea.

2c Oil Seal Packing Assembly 2 ea.

3 Hydrogate Head Gate 561 Series Assembly Size 15”x15” 2 l.s.

LIST OF ADDITIVE ALTERNATE ITEMS

Item Description Quant. Unit

4a Removal & Installation, 1/2” Dia. x 18” Long Anchor Bolt 8 ea.

4b Removal & Installation, 5/8” Dia. x 8” Long Anchor Bolt 12 ea.

5 Galvanized Schedule 40 Pipe, 2 1/2" Pipe Clamps 8 ea.

6a Replacement of 1/2" Bronze Nuts 16 ea.

6b Replacement of 5/8” Bronze Nuts 24 ea.

6c Replacement of 1/2" Stainless Steel Washers 16 ea.

6d Replacement of 5/8” Stainless Steel Washers 24 ea.

7a Stainless Steel Valve Stem, 1 1/2” Diameter 18 l.f.

7b Cold Rolled Steel Valve Stem, 1 1/2” Diameter 48 l.f.

Note: For List of Additive Alternate Items, the quantities specified are for material with observed surface corrosion and upon inspection is to be replaced if deemed necessary by the Engineer.

Item 1 – REMOVAL OF MATERIAL:

1.1 SCOPE: This specification applies to the removing of corroded cast iron steel head gate assemblies, galvanized valve stem encasement pipe, pipe coupling, oil seal packing assembly, collection and proper disposition of oil.

1.2 GENERAL: The Contractor shall utilize safe and meticulous methods to remove existing and corroded material. Damage to working materials shall not occur.

1.3 Disassembly:

Removal of Hydrogate Head Gate 501 (HG501): The Hydrogate HG501 assembly gates shall be disconnected from the lift assembly by separation of the stem key from the stem block. With the stem key removed the valve stem can be separated from the slide gate. Remove the bronze nuts and stainless steel washers from each 5/8 inch diameter anchor bolt location to detach the slide gate and frame from the concrete base pad. Care shall be taken to remove the slide gate and frame from the grout pad as corrosion will make removal difficult.

Removal of Grout: The Contractor will utilize meticulous means to remove the existing 1 inch thick grout layer. Damage to the concrete base pad structure shall be minimal. Damage to the anchor bolts will be kept to a minimum to re-use in installation of the Hydrogate Head Gate 561 (HG561) assembly.

Inspection of Concrete Base Pad Anchor Bolts: Upon removing the existing Hydrogate HG501 head gate frame and slide and grout, inspection of each 5/8 inch diameter anchor bolt for damage or corrosion will be performed by the Engineer. If damage or corrosion is observed on the threads or body of the bolt, they may be identified for replacement, at the discretion of the engineer.

Removal of Oil Seal Packing Assembly: After the Hydrogate HG501 head gate frame and slide is removed, the oil within the galvanized steel encasement pipe will be collected and properly disposed.

The Contractor will implement means to collect all oil without spillage.

Removal of Galvanized Schedule 40 Pipe and Pipe Couplings: Two sections of galvanized steel encasement pipe, each section approximately 15 foot and 6 inches in length, and one pipe coupling will be removed and replaced from each lift assembly. The Contractor shall take care in removal of this pipe as to not damage the internal valve stem.

Inspection of Internal Valve Stem: After the galvanized steel encasement pipe has been removed the

Engineer will inspect the internal valve stem for any damage or corrosion. If damage or corrosion is observed, the valve stem may be identified for replacement, at the discretion of the Engineer.

Item 2 – GALVANIZED PIPE AND OIL SEAL:

2.1 SCOPE: This specification applies to the supply and installation of all galvanized schedule 40 pipe, pipe couplings and oil seal packing assembly as part of this project.

2.2 MATERIAL:

a. Galvanized Pipe and Coupling: Galvanized ANSI Schedule 40 pipe supplied under this specification shall conform to the requirements of ASTM A36 and shall be 2 1/2 inch inner diameter pipe. The

ANSI schedule 40 steel pipe and pipe couplings shall be galvanized per ASTM A123.

b. Pipe Thread Sealant:

Hydrogate recommends the following pipe thread sealants with Teflon:

A. Lo-Co Slic-Tite Paste

B. Dayton Pipe Thread Sealant with Teflon

C. McMaster-Carr Pipe Thread Sealant with Teflon

D. Any other commercially available pipe thread sealant containing Teflon

c. Oil Seal Packing Assembly: Oil seal packing assembly consists of Hydrogate supplied extra heavy pipe coupling, bushing, washers and packing.

2.3 INSTALLATION:

General: The Contractor shall employ for the work of installing the pipe only workmen who are skilled and experienced in fitting pipe with the types of joint furnished. The pipe shall be placed to the existing lines and grades shown on the drawings or established in the field by the Engineer or his representative.

Pipe Installation: Pipe shall be installed in the existing configuration as appropriate. Pipe shall be secured with existing pipe clamps and aligned to provide proper alignment of the lift assembly. The valve stem pipe must be in vertical alignment within 1/8 inch per each 10 feet of distance.

Pipe to pipe couplings shall be installed with Teflon tape.

Oil Seal Packing Assembly Installation: Oil seal packing assembly shall be installed per the manufacturer’s instructions and drawings. A copy of the installation instruction has been included for reference in Appendix C.

Oil Refill Installation: Refill oil within the valve stem encasement assembly with environmentally friendly lubricant suitable for the temperatures and use experienced. No oil leaks shall be present at pipe coupling connections or the oil seal packing assembly locations. Oil shall be added at the 1 inch pipe location at the oil fill assembly.

Item 3 – HEAD GATE INSTALLATION:

3.1 SCOPE: This specification applies to the supply and installation of the Hydrogate HG561 series slide gate, frame and appurtenances.

3.2 MATERIAL:

a. Slide Gate: Slide gate shall be a 15”x15” Hydrogate HG561 series model. The head gate assembly shall consist of a channel mount frame and slide gate. The slide shall be stainless steel type 304 and conform to ASTM A276 with necessary reinforcing ribs designed to withstand the maximum hydraulic head above the center of the gate. The seat and slide shall be supplied with seating surfaces constructed of polymer bars in guide grooves and UHMW seals. The frame or guides shall be of stainless steel type 304 and conform to ASTM A276 with provisions made in the slides and guides, by means of wedges or other approved devices to insure the practical water-tight seating of the gate when closed.

b. Grout: Grout used behind the slide gate frame shall be non-shrink, suitable for use in constantly wet environments, and have a compressive strength equal to or exceeding the concrete used.

3.3 INSTALLATION:

General: The head gate frame, slide and appurtenances shall be carefully installed in conformance with the manufacturer’s recommendations and related drawings so as to ensure satisfactory operation and life.

Surfaces of all metal against which grout will be placed shall be unpainted and free from all oil, grease, dirt, loose mill scale and flaky rust.

Head Gate Frame, Slide and Appurtenances: The head gate frame and slide shall be installed in a manner which will prevent leakage. Gates should be machined and adjusted before it leaves the factory. It should not be disassembled in the field before installation. The head gate slide must be in position in the wedge blocks to prevent springing of the seat casing during installation.

When the head gate frame and slide is installed, it should be placed on the anchor bolts with the slide engaging the wedge blocks. The valve stem at the head gate slide interface shall have a hole drilled into

it. Hole size and location will be provided by Hydrogate. The valve stem shall be connected to the head gate slide by a clevis type connection. Valve stem guides and lift appurtenances should be carefully aligned so that the valve stem, after being attached to the slide, is parallel to the guide angles.

The concrete surface against which the channel mount frame is to be installed shall be properly cleaned, prepared and grouted with non-shrink material following placement of the head gate slide and frame on the anchor bolts. A one inch grout layer behind the slide gate frame shall be placed, as indicated on the drawings.

The lift assembly shall be installed complete with valve stems, valve stem guides, concrete valve stem supports, and all other appurtenant apparatus. The lift shall be assembled and placed in correct alignment with relation to the head gate slide and valve stem, and the entire installation shall operate without binding.

After the head gate and lift appurtenances have been completely installed, the head gate slide shall be tested by the Contractor by raising and lowering through its full range of operation. The Contractor shall make any changes or adjustments that are necessary for the head gate slide and lift appurtenances to operate satisfactorily.

All outlet works shall be verified operational by the State Engineer’s office prior to complete filling of the reservoir.

Item 4 – ANCHOR BOLTS

4.1 SCOPE: This specification covers the supply and installation of anchor bolts.

4.2 MATERIALS:

a. Anchor Bolts: Anchor bolts supplied under this specification shall be stainless steel type 304 and conform to ASTM A276. Anchor bolt diameter, size, embedment depth, and locations can be found within the provided plan drawings.

b. Epoxy: Epoxy supplied under this specification shall be Hilti RE500, Simpson SET epoxy, or equivalent.

4.3 REMOVAL:

If anchor bolts are significantly damaged or corroded upon inspection they shall be replaced, at the discretion of the Engineer. Removal of anchor bolts shall be performed by coring methods. The maximum oversized hole shall be 1 1/8 inch in diameter.

4.4 INSTALLATION

Verify drilled anchor holes are to the required diameter and depth. Each drilled anchor hole shall be blown, brushed, and cleaned in accordance with the epoxy manufacturer’s instructions. When setting anchor bolt with epoxy maintain proper projection and alignment with anchor bolt layout. Hydrogate has indicated that the drilled holes on the HG 561 stainless steel frame will maintain current anchor bolt alignment.

Item 5 – GALVANIZED PIPE CLAMP(S):

5.1 SCOPE: This specification covers the supply and installation of galvanized schedule 40 pipe clamps.

5.2 MATERIALS:

Galvanized ANSI schedule 40 pipe clamps supplied under this specification shall conform to the requirements of ASTM A36. The schedule 40 2 1/2 inch diameter steel pipe clamps shall be galvanized per ASTM A123. Clamps shall be provided for the size of pipe and at the locations shown on the plans.

5.3 REMOVAL:

If the pipe clamps are significantly damaged or corroded upon inspection they shall be replaced, at the discretion of the Engineer.

5.3 INSTALLATION:

The pipe clamps will be installed, leveled, and aligned to provide proper alignment of the head gate lift assembly. The steel valve stem must be in vertical alignment within 1/8 inch per each 10 feet of distance.

Item 6 – BRONZE NUT(S) AND STAINLESS STEEL WASHER(S):

6.1 SCOPE: This specification applies to the supply and installation of bronze nuts and stainless steel washers.

6.2 MATERIALS:

a. Bronze Nut(s): Bronze nuts supplied under this specifications shall be of type 651 alloy and conform to the requirements of ASTM B98.

b. Stainless Steel Washer(s): Stainless steel washers supplied under this specification shall be of type

304 and conform to the requirements of ASTM A276.

6.3 REMOVAL

If the bronze nuts or stainless steel washers are significantly damaged or corroded upon inspection they shall be replaced, at the discretion of the Engineer.

6.4 INSTALLATION:

Bronze nuts in conjunction with stainless steel washers are used for fastening of pipe clamps and head gate frame to concrete anchor bolt connections. Bronze nut and stainless steel washer sizes and locations can be found within the provided plan drawings.

Item 7 – VALVE STEM:

7.1 SCOPE: This specification applies to the supply and installation of valve stem steel material.

7.2 MATERIALS:

a. Stainless Steel Valve Stem: 1 1/2 inch diameter stainless steel type 304 valve stem supplied under this specification shall conform to the requirements of ASTM A276.

b. Cold Rolled Steel Valve Stem: 1 1/2 inch diameter cold rolled steel grade 1045 valve stem supplied under this specification shall conform to the requirements of ASTM 108.

7.3 REMOVAL

If the valve stem is significantly damaged or corroded upon inspection it shall be replaced, at the discretion of the Engineer.

7.4 INSTALLATION

a. Stainless Steel Valve Stem: The Contractor shall install stainless steel valve stem material from the head gate past the oil seal packing assembly. The actual installed length may vary, the approximate length of stainless steel valve stem is 8 feet and 4 inches for each lift assembly. Refer to lengths and locations as shown on the Hydrogate Head Gate 501 series plans in Appendix C.

b. Cold Rolled Steel Valve Stem: The Contractor shall install cold rolled steel valve stem material that is encased within the galvanized pipe material. The actual installed length may vary, the approximate length of cold rolled steel valve stem is 24 feet for each lift assembly. Refer to lengths and locations as shown on the Hydrogate Head Gate 501 series plans in Appendix C.

APPENDIX A - INSPECTION

All inspection will be provided by the Engineer, a subcontractor to the Engineer, or under the direct supervision of the Engineer for the Owner.

Inspection is expected to be necessary during removal of corroded material and observation of uncovered material. All inspection efforts will be closely coordinated with the Contractor, and will be discussed in detail during the pre-construction conference.

APPENDIX B

Hydrogate Head Gate 561 Installation, Operation, & Maintenance Manual

(Fabricated Stainless Steel Gates G2500)

7010 Broadway, Suite 400 • Denver • Colorado • 80221 • (303) 288-8531 • 1-800-678-8228 www.hydrogate.com

Installation, Operation, & Maintenance Manual

HG561

Fabricated Stainless Steel Gates

G2500

DO NOT DISASSEMBLE GATE FOR INSTALLATION

Revised 4/9/13

TABLE OF CONTENTS

Cautionary Statement …………………………………………………….. i Foreword …………………………………………………………………… ii

INSTALLATION

Safety Precautions ………………………………………… 1 Things to Do and not to Do during Installation ……… General Mounting ……………………………………….. 3 Mounting the Gate on Concrete Surface with Adhesive Stub Anchors ……………………………………………………………

4-5

Wall Thimble Installation ………………………………….. 6-7 Installation on Thimble or Flange with Machined or Nonmachined face……………………………………………………………………..

8-9

Installation of Flush Bottom Closure Gates ……………… 10 Gate Stem and Guides Installation ………………………. 11-12 Lift Installation and Adjustment of Stem Guides ………… 13-14 Installation of Tandem Stem ……………………………… 15 Gate Adjustment ………………………………………….. 16-17

OPERATION

General Operation Information ………………………… 18 Heavy Duty Fabricated Gate Operation Procedures 18-19

MAINTENANCE

Maintenance and Lubrication ……………………………. 20-22 Maintenance Schedule and Lubrication Summary …… 22- List of Lubricants ………………………………………….. 23 Leakage ……………………………………………………. 24 Troubleshooting Tips …………………………………… 25-26 Long-Term Storage Instructions ……………………… 27 Warranty ……………………………………………………. 28

EXPLODED VIEW & PARTS LIST …………………….……….. 29

Spare Parts………………………………………………. 30

--------------------------------------------------------------------- HG561 Fabricated Slide Gates

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CAUTIONARY STATEMENT FOR INSTALLATION, OPERATION, &

MAINTENANCE MANUAL

This manual describes the recommended procedures for installation, adjustment, operation and maintenance of Hydro Gate gates. When it is used in conjunction with installation drawings that have been supplied by Hydro Gate, this manual will be sufficient for most installations. Proper care and precautions must be taken in handling and storing the gates at the delivery site. For further details on the handling, storing, and installation of a specific project, contact Hydro Gate's headquarters.

PRECISE AND ACCURATE INSTALLATION IS CRITICAL TO

SATISFACTORY OPERATION. HYDRO GATE ASSUMES NO LIABILITY,

EXPRESSED OR IMPLIED, FOR INTERPRETATION OF THE CONTENTS

OF THIS MANUAL. IF YOU HAVE ANY QUESTIONS CONCERNING THE

INTERPRETATION OF THE CONTENTS OF THIS MANUAL OR

INSTALLATION PROCEDURES IN GENERAL, YOU SHOULD CONTACT

HYDRO GATE'S COLORADO FACILITY. HYDRO GATE EXPRESSLY

DISCLAIMS ALL LIABILITY, EXPRESSED OR IMPLIED, FOR FAULTY

INSTALLATION OF ANY GATE OR ASSOCIATED EQUIPMENT AND FOR

ANY DIRECT, CONSEQUENTIAL, OR INCIDENTAL DAMAGES THAT

MAY RESULT.

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FOREWORD

The purpose of this Installation, Operation, and Maintenance Manual is to provide information on the correct procedures for installation, adjustment, operation, and maintenance of Hydro Gate HG561 Fabricated Stainless Steel Gates and their component parts.

The gate, lift, and accessories were accurately machined, fabricated, assembled, adjusted, and inspected before leaving the Hydro Gate Corporation factory. For best results, read and follow the applicable parts of this Manual carefully, including thorough cleaning and lubrication of moving parts and final wedge adjustment. If the gate will not be installed immediately, consult the long-term storage instructions following.

Installation Note Do not disassemble the gate or lift for installation.

Warranty Note Installation and/or operation of the gate lift and stem without proper lubrication will void the equipment warranty. Thorough cleaning of the stem and seating faces is required before gate operation. Details are described in the appropriate sections of this Manual.

Notes

Spare Parts – Hydro Gate does not recommend the stocking of spare parts. If spare parts are required see the last page. Replacement parts are readily available for worn or broken parts.

Contact Hydro Gate or our representative in your area.

Special Tools – Special tools are not required to operate and/or maintain the equipment supplied by Hydro

Gate on this project.

Price List – Prices for individual parts and/or assemblies may be obtained from Hydro Gate at the time that they are needed.

Disassembly – Hydro Gate does not recommend the disassembly/reassembly of any of the equipment on this project.

Emergencies – Emergency/shutdown procedures do not differ from normal operating procedures for this project. If you should need assistance, please contact Hydro Gate's Field Service Department at (303) 288-7873.

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INSTALLATION

Safety Precautions

To help ensure your workers' safety, Hydro Gate recommends the personnel responsible for installation, operation, and maintenance of the gates for this project read and study the instructions and precautions in the Installation, Operation, and Maintenance Manual, and follow all directions carefully. The following are major items associated with safe installation, operation, and maintenance of this slide gate.

Do not operate equipment before carefully reviewing the Installation, Operation, and Maintenance

Manual.

Always use proper equipment when lifting or unloading heavy items.

Do not stack equipment too high for storage. Always use heavy wood blocking between equipment.

Refer to the storage instructions contained herein for details.

Adequately support and brace heavy items during placement of equipment.

Wear proper personal protective equipment (PPE) and clothing when working on or around gates, (e.g., hard hats, heavy boots, safety glasses, and breathing apparatus, if necessary).

Never place bodily obstructions in the path of moving parts. When operating gates and accessories, stand clear of all moving parts. Serious injury can result from contact with moving parts.

Use caution when performing operations and maintenance. Watch for loose or damaged parts. Stop all functions until any damage has been corrected.

Do not use any mechanical devices other than the factory-supplied equipment to operate the gates for this project.

Do not attempt operational procedures other than set forth in the Installation, Operation and

Maintenance Manual.

Contact your Hydro Gate representative with any questions you may have regarding safety in installing, operating, and handling Hydro Gate products.

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Things To Do and Not To Do during Installation of This Gate

To properly install this gate, Hydro Gate recommends that personnel study these instructions and installation drawings and follow the installation directions carefully. This gate is shop adjusted, quality checked, and designed for low leakage. Attention must be given to proper storage, careful handling, and accurate location of embedded items for this gate to operate as designed.

Some DO'S and DON'TS to ensure proper gate installation.

DO – Read and follow the Installation instructions and drawings in this Manual.

DO – Carefully inspect the gates and accessories when received, before unloading trucks or cars.

Report ALL shortages or suspected damage by marking the Bill of Lading and Receiving Reports at this time. Latent shortages must be reported in writing within 30 days of shipment.

DO – Store gates evenly on planks or timbers. Even the heaviest castings are subject to permanent warpage if unevenly blocked during storage.

DO – Support full length of stems and protect threads during storage and handling.

DO – Accurately locate and brace embedded items during placement of concrete.

DO – Contact your Hydro Gate representative with questions regarding this gate. Hydro Gate and its related companies have 100 years combined experience in the water control industry.

DON'T – Disassemble the gates for installation.

DON'T – Allow excess concrete to overlap gate thimble or frame.

DON'T – Tighten nuts for studs unevenly, or try to pull a gate frame tightly against an uneven wall surface. This, in most cases, will cause excessive leakage.

DON'T – Operate gates with concrete and debris on them.

DON'T – Operate gate stems dry (without grease).

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General Mounting

HG561 Fabricated Stainless Steel Gates are most commonly mounted on stud anchor bolts and grout pads; however, they may also be mounted on a fabricated thimble or flange or on machined flanges and thimbles. The gate flange is not machined. A thick layer of hard setting mastic is required between gate and the thimble or pipe flange. Recommended mastic is polyurethane sealant such as Sika-Flex 1A or equivalent. Normal polyurethane sealants require 36+ hours setting time before submerging. Fast cure polyurethane sealants are available (These are glass and windshield setting compounds). They are a good alternative; however, their fast setting property requires quick, well-planned installation and clean up of hardened material is difficult.

Foam (Polyurethane) gasket may also be used. Consult Hydro Gate’s Engineering Department for additional information.

Installation Note Thin solid rubber gaskets are not satisfactory. Gaskets, gasket materials, and mastic are not furnished by Hydro Gate.

Flanges for gate mounting must be flat (non-warped) within +/- 1/16 inch. The gate can function with some twist/warp/non-flat conditions. The larger the gate, the more out-of-plane conditions can be tolerated.

Consult factory for extreme limits.

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Mounting the Gate on Concrete Surface with Adhesive Type Stud Anchors

1. Use only adhesive-type or epoxy-grouted studs. Mechanical wedge studs are not recommended and gate performance cannot be guaranteed with wedge-type studs. Hydro Gate usually furnishes the all-thread studs but does not furnish the adhesive capsules or cartridges.

Note Adhesive such as Hiti HY150 is not supplied by Hydro Gate due to its stringent storage requirements and limited shelf lifetime

2. Accurately layout positions of studs or use the gate as a template.

3. Drill holes to diameter and depth required for size studs used. If rebar is encountered during drilling causing an impossible completion of hole, consult the owner's site engineer for instructions on how to proceed. Cutting of rebar may not be permitted. In some cases, a new hole (or holes) may be field drilled in the gate frame to compensate for out of position studs. Consult Hydro Gate's Engineering Department for advice and limitations.

4. Blow and brush all holes clean according to adhesive system instructions and place studs with adhesive. Maintain proper projection and alignment and allow sufficient cure time, particularly in cold weather.

Safety Note Concerning Mechanical Studs Because of the dynamic/reversing load on the gates involving unseating or seating loads and the use of front and back nuts for alignment, wedge studs are not satisfactory since they require tension in them at all times to "grip" the concrete. The loss of "tension" in the wedge stud may cause them to fail.

5. Two nuts are provided for each stud bolt (Figure 1). These are for precise plumbing and alignment with a nut on both sides of the gate flange.

6. Check the placement and plumbness of pattern of stud bolts. Fit check the gate onto stud bolts.

Perform minor bending adjustment to studs, as needed.

7. Clean stud bolt threads. Apply anti-galling compound (anti-seize) and run one nut on each stud up to or near the concrete.

8. Establish a plumb/vertical plane with back nuts starting with the two upper corner stud bolt back nuts.

Leave room for grout and some in/out adjustment from the wall. With plumbline or builder's level and straight edge, bring all other nuts to a vertical plane established by upper corner nuts.

9. Being sure flange of gate is clean, place the assembled gate over/on the stud bolts. Run the front nuts on stud bolts until they touch the gate flange.

10. Take note of how well the gate frame fits the previously established flat vertical plane of back nuts on studs. Some variation of the free-hanging gate flatness is normal (1/8 inch in small/medium sized gates; 1/4 inch in large gates).

11. Tighten the front nuts on side studs until frame contacts back nuts. Tighten the two nuts against each other, against the frame flange.

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12. Note that the gate slide should be in tight contact with seals at horizontal frame members. Some curvature or non-flatness of frame member may be required for good seal contact with the slide.

Tighten front and back nuts up to the flange while observing that no gap between the slide and horizontal frame seal exists or develops.

13. Grouting of gate frames is not recommended until after the lift and stem has been installed and gate has been cycled open/close to ensure smooth operation.

14. After operation has been verified, carefully pack the space between the gate and the wall around the opening with "non-shrink" grout. Alternatively, the space may be formed and slurry grouted with concrete. Grouting behind the frame guide (legs) extensions is not necessary.

15. Be sure the frame extension stud bolts are in place and front and back nuts are tight and hold the frame stable.

Figure 1 – Top View of Stud Bolt Mounting

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Wall Thimble Installation

1. Place the wall thimble in the correct position in the forms and block it in this position. The top centerline of the thimble is stamped on its flange face. The bottom centerline is also marked

2. Plumb the front face of the thimble using the marks indicating top and bottom centerline. This face should be plumbed with respect to final location of the gate, stem, and lift. “Plumb” is a relative term.

More precisely the thimble gate and operating system consisting of stem, stem guides and lift must be in close co-linear alignment for smooth operation. Alignment tolerance is + or – 1/8” over the travel of gate (gate opening height). True or perfect plumb is primarily for esthetics and simplification of installation and alignment.

3. Studs furnished for attaching the gate may be used in the attachment of the thimble to the forms. If these studs are not used, threaded holes in the thimble must be plugged to prevent concrete from entering them.

4. Use timbers or other bracing material on the inside opening of the thimble while concrete is being poured (Figure 2).

Installation Note Use extreme care in placing of these supports to prevent warping of the thimble.

5. Pour concrete, being careful not to tilt the thimble from its original position in the forms.

6. Remove forms and bracing.

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Figure 2 – Front and Side View of Thimble Showing Bracing

Block out for top anchors or place J-bolt anchors in form

See installation drawing for location.

Provide timber blocking as required to support thimble during pouring.

Plumb thimble in forms using top and bottom.

for concrete pour.

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Installation on Thimble or Flange with Machined or Nonmachined Face

1. Clean face of thimble with scrapers and wire brush so no sand, concrete, dirt, or foreign material are present (Figure 3).

2. Check for plumb, flatness, and warp with builder's level or straight edges. Flatness should be within +/-

1/16 inch. If not, consult Hydro Gate’s Engineering Department or Field Service Department for recommendations.

3. Install mounting studs in thimble/flange face.

4. Fit check the gate onto the thimble to be certain the gate sits well on its face without obstruction from surrounding concrete. The frame extensions are in the same plane as the gate-opening flange;

therefore, some local chipping of the concrete wall above the opening may be needed to avoid distortion of the frame extensions.

5. Apply heavy layer of hard-setting mastic. Trowel out or otherwise spread mastic so entire contact face of frame flange will be covered. A layer 1/16 inch to 1/8 inch thick is usually sufficient. Excessive thickness results in more cleanup; too thin may result in flange leaks. Recommended mastic is polyurethane sealant such as "Sika-Flex 1A", "Bostik 920 marine grade polyurethane", "Devcon Flexane 80 trowelable grade putty", or equivalent. Asphalt (tar) mastic may be used in lieu of polyurethane except in potable water.

Normal polyurethane sealants require 36+ hours setting time before submerging. Fast cure polyurethane sealants such as "Bostik 920 Fast Set" or "ADCO Fast Cure" are available (These are glass and windshield setting compounds). They are a good alternative; however, their fast setting property requires quick, well-planned installation and cleanup of hardened material is difficult. Foam (Polyurethane) gasket 1/2 inch thick may also be used. Consult Hydro Gate’s Engineering Department for additional information.

Note Mastic due to its limited shelf life is not supplied by Hydro Gate.

6. Mount the gate over studs, install nuts and tighten. Anti-seize compound is recommended. See Torque Table for approximate bolt nut tightening. Precise torque tightening is not required.

7. Check the squeeze-out of mastic on the inside and outside of the flange. No squeeze-out indicates insufficient mastic and likelihood of future leak. Clean off excess mastic.

8. Allow sufficient cure time of mastic before applying water pressure to the gate.

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Torque Table for Tightening Nuts or Hex Bolts Used for Assembly

Cap screw diameter (Inches)

Torque to be applied (Pound feet)

3/8 20

1/2 45

5/8 75

3/4 125

7/8 200

1 300

1 1/8 450

1 1/4 500

1 1/2 600

Figure 3 – Front Cross Section of Fabricated Thimble

Tapped Hole

Clean Front Machine Face

"F" Wall Thimble Typical Thimble Installation in Thimble.

Concrete or Grout.

of Thimble.

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Installation of Flush Bottom Closure Gates

Gates that are to be installed with bottom frame members embedded in the concrete are furnished with a rubber seal attached to the invert of the gate frame (Figure 4). The top surface of the rubber seal is installed at the same elevation as the invert of the gate opening. Refer to the Hydro Gate installation drawing.

1. Form a recess for the bottom of the gate in the original pour of concrete. The dimensions of this recess are shown on the installation drawing.

2. After the forms are stripped, install the gate as shown for other types of installations in this Manual.

Figure 4 – View of Gate Slide and Invert Surface

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Gate Stem and Guides Installation

1. Install the stud bolts for the lift and stem guides as shown on the installation drawings. Check for proper alignment of the lift, stem guides, and gate. The lift stem and gate stem block must be in vertical alignment within 1/8 inch per each 10 feet of distance.

2. Provide opening with adequate clearance in the lift platform for the gate stem.

3. Install stem guide brackets on studs, but do not tighten nuts; leaving them loose so the bracket can be moved for later alignment. Loosen all assembly bolts holding the collars to the bracket. Stem guide collars are 2-piece construction.

4. When more than one gate is to be installed, stems may be of different diameters or lengths. Stems are marked and/or tagged for each installation. Separate the stems per individual gate installation.

Installation Note Exercise care when handling and installing threaded stems; nicks or burrs will damage lift nut threads.

5. Insert the stem block into the gate slide pocket.

6. Stems may be in more than one piece to facilitate shipment and installation. If two or more pieces are furnished for an installation, they must be installed in their proper order from bottom to top to place splices in correct location so they will not interfere with the stem guides when the gate is opened or closed. Measure the stem section lengths and install.

7. Lower the bottom section of the stem into place through the hole of the gate slide and thread it all the way into the block and align the keyways (Figure 5).

Installation Note Immediately insert the key to lock the bottom section of the stem to the block. (The key is omitted on non-rising stem gates as the turning motion is between the block and the stem.)

8. Place all of the succeeding stem sections. Double-check the installation drawings to ensure that the stem guide collars are in place. Join together with splices as provided (Figure 6).

Safety Note Insert all bolts or keys in each stem splice immediately after sections are installed and aligned to prevent one section disconnecting from another when the gate is operated.

9. Immediately before lowering the lift over the threaded portion of the stem, remove the protective wrapping from the stem and thoroughly clean off all foreign material.

10. Lubricate stem threads with recommended lubricants. Do not leave lubricated stem exposed to contamination before completing the installation.

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Figure 5 – Stem Connections to Gate

Figure 6 – Stem with Splice

Stem

Key

Stem Splice

Stem block

K ey

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Lift Installation and Adjustment of Stem Guides

1. Clean the threaded section of the stem, removing all foreign material, and lubricate with recommended lubricant as described in the “Gate Stem and Guide” section of this Manual.

Warranty Note Operation of the gate assembly without proper lubrication of the stem will void the equipment warranty.

2. Raise the lift and lower it over the previously installed and lubricated threaded stem section. When starting threaded stem into the bottom of lift nut, care must be taken to avoid damage to the threads. Rough handling may result in damage to the bottom edge of the threaded lift nut and prevent the stem from being threaded into the lift nut freely. Hold the lift to prevent its rotation. Turn the handwheel or crank to lower the pedestal onto its stud bolts.

Installation Note: When all parts are cleaned, the threaded lift nut will turn onto the threaded stem with very little effort.

3. Using shims, double nuts on studs, or other leveling devices under the lift, align the centerline of the lift nut until parallel with the stem centerline. Vertical alignment of gate stem and the gate slide stem block must be within 1/8 inch per 10 feet of distance. Tighten nuts on the studs uniformly.

4. The crank should turn freely for two or three turns in each direction until the clearance between the top or bottom of the stem block in the gate slide is taken up. If any binding occurs during operation of the lift with the slight vertical movement of the gate slide, the stem alignment should be checked. Slight misalignment will cause undue wear to the threaded lift nut. When binding is not caused by misalignment, recheck to be certain all threads on the stem and in lift nut are clean.

5. Place the two-piece stem guide collars around the stem above each bracket. Place the bolts through the projection of the bracket and the ends of the collars. Do not tighten the bolts.

6. Grout under the lift (if required). After the grout has set, tighten the stud bolts uniformly.

Installation Note Before opening the gate, clean all grout, stones or other foreign material from the top of the gate (or bottom in the case of a downward opening gate).

7. Turn the lift crank or handwheel to open the gate, until the gate slide has moved at least 2”. The stem is now in tension. Check the stem to be certain it is straight. Tighten the nuts on the studs through the stem guide brackets, center the stem guide collars around the stem, and tighten the assembly bolts holding the collars in position on the brackets.

8. Move the gate to its fully opened position and check the position of the stems. If the stem is being deflected by the collars, a stem alignment problem exists and must be corrected, indicating the gate may not be plumb. Consult Hydro Gate for ways to correct or compensate for this condition.

9. Lower the gate to fully closed position. Run the stop nut down on top of the projecting threaded stem until it contacts the top of the lift nut or stem cover holder. Back the nut up until 1/16 to 1/8-inch gap appears between the lift and the stop nut to allow complete gate closure as sliding and bearing surfaces wear in.

10. Tighten the setscrews through the stop nut to hold it in place (Figure 7).

11. Install the stem cover, indicator, etc., as required.

12. Check to see if the gate slide is making full contact across the bottom invert seal.

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Figure 7 – Handwheel and Stop Nut

Figure 7 – Removable CRANK

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Installation of Tandem Stems

Some gates have wide openings with relatively short gate heights. When the installation drawings show tandem lifts, install each lift in accordance with the preceding steps 1 through 5. After each lift has been installed and each stem is connected to the gate slide at the bottom and the lift at the top, proceed as follows:

1. Turn the input shaft of each lift in the direction to open the gate until each stem makes firm contact with the top of its connection on the gate slide.

2. Place a level on the top of the gate slide and move one stem or the other of the gate up or down until the slide is completely level.

3. A tandem interconnecting shaft is furnished to connect the two lifts and cause them to act in unison for raising or lowering the gate. Loosen the fasteners on one of the jaws of the flexible coupling and slide it toward the center of the shaft until the shaft can be connected between the two lifts. Complete the connection and retighten all fasteners.

4. Move the gate slide up and down by turning the input shaft of one lift. Ensure the gate is installed with its top level and that the gate is moving freely.

5. Complete the installation of any stem guides, lubricate the stem, adjust the stop nuts, etc, as described in the preceding steps 1 through 9 in the section entitled Lift Installation and Adjustment of Stem Guides for Gates Not Self-Contained.

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Gate Adjustment

This gate is equipped with low-friction polyethylene (UHMWPE) seats and guides. The seats rest on a neoprene (rubber) pad for cushioned Gasketing to the frame. Sealing at the side is accomplished by pinching the seal lips against the slide plate using the compression of the rubber gasket pad. Top horizontal member seal (and also bottom, if standard bottom) are loaded by the compression pad and assisted with adjustable hook-type wedges on medium and larger width gates (Figures 9and 10).

This gate has been factory adjusted. However, if the shake-proof nuts have been loosened, readjustment may be required.

Visual Tightness of the Seat against the Side

No light should be visible through the seat or measurable gaps between the slide plate and the seat. A .004 inch gauge may be used to check the seat gap as a starting point; however, the best test and proof of performance is an unseating hydrostatic test. This gate is required to comply with AWWA C561 leakage specifications.

Figure 9 – Top View of Side Section Seal Configuration

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Figure 10 – Side View of Bottom Section Showing Seal Arrangement

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OPERATION

General Operation Information

HG561 Fabricated Stainless Steel Gates are used to control flow of or retain a volume of water, effluent, or other fluids. Typical applications include industrial water treatment facilities, municipal water treatment facilities, irrigation, dams, flood control, and many other…