Enclosure 2 - CPCS Technical Specifications.pdf

Enclosure 2 – Technical Specifications

TABLE OF CONTENTS

Division 05 – METALS

05 50 03.00 12 Metalwork Fabrication, Machine Work, and Miscellaneous

Provisions

Division 26 – ELECTRCIAL

26 05 19.00 12 Insulated Wire and Cable 26 20 00 Interior Distribution System 26 42 19.10 01 Cathodic Protection Systems (Impressed Current) For

Sector Gates

Division 40 – PROCESS INTERGRATION

40 60.00 Process Control

Division 41 – MATERIAL PROCESSING AND HANDLING EQUIPMENT

41 24 26 Hydraulic Power Systems

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. 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 MEASUREMENT AND PAYMENT

No measurement will be made for miscellaneous metalwork required by this section. Payment will be made at the contract job price for "Miscellaneous Metalwork". Price and payment shall constitute full compensation for furnishing of all plant, equipment, labor and materials required to complete the metal work; as specified herein and as shown on the drawings.

1.3 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.

AEROSPACE INDUSTRIES ASSOCIATION / NATIONAL AEROSPACE STANDARD

(NAS)

NAS1330 (11 Apr 2000) Nut, Blind Rivet - Countersunk Head, Internal Thd, Non-Locking (Free-Running) and Self-Locking (Prevailing Torque)

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

AISC 325 (2017) Steel Construction Manual

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 36/A36M (2019) Standard Specification for Carbon Structural Steel used in general construction and structural applications

ASTM A53/A53M (2020) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

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

ASTM A153/A153M (2016a) Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware

ASTM A193/A193M (2020) Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service and Other Special Purpose Applications

ASTM A194/A194M (2020a) Standard Specification for Carbon Steel, Alloy Steel, and Stainless Steel Nuts for Bolts for High-Pressure or High-Temperature Service, or Both

ASTM A252 (2019) Standard Specification for Welded and Seamless Steel Pipe Piles

ASTM A276/A276M (2017) Standard Specification for Stainless Steel Bars and Shapes

ASTM A280 (2018) Standard Specification for SEAMLESS

CHROMIUM-MOLYBDENUM ALLOY-STEEL PIPE FOR

SERVICE AT HIGH TEMPERATURES

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

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

ASTM A488/A 488M (2007) Standard Practice for Steel Castings, Welding, Qualifications of Procedures and Personnel

ASTM A514/A514M (2018) Standard Specification for High-Yield-Strength, Quenched and Tempered Alloy Steel Plate, Suitable for Welding

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

ASTM A 563/A563M (2021) Standard Specification for Carbon and Alloy Steel Nuts (Inch and Metric)

ASTM 572/A572M (2018) Standard Specification for High-Strength Low-Alloy Columbium-Vanadium Structural Steel for plates used in general construction and structural applications

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

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

ASTM A 780/A 780M (2009) Standard Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings

ASTM E 94 (2004) Standard Guide for Radiographix Examination

ASTM E 186 (1998(2004el) Standard Reference Radiographs for Heavy Walled (2 to 4 1/2

in. (51 to 114 mm)) Steel Castings) Standard Guide for Radiographix Examination

ASTM E 446/ (1998(2004el) Standard Reference Radiographs for Heavy Walled (2 to 4 1/2

in. (51 to 114 mm) Steel Castings

ASTM E 709/ASTM E709 (2015) Standard Guide for Magnetic Particle Examination (2008) Standard Guide for Magnetic Particle Testing

ASTM F 436/ASTM F436 (2011) Hardened Steel Washers

(2009) Standard Specification for Hardened Steel Washers

ASTM F 467/ASTM F468 (2016) Standard Specification for Nonferrous Bolts, Hex Cap Screws, and Studs for General Use

(2008a) Standard Specification for Nonferrous Nuts for General Use

ASTM F467 (2013; E 2014; E 2014) Standard Specification for Nonferrous Nuts for General Use

ASTM F 593/ASTM F593 (2017) Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs

(2002(2008)) Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs

ASTM F 594/ASTM F594 (2009; R 2020) Standard Specification for Stainless Steel Nuts

(2008) Standard Specification for

Stainless Steel Nuts

ASME INTERNATIONAL (ASME)

ASME B18.21.1 (1999(2005)) Lock Washers (Inch Series)

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2008) Structural Welding Code - Steel

AWS D1.2/D1.2M (2008) Structural Welding Code - Aluminum

AWS D1.5 (2008-Errata) Bridge Welding Code

AWS D1.6 ((2007) Structural Welding Code - Stainless Steel

AMERICAN SOCIETY OF NONDESTRUCTIVE TESTING (ASNT)

ASNT-TC-1A (2015) Specificatnion for employers to establish in-house cerfication programs

ASNT-CP-189 (2014) Specificatnion for establishing minimum requirements for the qualifications

U.S. GENERAL SERVICES ADMINISTRATION (GSA)

FS FF-S-85C(3) (1996) Screw, Cap, Slotted and Hexagon Head

FS FF-S-200A(3) (15 Apr 1994) Setscrews: Hexagon Socket and Spline Socket, Headless

FF-W-92B(1) (9 May 1974) Washer, Flat (Plain)

RESEARCH COUNCIL ON STRUCTURAL CONNECTIONS (RCSC)

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

U.S. DEPARTMENT OF DEFENSE (USDOD)

NASM17830 Nut, Self-locking, Hexagon-Regular, 250ºF and 450°F, Non-Metallic Insert,300 Series

CRES

1.2 SUBMITTALS

Submit the following in accordance with the PWS:

SD-02 Shop Drawings

Shop Drawings

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.

Welding Procedure Specifications (WPS)

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

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)

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

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

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 procedure shall be modified to reflect the requirements of the project.

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 and shown on the drawings. 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.

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.

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.

2.1.2.2 Nuts

Nuts shall be hex nuts meeting the requirements of ASTM A 563, Grade A, heavy hex style.

2.1.2.3 Cap Screws

Cap screws shall conform to the applicable provisions of FS FF-S-85C(3), Type I, Style 2s, or Type II, Style 10p, Grade 2, standard thread unless indicated otherwise on the drawings or in another section of the specifications.

2.1.2.4 Washers

Washers shall meet the requirements of ASTM F 436.

2.1.2.5 Ogee Washers

Ogee washers shall be cast iron.

2.1.2.6 Lock Washers

Lock washers shall meet the requirements of ANSI/ASME B18.21.1. Washers shall be heavy helical spring-lock washers as specified in Table 2 of

ANSI/ASME B18.21.1.

2.1.2.7 Anchor Bolts

Anchor bolts shall conform to ASTM F1554, Grade 36, unless otherwise noted on the contract drawings. Nuts and washers for anchor bolts shall be as specified in paragraph 2.1.2.2 and 2.1.2.4 above.

2.1.2.8 Galvanizing

Bolts, nuts and washers shall be hot-dipped galvanized in accordance with

ASTM A 153/A 153M.

2.1.3 Stainless Steel Bolts, Hex Cap Screws, Nuts, Washers, and Set Screws

2.1.3.1 Bolts and Hex Cap Screws

Stainless steel bolts and hex cap screws shall conform to ASTM F 593, Group 2, Alloy 316, Condition CW.

2.1.3.2 Nuts

Nuts shall conform to ASTM F 594, Group 2, Alloy 316, Condition CW.

2.1.3.3 Lock Nuts

Lock nuts shall be nylon insert nuts conforming to NASM17830, Alloy 316.

2.1.3.4 Washers

Washers shall conform to Fed. Spec. FF-W-92B(1), Type A, Grade 1 (Sizes:

Light and Heavy), Class B (Alloy 316).

2.1.3.5 Lock Washers

Lock washers shall meet the requirements of ANSI/ASME B18.21.1. Washers shall be heavy helical spring-lock washers as specified in Table 2 of ANSI/ASME B18.21.1. Material for washers shall be Alloy 316 stainless steel.

2.1.3.6 Stainless Steel Set Screws

Stainless steel set screws shall conform to Fed. Spec. FF-S-200A(3), Type I, Style 1, Alloy 304.

2.1.3.7 Turned Bolts

Turned bolts and pintle anchor bar shall be made from steel meeting the requirements of either ASTM A 276, Type 304193/A 193M, Grade B7 or ASTM B 164. Nuts for turned bolts shall meet the requirements of either ASTM A 194/A 194M, Grade 8MN, Type 316 or ASTM F 467, Alloy CU 464. Hinge turned bolts shall have bolt threads covered with an approved anti-seize lubricant upon installation.

2.1.3.8 Stainless Steel Internally Threaded Rivets

Stainless steel internally threaded rivets shall be countersunk head, open or closed end, and conform to NAS1330.

2.2 Steel Handrails

Rails and posts shall consist of nominal size schedule 40 steel pipe conforming to ASTM A 53/A 53M Grade B. Posts shall not be spaced more than five (5) feet on center and shall be located at all corners and changes in direction. All steel handrail shall be hot dipped galvanized after fabrication as specified herein and in Section 05 50 03.00 12, "METAL

FABRICATION AND MISCELLANEOUS PROVISIONS".

2.3 Grating

Grating shall be fabricated to span the opening required and shall support a uniform design load of one hundred (100) pounds per square foot. Grating shall be designed in accordance with NAAMM MBG 531 and/or NAAMM MBG 532 to meet the indicated load requirements. Edges shall be banded with bars 1/4 inch less in height than bearing bars for grating sizes above 3/4 inch.

Banding bars shall be flush with the top of bearing grating. Grating bars shall be connected together by cross bars that are swaged on either side of the bearing bars. Grating bars shall have a serrated surface for foot traffic and shall have a minimum of one and a quarter (1 1/4) inches deep by one eighth (1/8) inch wide and spaced at maximum one and three-sixteenths (1 3/16)inch centers. At maximum span, the grating shall have a safe uniform load capacity of at least one hundred (100) pounds per square foot, with a mid-span deflection of one quarter (1/4) inch or less.

All grating shall be secured on twenty (20) inch on center spacing with Type 316 stainless steel saddle type clips and fastened to the support frame.

2.3.1 Steel Grating

Grating shall be fabricated from either ASTM A36/A36M or ASTM A 572/A 572M steel and shall be galvanized after fabrication in accordnace with Section

05 50 03.00 12, "METAL FABRICATION AND MISCELLANEOUS PROVISIONS".

2.4 Pipe Sleeve

Pipe shall be sized as shown in the drawings and shall conform ASTM A 252, Grade 3. Pipe shall be seamless or welded; spiral welded pipe is prohibited.

2.5 Plates & Shims

Plates and shims shall conform to ASTM A 572/A 572M, Grade 50.

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 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 Government Representative. 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.

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 in Section 35 20 16.60 12 SWING GATES of these specifications 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, Subsection 5.15 and approved WPS for non-fracture critical member welds or in accordance with AWS D1.5, Subsection 12.10 and approved WPS for fracture critical member welds.

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 that are to be exposed or visible shall be chipped, ground or machined to sound metal. In all 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. Splices, not designated on the drawings, shall be submitted to the Government Representative for approval.

3.2 CASTINGS

3.2.1 General

Each casting shall bear cast or stamped mark numbers. Castings weighing more than five hundred (500) required pounds shall also bear cast or stamped heat numbers. Deviations from the dimensions of castings shown on the drawings shall not exceed amounts that will impair the strength of castings by more than ten percent (10%) as computed from the dimensions shown. Dimensions of castings shown on approved shop drawings shall be finished dimensions. Castings that are warped or otherwise distorted or that are oversize to an extent that will interfere with proper fit with other parts of the machinery or structure will be rejected. The structure of metal in castings shall be homogeneous and free from excessive nonmetallic inclusions. Excessive segregation of impurities or alloys at critical points in castings will be cause for rejection. Repairs to castings shall not be made prior to approval. Minor surface imperfections not affecting the strength of casting may be welded in the "green" if approved. Surface imperfections shall be considered minor when the depth of the cavity prepared for welding is the lesser of twenty percent (20%) of the actual wall thickness or one (1) inch. Defects other than minor surface imperfections may be welded only when specifically authorized in accordance with the following requirements:

(1) The defects have been entirely removed and are judged not to affect the strength, use or machinability of the castings when properly welded and stress relieved.

(2) The proposed welding procedure, stress relieving and method of examination of the repair work have been submitted and approved.

Repairs shall be in accordance with ASTM A 488.

3.2.2 Inspection

The Contractor shall perform seventy-five percent (75%) radiographic inspection of all steel castings. The procedure for making, evaluating and reporting the radiographic inspection shall conform to the requirements of ASTM E 94. Radiograph film shall be in the density range of 1.5 to 4 H&D with a 2-2T Quality Level. The castings shall be unacceptable if shown to have defects of greater severity than the applicable reference standard specified in the following table:

DISCONTINUITY SEVERITY LEVELS

CATEGORY

A 4 B 4 C 4 D-G *

* Discontinuities in Categories D through G are not allowed except as noted in paragraph 3.2.1, above.

The results of the radiographic inspection shall be submitted to the Contracting Officer as soon as possible. Depending upon the defects found in a casting, the Contractor Officer may require the Contractor to perform radiographic inspection on the remaining twenty-five percent (25%) of that casting. Standards of acceptance shall be in accordance with the provisions of ASTM E 446, ASTM E 186 and ASTM E 280. The evaluation of the radiographs shall be subject to the approval of the Government Representative and all records including film shall become the property of the Government.

3.2.3 Repair

Unsound material shall be removed from the surfaces of steel castings to be incorporated into welded connections by chipping, machining, air-arc gouging or grinding. Major connections designed for transfer of stresses shall not be welded if the temperature of the casting is lower than 100 degrees Fahrenheit. Castings containing over 0.35 percent carbon or over

0.75 percent manganese shall be preheated to a temperature not to exceed 450 degrees Fahrenheit and welding shall be accomplished while the castings are maintained at a temperature above 350 degrees Fahrenheit. Welding will not be permitted on castings containing carbon in excess of 0.45 percent except on written authorization by the Government Representative. Castings requiring welding repairs after the first annealing and castings involving welding fabrication shall be stress-relieved annealed prior to receiving final machining unless otherwise permitted by the Government Representative.

3.3 PATTERN

In the construction of patterns, care shall be taken to avoid sharp corners or abrupt changes in cross section, and ample fillets shall be used. The Contractor shall add such draft and increases in pattern thicknesses as will conform to his standard foundry practice and as may be necessary to insure that all metal thicknesses of the finished castings conform to the dimensions shown on the drawings, within the tolerances specified in paragraph "Dimensional Tolerances for Structural Work." Patterns shall be furnished by the Contractor and shall be turned over to the Government Representative at the end of the contract.

3.4 STEEL WELDING

3.4.1 Structural Steel

3.4.1.1 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.

3.4.1.2 Welding Equipment

All items of welding equipment shall conform to the requirements of

AWS D1.1/D1.1M.

3.4.1.3 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 and approved WPS.

3.4.1.4 Welding Procedure Specifications (WPS)

The Contractor shall prepare for submission to the Contracting Officer a 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. A CWI or NDT Inspector meeting the qualification stated herein shall approve all WPS's and PQR's.

The CWI's or NDT Inspector's signature and if applicable stamp shall be on every WPS and PQR submitted.

3.4.1.4 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.

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. A CWI or NDT Inspector meeting the qualification stated herein shall approve all Welder Qualifications. The CWI's or NDT Inspector's signature and if applicable stamp shall be on every WPS and PQR submitted.

3.4.1.5 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 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.

3.4.1.6 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.

3.4.1.7 Inspection

Weld inspection is the responsibility of the Contractor. 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 below subparagraph "Repairs".

b. Nondestructive Testing - Fillet and Partial Penetration Welds - Inspection shall be in accordance with paragraph "Nondestructive Examination". The Contractor shall test all fillet welds and partial penetration welds where indicated on the drawings.

Additionally, there will be twenty-five percent (25%) random testing of the remaining fillet and partial penetration groove welds. This testing shall be done by the magnetic particle testing procedures. This additional twenty-five percent (25%) shall include a representative sample of welds from all welders and each of the processes each welder used. The random testing shall be spread throughout the project. A schedule will be developed during the preconstruction meeting for the random testing and this schedule shall be included in the Contractor's Quality Control Plan. (d)

c. Nondestructive Testing - Full Penetration Welds - Inspection shall be in accordance with paragraph "Nondestructive Examination". The Contractor shall test all full penetration welds where indicated on the drawings. Additionally, there will be twenty-five percent (25%) random testing of the remaining full penetration groove welds. This testing shall be done by ultrasonic testing (UT) and/or radiographic testing (RT) procedures. This additional twenty-five percent (25%) shall include a representative sample of welds from all welders and each of the processes each welder used. The random testing shall be spread throughout the project.

A schedule will be developed during the preconstruction meeting for the random testing and this schedule shall be included in the Contractor's Quality Control Plan. (d)

d. Acceptance of Welds - Welds shall be unacceptable if shown to have defects prohibited by AWS D 1.1/D 1.1M, Section 6, Part C. Visual and magnetic particle testing acceptance criteria shall be for the applicable criteria for either "Cyclically Loaded Nontubular Connections" or "Tubular Connections" per AWS D 1.1/D 1.1M, Table

6.1. Ultrasonic acceptance criteria shall be the applicable

criteria for either "Cyclically Loaded Nontubular Connections" or "Tubular Connections, Class R". The RT will have to meet the applicable criteria for either "Cyclically Loaded Nontubular Connections (Tensile Stress)" or "Tubular Connections".

e. 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).

f. 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.

g. 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.

h. 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.

3.4 STUD WELDING

Stud welding, unless otherwise specified shall conform to the applicable provisions of AWS D1.1/D1.1M, Section 7, AWS D1.2, Section 6, or AWS D1.6, Section 7 as applicable

3.4.1 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, AWS D1.2, Section 6.2, AWS D1.6, Section 7.

3.4.2 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 AWS D1.1/D1.1M, Section 7.4, AWS D1.2, Section 6.4, or AWS D1.6, Section 7.6, as applicable. The test specimens shall be prepared using suitable specimen plates of the same base metal to which the studs are to be welded.

3.4.3 Workmanship

The studs shall be welded in accordance with the provisions of Article 7.4 of AWS D1.1/D1.1M, Section 7.4, AWS D1.2, Section 6.3, or AWS D1.6, Section 7.4, as applicable. 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.

3.4.4 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."

3.4.5 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, AWS D1.2, Section 6, or AWS D1.6, Section 7. 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.

3.7 NONDESTRUCTIVE EXAMINATION

The nondestructive (NDT) examination of welds shall be performed as designated on the drawings and/or described in the sections of these specifications covering the particular items of work.

3.6.1 Testing Personnel

Certified Welding Inspectors (CWI) shall be qualified and certified in accordance with the provisions of AWS QC1. The NDT Level III who certified the Level I and Level II Technicians performing nondestructive testing shall be qualified in accordance with ASNT CP-189. Only individuals qualified for NDT Level II or individuals qualified for Level I and working under the direct supervision of a Level II shall perform nondestructive testing. NDT Level I and Level II Technicians shall be certified to either ASNT-TC-1A or ASNT CP-189. Level III NDT Inspectors shall posses a currently valid ASNT Level III certificate in each of the processes they are qualifying inspectors to. Copies of the certifications, including the Level III NDT Technician that certified the Level I and Level II Technicians shall be included in the submittals.

3.6.2 Examination Procedures

3.6.2.1 Ultrasonic Testing

Making, evaluating and reporting ultrasonic testing of welds shall conform to the requirements of AWS D1.1/D1.1M, Section 6, Part F, AWS D1.2, Section 5, Part C, AWS D1.5 , Subsection 12.16, or AWS D1.6, Section 6, Part C, as applicable.

3.6.2.2 Radiographic Testing

Making, evaluating and reporting radiographic testing of welds shall conform to the requirements of AWS D1.1/D1.1M, Section 6, Part E, AWS D1.2, Section 5, Part B, AWS D1.5, Subsection 12.16, or AWS D1.6, Section 6, Part B,as applicable. Only film types designated as "fine grain" or "extra fine" shall be employed.

3.6.2.3 Magnetic Particle Inspection

Magnetic particle inspection of welds shall conform to the applicable provisions of ASTM E 709 or AWS D1.5 Subsection 12.16, as applicable and in addition all magnetic particle inspections of welds shall be made using the Wet Contrasting Black on White Method.

3.6.2.4 Dye Penetrant Inspection

Dye penetrant inspection of welds shall conform to the applicable provisions of ASTM E 165.

3.5 BOLTED CONNECTIONS

3.5.1 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 materials, workmanship and installation shall conform to the applicable provisions of RCSC A.1.

3.5.1.1 Bolt Holes

Bolt holes shall be accurately located, smooth, perpendicular to the member and cylindrical. Number of bolts shall be as shown on the drawings. Bolt spacing shall meet the minimum tolerances specified in AISC 325.

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 turned bolts shall be match-reamed or drilled in the shop. Bolt holes shall be bored or drilled using a steel template. The same template shall be used at all appropriate locations. The templates shall be turned over to the Government Representative at the end of the Contract. 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.

3.6 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.

3.7 MACHINE WORK

3.7.1 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 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.

3.7.2 Finished Surfaces

3.7.2.1 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.

3.7.2.2 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.

3.7.3 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.

3.7.4 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.

3.7.5 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.

3.7.6 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.