Div11.pdf

Lower Rio Grande Flood Control Project North Banker Floodway Levee Improvements Project Hidalgo County, Texas

DIVISION 11-

USIBWC Contract No.: IBM09B0002 EQUIPMENT

US INTERNATIONAL BOUNDARY & WATER COMMISSION

GOVERNING TECHNICAL SPECIFICATIONS AND PROVISIONS

DIVISION 11 – EQUIPMENT

DIVISION 11-

USIBWC Contract No.: IBM09B0002 EQUIPMENT

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SLUICE GATES

USIBWC Contract No.: IBM09B0002 Page 11.68.00 - 1 4287-06

Section 11 68 00

PART 1 GENERAL

1.01 SECTION INCLUDES

A. Sluice gates, wall thimbles, pipe connections, operators, and appurtenances necessary to construct and install hydraulic control equipment as shown on the Drawings.

1.02 MEASUREMENT AND PAYMENT

A. Unit Prices

1. Include cost of work and materials provided under this section in the pay items of which this work is a component, gatewell structures as applicable.

B. Reserved.

1.03 GENERAL

A. The equipment provided under this section shall be fabricated, assembled, erected, and placed in proper operating condition in full conformity with the Drawings, specifications, engineering data, instructions and recommendations of the equipment manufacturer.

B. Gates and operators shall be supplied (unless otherwise noted in the Drawings to be provided by the

Government) with all the necessary parts and accessories indicated on the Drawings, specified, or otherwise required for a complete, properly operating installation, and shall be the latest standard product of a manufacturer regularly engaged in the production of fabricated gates.

C. Gates shall be furnished (unless otherwise noted in the Drawings to be provided by the Government) and installed complete with wall thimble or anchor bolts, operating stem, gate lift operator and other appurtenances as specified or needed to make a complete and operable installation.

D. Except as modified or supplemented herein, all gates and operators shall conform to the applicable requirements of American Water Works Association standards.

E. Gates supplied under this section shall be Series 7000, 5000, 4000 Heavy Duty Sluice Gates manufactured by Waterman or as identified on the Drawings.

1.04 SUBMITTALS

A. Conform to the requirements of Section 01 33 00 – Submittal Procedures.

B. The Contractor shall submit, complete engineering design calculations in compliance with AWWA standards latest edition.

1.05 PERFORMANCE REQUIREMENTS

A. Leakage: Sluice gates shall be substantially watertight under the design head conditions. Under the design seating head, the leakage shall not exceed 0.05 US gallon per minute per foot of seating perimeter.

Under the design unseating head, the leakage for heads of 20 feet or less shall not exceed 0.1 US gallon per minute per foot of perimeter. For unseating heads greater than 20 feet, the allowable leakage shall not exceed the rate per foot of perimeter specified by the following equations:

MAXIMUM ALLOWABLE LEAKAGE

Gallons per minute per foot of perimeter = 0.10 + (0.0025 X (unseating head in feet-20))

B. Design Head: Sluice gates shall be designed to withstand the design head shown in the Drawings.

C. Seal Performance Test: Gate sealing systems shall be tested through a cycle test in an abrasive environment and shall show that the leakage requirements are still obtained after 25,000 cycles with a minimum deterioration.

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1.06 QUALITY ASSURANCE

A. The manufacturer shall have experience in the production of substantially similar equipment, and shall show evidence of satisfactory operation in at least 50 installations. The manufacturer’s shop welds, welding procedures and welders shall be qualified and certified in accordance with the requirement of the latest edition of American Welding Society.

B. The fully assembled gates shall be shop inspected, tested for operation and leakage, and adjusted before shipping. There shall be no assembling or adjusting on the job site other than for the lifting mechanism.

PART 2 MATERIALS AND EQUIPMENT

2.01 SLUICE GATES

A. All materials used in the construction of the gates and appurtenances shall be the best suited for the application.

1. General. Gates, stems, lifts and other appurtenances shall be the size, type, and material and construction as shown on the Drawings and specified herein. Gates shall meet the requirements of AWWA Specifications C-501 (latest version) or as modified herein. Gates shall be Waterman Heavy Duty Sluice Gates or compliance-confirmed equal. All component parts shall be of the type of material shown, and interchangeable where size and material are the same without grinding, chipping or special fitting in the field. The gates shall be the product of one manufacturer having five or more years of experience in the manufacture of similar gates for similar use. All mating and sliding parts shall be fully machined. All sluice gate parts, including lift, shall be designed for the heads shown with a minimum safety factor of five. Gates shall be either self-contained or non self-contained of the rising stem, non-rising or telescopic stem configuration as indicated on the gate schedule.

2. Wall Thimble. Wall thimbles shall be provided with all gates except those to be mounted on pipe flanges or those gates to be attached to concrete headwalls with anchor bolts, as shown on the Drawings. Each thimble shall be of one-piece cast iron construction and of the section and depth as specified in the Drawings and gate schedule. There shall be an integrally cast water stop around the periphery of the thimble. The front flange of the thimble shall be machined, drilled and tapped to receive the sluice gate attaching studs. Bolt pattern shall match gate bolt pattern. After machining, the front flange shall be marked with vertical centerline and the word "top" for correct alignment. Large square and rectangular opening thimbles shall be provided with grout holes in the invert to permit entrapped air to escape. The holes shall be 1 1/2" in diameter, no more than two feet apart and shall be upstream and downstream of the water stop. A mastic type gasket shall be provided between the sluice gate and the wall thimble. Anchor bolts shall be corrosion resistant. Gates mounted directly upon the headwall shall be sealed between the gate back and wall with a non-shrink grout. Follow manufacturers detailed installation instructions.

3. Frame and Guide Rails. The frame and guide rails shall be cast one-piece construction or may have guides dowelled and bolted to the frame. Frames shall be of the standard flangeback or extended flange type with round or rectangular opening as indicated on the Drawings and in the sluice gate schedule. A machined dovetail groove for the mounting of the bronze seat facings shall be provided on the front face of the frame around the full periphery of the opening. The frame shall be provided with cast-on pads which shall be machined, drilled, and tapped for the mounting of the wedge device. The back of the frame flange shall be machined to a plane and drilled to match the wall thimble, pipe flange, or anchor bolt pattern. Guide rails shall be of such length as to retain at least one-half of the vertical height of the slide when it is in the fully opened position. A groove running the full length of the guide rail shall be accurately machined to receive the slide tongue, with a nominal clearance of 1/16-inch.

4. Slide or Cover. The cover shall be of one piece cast construction with vertical and horizontal ribs, a reinforced pocket to receive the thrust nut, pads to receive the wedges, and a reinforced periphery around the back side of the cover for machining of the dovetail grooves in which the seating faces shall be mounted. All wedge pads shall be machined, drilled and tapped to receive the wedge devices. The cover shall have fully machined tongues running the full length of each side to properly engage the guide rail grooves. A thrust nut shall be provided to attach the slide to the stem. The nut shall be threaded and, in the case of rising stems, provided with keys on two

USIBWC Contract No.: IBM09B0002 Page 11.68.00 - 3 4287-06 set screws locked into indents in the stem to prevent rotation of the stem. For non-rising stems, the stem shall turn freely in the thrust nut, to open and close the slides as the stem is rotated.

5. Guides and Seals. The guides shall be made of ultra high molecular weight polyethylene (UHMWPE) and shall be of such length as to retain and support at least two thirds (2/3) of the vertical height of the slide in the fully open position.

a. Side and top seals shall be made of UHMWPE of the self-adjusting type. A continuous compression cord shall ensure contact between the UHMWPE guide and the gate in all positions. The sealing system shall maintain efficient sealing in any position of the slide and allow the water to flow only below the slide plate.

b. The flush bottom seal shall be made of resilient neoprene set into the bottom member of the frame.

B. Lift Assemblies.

1. General. Sluice gates shall be operated manually by handwheel or crank operated pedestal floor stands or bench stands as required. Each lift shall be provided with a threaded cast bronze lift nut to engage the threaded portion of the stem. The lift nut shall have a machined flange, fitted above and below with thrust ball or roller bearings. Handwheel lifts shall be without gear reduction while crank operated lifts shall have either a single or double reduction. Lifts having a reduction greater than 4:1 shall be two-speed. A maximum effort of 40 lbs. pull (25 lb. pull) on handwheel or crank, shall operate the gates under the specified operating head. The gears, when required, shall be steel with machine-cut teeth. Pinion gears shall be supported by bronze bushings or roller bearings. The lift mechanism shall be totally enclosed within a cast iron housing adequately provided with lubrication fittings. The pedestal shall be structural steel or cast iron. The crank shall be of cast iron with a revolving brass handle and shall be removable. The crank shall be a maximum of 15" long. All lifts for rising stems shall be provided with a counter type position indicator and a galvanized steel stem cover or a transparent plastic stem cover with mylar strip position indicator. Non-rising stem gates shall be provided with a counter type position indicator unless extension stems, valve boxes, or T-handle wrenches make an indicator impractical.

Handwheels and crank input shafts shall be approximately 36" from the operating floor unless otherwise shown. The word "open" shall be cast onto the housing or handwheel indicating direction of rotation to open the gate.

2. Stem and Couplings. Operating stems shall be of a size to safely withstand, without buckling or permanent distortion, stresses induced by normal operating forces. Stems shall be fabricated from round bar stock of cold-finished steel, stainless steel or bronze, as shown on the Drawings or gate schedule and shall be provided with 29º modified or full acme threads. Stems composed of two or more sections shall be joined by bronze couplings threaded and keyed to stems, or couplings of the same material as the stems, pinned, bolted or welded and pinned to the stems.

In section, couplings shall be stronger than the stems. Rising stems with manual lifts shall be provided with adjustable limit nuts or stop collars above and below the floor stand lift nut to prevent over travel of the gate in either direction.

3. Stem Guides. Stem guides shall be cast, with bronze bushings, and mounted on cast brackets.

Guides shall be adjustable in two directions and shall be so constructed that when properly spaced they will hold the stem in alignment and still allow enough play to permit easy operation.

Stem guide spacing shall be as recommended by the manufacturer, but in no case shall it exceed an l/r ratio of 200. Brackets shall be attached to the wall by anchor bolts and sufficient strength to prevent twisting or sagging under load.

4. Stem Cover. Rising stem gates shall be provided with a clear polycarbonate stem cover. The stem cover shall have a cap and condensation vents and a clear mylar position indicating tape.

The tape shall be field applied to the stem cover after the gate has been installed and positioned.

C. Seating Faces. All seating faces for both covers and frames shall be malleable extruded corrosion resistant material (see materials section) of a shape that will fill and permanently lock in the full width dovetail grooves of the slide and the frame. No other means of attachment will be allowed.

They shall be machined to a 63 micro-inch finish, or better.

D. Wedges. All wedges and wedge blocks shall be solid corrosion resistant material and shall be of sufficient number to provide a practical degree of watertightness. All wedge bearing surfaces and contact faces shall be machined to give maximum contact and wedging action. Wedges shall be

USIBWC Contract No.: IBM09B0002 Page 11.68.00 - 4 4287-06 fully adjustable, but once set shall not rotate or move from the desired position. All fasteners and adjustment screws shall be corrosion resistant.

E. Self-Contained Gates with Rising & Non-Rising Stems. When a self-contained gate is specified, a heavy yoke shall be mounted on the machined pads provided on the upper ends of the guide rails.

The yoke shall have a machined bearing surface for the lift nut or pedestal mounting plate. On non-rising stems gates the nut pocket shall be cast on top of the slide so that the stem does not project into the waterway when the gate is fully opened. The thrust generated by gate operation shall be transferred to the yoke by the stem thrust collar or lift. When the operating floor is above the self-contained gate, a stem extension of cold-rolled or stainless steel shall be coupled to the operating stem with a bronze coupling or cast iron stem extension bracket. Operation shall be by a T-handle wrench or floor stand, shown on the plans and gate schedule. In a T-handle arrangement the stem extension shall be supported by at least one stem guide or a floor box with integral guide embedded in the operating floor.

F. Flushbottom Sluice Gates. When a flushbottom closure is specified, a resilient seal shall be attached to the frame so that it is flush with the invert. It shall be supported by a cast iron bracket which shall be bolted to machined pads provided on the frame. The seal shall be held in place by a bronze or stainless steel bar which shall be bolted through the seal to the bracket with stainless steel fasteners. The cover (slide) shall be shortened and provided with a smooth rounded surface along the bottom to depress the seal. When unseating heads are to be acting on a flushbottom gate, top wedges shall be added, but bottom wedges will not be required. Sealing pressure shall be varied by adjusting side and top wedges.

G. Painting. All cast iron parts of the sluice gate (not bearing or sliding contact) and stem guides shall be factory painted. Portion of the wall thimbles in contact with concrete shall not be painted.

H. Shop Testing. The completely assembled gate and hoist shall be separately shop-operated to insure proper assembly and operation. The gate shall be adjusted so that a .004" thick gauge will not be admitted at any point between frame and cover seating surfaces. All gates and equipment shall be inspected and compliance-confirmed by a qualified shop inspector prior to shipment.

PART 3 E X E C U T I O N

3.01 STORAGE AND INSTALLATION

A. Contractor shall store and install the sluice gates and equipment in accordance with the installation manual furnished by the gate manufacturer. After installation, the completely assembled gate, stem, guides and lift shall be operated through one full cycle to demonstrate satisfactory operation. Such adjustments as necessary will be made until operation is compliance-confirmed by the COR. When required by the COR, the gate shall be subjected

3.02 FIELD TESTS

A. Following the completion of each gate installation, the gates shall be operated through at least two complete open/close/open cycles. If an electric or hydraulic operator is used, limit switches shall be adjusted following the manufacturer’s instructions. Gates shall be checked for leakage by the contractor after installation.

END OF SECTION

GRATES AND LADDERS

USIBWC Contract No.: IBM09B0002 Page 11.71.00 - 1 4287-06

Section 11 71 00

PART 1 GENERAL

1.01 SECTION INCLUDES

A. Grates, ladders, and appurtenances necessary to provide access to hydraulic control equipment as shown on the Drawings.

1.02 MEASUREMENT AND PAYMENT

A. Unit Prices

1. Include the cost of work performed under this Section in the pay item of which this work is a component, gatewell structures as applicable.

B. Reserved.

1.03 SUBMITTALS

A. Conform to the requirements of Section 01 33 00 – Submittal Procedures.

PART 2 MATERIALS AND EQUIPMENT

2.01 MATERIALS

A. Welded Steel Grates, Ladders, and Frames. Provide (unless otherwise noted in the Drawings to be provided by the Government) welded steel grates and frames as an assembly conforming to the member size, dimensions, and details shown on the Drawings. Fabricate these assemblies in accordance with Section 05 50 10 – Metal Fabrications.

B. Castings. Provide (unless otherwise noted in the Drawings to be provided by the Government) clean castings conforming to the shape and dimensions shown on the Drawings and in accordance with Section 33 08 20 – Frames, Grates, Rings, and Covers.

C. Documentation. Unless otherwise noted to be provided by Government, furnish mill test reports or manufacturer’s certification to the Government for each lot or shipment of steel and iron materials.

PART 3 EXECUTION

3.01 INSTALLATION

A. Install frames, grates, rings, and covers in accordance with the details shown on the Drawings and manufacturer’s recommendations. Tack-weld grates and covers to the frame or ring when directed by the COR. Galvanize steel items in accordance with Section 05 50 10 – Metal Fabrications. Provide fasteners in accordance with Section 05 50 10 – Metal Fabrications.

END OF SECTION

USIBWC Contract No.: IBM09B0002 Page 11.71.00 - 2 4287-06

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