J.01_FINAL_-_Stop_Log_Condition_Assessment_SOW.pdf

STATEMENT OF WORK

FALCON DAM STOP LOGS

AND LIFTING BEAM

REHABILITATION AND

RECERTIFICATION

I. Background

Falcon Dam is located on the Rio Grande on the border between the United States and Mexico, and was completed in 1953 and is operated by the U.S. International Boundary Water Commission (USIBWC). Falcon Dam consists of an earth dam approximately 5 miles with a height of about 139 ft. A central outlet works is located on the Mexico side of the border and two hydro-power plants (one each on the U.S. and Mexico sides of the border, operate to release flows. A spillway is located on the left side of the dam (on the U.S. side of the border). The spillway is approximately 350 ft long with six - 50 ft. x 50 ft. fixed wheel gates. The spillway operates frequently, particularly throughout the wet season.

There are a total of 12 stop logs that comprise one stoplog set that are used when maintenance is done to one of the 50 ft. x 50 ft. gates. The approximate weight of one stop log is 44,000 pounds.

Stop log dimensions vary in size / dimensions and are divided into:

One lower tier stoplog (details can be found in Appendix A, sheet 0A-4-870) Five intermediate tier stoplogs (details can be found in Appendix A, sheet 0A-4-872) Six top tier stoplogs (details can be found in Appendix A, sheet 0A-4-874)

Typical dimensions (approximate) of the stop logs are:

Height = 2.7 ft.

Length = 50 ft.

Width = 3.7 ft.

There is one lifting beam that is used to raise and lower the stoplogs into place when they are in use and not in use. The approximate weight of the lifting beam is 10,000 pounds. The lifting beam dimensions are as follow:

Height = 2.5 ft. F Length = 52.8 ft.

Width = 1.4 ft.

Further detail regarding the lifting beam can be found in Appendix G: sheets 0A-4-876 and 0A-4- 877.

II. Objectives

The United States Section of the International Boundary and Water Commission (USIBWC), Falcon Field Office has a requirement for a condition assessment of the existing stoplogs and lifting beam at Falcon Dam, located in Falcon Heights, Texas. The Contractor shall provide all labor, material, equipment, subcontract, supervision, and management to perform the requirements of this Statement of Work (SOW) briefly described below:

Phase I:

Pick up and hauling of stop logs and lifting beam to Contractors shop.

Cleaning of the stop logs and lifting beam by way of sand blasting in preparation for visual and non-destructive testing.

Visually inspect the stop logs and lifting beam and document various types of defects that can be visually identified such as cracks, distortion, deformation, delamination, corrosion and incomplete/missing welds per USACE EM 1110-2-6054 Engineering and Design Manual for Inspection, Evaluation, and Repair for Hydraulic Steel Structures.

Perform Non-Destructive Testing (NDT) on stop logs and lifting beam per USACE EM 1110-2-6054 Engineering and Design Manual for Inspection, Evaluation, and Repair for Hydraulic Steel Structures.

Develop, execute and deliver a Work Plan that documents a successful and repeatable procedure for future operations and maintenance activities for preventative measures in maintaining the stop logs and lifting beam.

Provide a report summarizing the results of the inspection, design checks, NDT results and recommendations for structural reinforcements or rehabilitation plan, if needed.

Re-painting of stop logs and lifting beam prior to delivery.

Delivery of the stop logs and lifting beam back to Falcon Dam.

Phase II – Option Work:

Provide rehabilitation for stop logs as needed for recertification purposes to include but not limited to welding, reinstallation of nuts/bolts, replacement of wooden planking, and installation of epoxy seals.

Provide rehabilitation for lifting beam as needed for recertification purposes to include but not limited to welding, reinstallation of nuts/bolts, and straightening of the beam.

The work in this Contract shall be accomplished by a fabricating plant and fabricator that is certified under the AISC (American Institute of Steel Construction) Quality Certification Program, and shall be designated an AISC Certified Plant, Category CBR (Major Steel Bridge) with a Fracture Critical Endorsement (F). The stoplogs and lifting beam shall be picked up and returned after completion of testing/rehabilitation to the Falcon Dam stoplog storage yard. Directions and guide to storage yard will be available at the Falcon Dam project Office, 1 Reservoir Road, Falcon Heights, Texas 78545.

The stoplogs and lifting beam can be viewed and photographed at time of site visit prior to the bid closing, a site visit is highly recommended. The sand blast cleaning and repainting of the stop logs and lifting beam is not considered option work and is required to be performed by the Contractor.

Please see Section IX of this scope of work for further detail regarding the option rehabilitation work.

Goals

1.1 Goal Synopsis:

The Contractor will provide services in support of the USIBWC’s spillway rehabilitation at Falcon Dam, in particular a condition assessment of the stoplogs. The Scope of Work for this contract shall include a description of the Contractors approach and work plans that will be performed as part of this contract, condition assessment tasks (field inspection and analysis of the conditions encountered), cleaning of the stop logs by means of sand blasting and lifting beam, non-destructive testing of the stoplogs and lifting beam, field documentation and condition assessment report. The Phase II Option of this scope of work will have the Contractor provide rehabilitation of the stoplogs and lifting beam as outlined in Section IX of this scope of work.

1.2 Desired Results:

The objective of the condition assessment is to

Confirm the configuration and dimensions of the stoplogs relative to the engineering drawings;

Identify the condition of stoplogs members and plates;

Document various types of defects that can be visually identified such as cracks, distortion, deformation, delamination, corrosion and incomplete/missing welds; Identify areas of corrosion and the extent of corrosion;

Visually observe the condition of welds and identify insufficient throat or leg sizes, cracks, undercutting, overlap, excessive convexity or reinforcement and other surface defects;

Cleaning of the stop logs and lifting beam by means of sand blasting;

Conduct Nondestructive Testing of the stoplogs and lifting beam to document current conditions.

Conduct Nondestructive testing on welds on all stoplogs and lifting beam in accordance with the requirements of AWS D1.5M/D1.5.

Complete an analysis report of each stoplog and lifting beam with recommended rehabilitation work.

2.0 Applicable Documents and Stakeholders

2.1 Applicable Documents:

Falcon Dam As-Built Drawing Sheets OA-4-866 to OA-4-875 (found under Appendix A of this SOW).

Falcon Dam As-Built Drawing Sheets OA-4-876 to OA-4-877 (found under Appendix G of this SOW).

USACE EM 1110-2-6054; Chapter 4 - Engineering and Design Manual for Inspection, Evaluation, and Repair for Hydraulic Steel Structures (found under Appendix B of this

SOW).

USACE EM 1110-2-6054; Chapter 6 - Engineering and Design Manual for Inspection, Evaluation, and Repair for Hydraulic Steel Structures (found under Appendix C of this

SOW).

USACE EM 1110-2-6054; Chapter 8 - Engineering and Design Manual for Inspection, Evaluation, and Repair for Hydraulic Steel Structures (found under Appendix D of this

SOW).

USACE EM 385-1-1 Safety and Health Requirements Manual. The manual can be obtained at the follow website: http://140.194.76.129/publications/eng-manuals/EM_385-1- 1_languages/EM_385-1-1_English_2008/toc.html (found under Appendix E of this SOW).

OSHA 29 CFR 1910. The standard can be accessed at http://www.osha.gov/ or http://www.gpo.gov/fdsys/

OSHA 29 CFR 1926. The standard can be accessed at http://www.osha.gov/ or http://www.gpo.gov/fdsys/

Specification Section 05 59 13 – Fabrication of Hydraulic Steel Structures (found under Appendix E of this SOW).

Specification Section 09 09 65 – Painting: Hydraulic Structures (found under Appendix F of this SOW).

American Welding Society Standards (AWS) to include Standard D1.5M/D1.5.

Federal Acquisition Regulations (FAR) to include FAR Clause 52.212-4.

2.2 Applicable Stakeholders:

Department of Homeland Security

III. Requirements and Tasks The performance requirements analysis identifying activities supporting desired outcomes is shown in Section 3.1 below. Deliverables will include Visual and NDT Inspection results and recommended rehabilitation work, are shown in Section 3.3 below.

3.1 Condition assessment of the stoplogs a n d l i f t i n g b e a m including the following activities:

Review of the existing stoplog a n d l i f t i n g b e a m drawings for the structural member sizes and overall layout;

Visual inspection of the condition of the stoplogs and lifting beam per Chapters 4, 6, and 8 of the USACE EM 1110-2-6054 Engineering and Design Manual for Inspection, Evaluation, and Repair for Hydraulic Steel Structures;

Cleaning of the stop logs by means of sand blasting;

Non-destructive testing (NDT) of the stoplogs and lifting beam per Chapters 4, 6, and 8 of the USACE EM 1110-2-6054 Engineering and Design Manual for Inspection, Evaluation, and Repair for Hydraulic Steel Structures;

3.2 Condition Assessment and Report

Design checks to confirm structural adequacy of the stoplogs and lifting beam.

Complete a detailed assessment of the current condition of the stop logs and lifting beam in comparison with the original design.

Preparation of a report summarizing the results of the inspection, design checks, NDT results and recommendations for structural reinforcements or rehabilitation of the stop logs and lifting beam.

Contractor shall include photo documentation showing stop log and lifting beam deficiencies noted during the NDT and Visual Inspections.

NDT procedures and measurements shall be included in the report.

Corrosion depth measurements, crack propagation lengths and depths, and all other measurements / data used to recommend rehabilitation of the stop logs and lifting beam shall also be provided as an appendix to the detailed assessment report.

Recommendations for rehabilitation/refurbishment in the short term (less than five years) and/or long-term maintenance (more than five years) and refurbishment schedule, as appropriate shall be included as part of the report.

- Justification/reasoning supporting the recommended rehabilitation/refurbishments should be provided prior to conducting any rehabilitation work.

The Assessment Report shall be sealed by a professional engineer holding certification in the respective state the report is being generated in.

3.3 Rehabilitation Work

Provide rehabilitation for stoplogs and lifting beam as needed (for recertification) to include but not limited to cleaning, welding, painting, reinstallation of nuts/bolts, installation of epoxy seals, replacement and re-greasing of rollers, replacement of wood planking and repainting of stop logs and lifting beam.

3.4 Period of Performance

Contractor shall complete all work within 180 days after receipt of award.

IV. Quality Assurance

4.1 Qualification of Welders and Welding Operators

Submit welder, welding operator and tacker qualification certification for each welder, welding operator or tack welder to the Government Representative/Contracting Officer/ Engineer and approved before fabrication is commenced in accordance with paragraph Welded Connections.

A CWI meeting the specified qualifications shall approve all welder qualifications. Welders, welding operators, and tack welders shall be limited to welding procedures for which they are certified. Test welds shall be prepared, welded, and tested in accordance with the requirements of AWS D1.5M/D1.5. Before assigning any welder, welding operator, or tacker to work under this Contract, submit the names of the welders, welding operators, and tackers to be employed, and certification that each individual is qualified as specified. The certification shall state the type of welding and positions for which the welder, welding operator, or tacker is qualified, the code and procedure under which the individual is qualified, the date qualified, and the name of the firm and person certifying the qualification tests. The certification shall be kept current for the duration of the Contract. Welder and welding operator qualification test records shall be submitted on forms similar or equivalent to the sample forms in AWS D1.5M/D1.5, Annex III.

All welders performing fracture critical welds under this specification shall be qualified according to Section 12 of AWS D1.5M/D1.5. All welders performing non-fracture critical welds shall be qualified according to Section 6 of AWS D1.5M/D1.5. All qualifications shall be current prior to commencing any work. Submit a log for each welder showing that he/she is current in the process and procedures being proposed for this work.

4.2 Inspector Qualifications

All inspectors, performing structural steel inspection in accordance with these specifications, shall be qualified and certified in conformance with AWS QC1. Provide an AWS Certified Welding Inspector (CWI) as the primary point of contact for quality control of welding. When several CWI and NDT technicians are working, one primary individual shall be designated as having primary responsibility for all quality control in accordance with AWS D1.5M/D1.5 Section 6.1.2.2. Non-certified inspectors and certified associate weld inspectors (CAWI) shall not be used for inspection under these specifications. All personnel who perform NDT shall be qualified in accordance with: ASNT SNT-TC-1A NDT Level II or III. All personnel performing NDT shall be supervised by personnel possessing a Level III ASNT NDT certification in accordance with AWS D1.5M/D1.5 section 6.1.3.4 and section 12.16.1.2. Submit copies of certificates showing evidence of qualifications or certifications for welding inspectors and NDT personnel.

4.3 Qualification of Structural Steel Fabricator

The fabricating plant and fabricator shall be certified under the AISC (American Institute of Steel Construction) Quality Certification Program, and shall be designated an AISC Certified Plant, Category CBR (Major Steel Bridge) with a Fracture Critical Endorsement (F) at time of bid. The fabricator or fabrication plant shall possess five 5 years documented experience on projects of similar scope. Similar scope means projects of similar size and similar amounts of welding and detail types. Submit copies of the AISC certificate indicating that the fabrication plant meets the specified structural steelwork category and documented experience. The [insert items excluded from this requirement, such as wire rope slings, rubber seals etc.] are excluded from the AISC fabricator certification requirements.

4.5 Shop Drawings

Prepare all shop drawings using a Registered Professional Engineer or under the direct supervision of a Registered Professional Engineer. Elements of fabricated items inadvertently omitted on Contract drawings shall be returned to the Engineer of Record for detailing or shall be detailed by the fabricator and so indicated on the shop drawings. Any and all details developed by the fabricator shall be clouded on the shop drawings for separate approval by the Engineer of Record. Any items designed by the Contractor shall be prepared and sealed by a Registered Professional Engineer. No splices shall be included in the structure without approval of the Engineer of Record. All field welds required shall be identified on the shop drawings.

Each weld, both shop and field welds, required shall be provided a unique identifier to permit tracking on the weld tracking log. Prior to performing any fabrication of the HSS structures listed in paragraph System Description above, submit complete, detailed shop drawings to the Contracting Officer and Engineer of Record for approval. Shop drawings shall show complete details of materials, tolerances, connections, and proposed welding sequences. Shop drawings shall include catalog cuts, templates, fabrication and assembly details, and type, grade, and class of materials, as appropriate. All FCM, including attachments that meet the FCM definition, shall be identified on the shop drawings as well as all temporary and tack welds. Each member shall be identified following the numbering scheme shown on the drawings. A table shall be provided containing a list of all members and a reference to each material certificate and test report that applies to that member. Shop drawings shall identify weld procedures and NDE required for each weld. Any and all splices shall be included in the shop drawings and clouded for engineer approval.

V. Qualifications

The contractor shall possess the following qualifications and certifications:

5.1 The Contractor shall be certified under the AISC (American Institute of Steel Construction) Quality Certification Program, and shall be designated an AISC Certified Plant, Category CBR (Major Steel Bridge) with a Fracture Critical Endorsement

(F) at time of bid. The Contractor or fabrication plant shall possess five 5 years documented experience on projects of similar scope.

5.2 Welder and welding operator qualification test records shall be submitted on forms similar or equivalent to the sample forms in AWS D1.5M/D1.5, Annex III. All welders performing fracture critical welds under this specification shall be qualified according to Section 12 of AWS D1.5M/D1.5. All welders performing non fracture critical welds shall be qualified according to Section 6 of AWS D1.5M/D1.5.

5.3 All inspectors, performing structural steel inspection in accordance with these specifications, shall be qualified and certified in conformance with AWS QC1.

5.4 All personnel who perform NDT shall be qualified in accordance with: ASNT SNT-TC-1A NDT Level II or III. All personnel performing NDT shall be supervised by personnel possessing a Level III ASNT NDT certification in accordance with AWS D1.5M/D1.5 section 6.1.3.4 and section 12.16.1.2. Submit copies of certificates showing evidence of qualifications or certifications for welding inspectors and NDT personnel.

5.5 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 D1.5M/D1.5. Before assigning any welder, welding operator, or tacker to work under this contract, submit the names of the welders, welding operators, and tackers to be employed, and certification that each individual is qualified as specified.

6.6 Only individuals qualified for NDT Level II or Level III may perform nondestructive testing. The Level III NDT inspector who supervises all NDT shall posses a currently valid American Society for Nondestructive Testing (ASNT) Level III certificate for each of the processes for which they are qualified. Copies of the certifications, including the ASNT certificate of Level III NDT Technician that certified the Level II Technicians shall be provided.

VI. Fabrication

6.1 Structural Fabrication

Rehabilitation work of the stoplogs and lifting beam shall be conducted as specified in Section 05 59 13: FABRICATION OF HYDRAULIC STEEL STRUCTURES (located under Appendix E of this Statement of Work). Material shall 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 or otherwise approved. Bends 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 that will not impair the original properties of the metal. Proposed flame cutting of material, other than structural steel, shall be subject to approval and shall be indicated on detail drawings. Shearing shall be accurate and all portions of the work shall be neatly finished. Corners shall be square and true unless otherwise shown. Re-entrant cuts shall be filleted round to a minimum radius of 1 inch in accordance with AWS D1.5M/D1.5 section 3.2.4 unless otherwise indicated or approved.

Finished members shall be free of twists, bends and open joints.

a. Dimensional Tolerances for Structural Work.

(1) Dimensions shall be measured by an approved measuring system. Submit the measuring system for approval with the work plan (i.e. calibrated steel tape of approximately the same temperature as the material being measured). The overall dimensions of an assembled structural unit shall be within the tolerances indicated on the drawings or as specified for the item of work. Where tolerances are not specified in other sections of these specifications or shown, a variation of 1/32 inch is permissible in the overall length of component members with both ends milled and component members without milled ends shall not deviate from the dimensions shown by not more than 1/16 inch for members 30 feet or less in length and by not more than 1/8 inch for members over 30 feet in length.

(2) Structure dimensions indicated on the drawings are based on a structure temperature of 70 degrees F. The Contractor is responsible for any and all dimensional adjustments to compensate for actual temperature variations during construction.

b. Structural Steel Fabrication.

Structural steel may be cut by mechanically guided or hand-guided torches, provided an accurate profile with a surface that is smooth and free from cracks and notches is obtained.

Surfaces and edges shall be prepared in accordance with AWS D1.5M/D1.5, Subsection

3.2. Hand-guided cuts shall be chipped, ground or machined to sound metal.

6.2 Assembly

Provide Assembly Drawings indicating the sequence of fabrication and assembly and provide details for connecting the adjoining fabricated components in the shop. Assembly details shall identify the required order of assembly and details of witness points as described in these specifications.

6.3 Materials Disposition Record

Submit two copies of all purchase and mill orders, shop orders for materials and work orders, including all new orders placed by subcontractors and old orders extended for each supplier.

Furnish, at the time of submittal of shop drawings, a list designating the material to be used for each item. Where mill tests are required, purchase orders shall contain the test site address and the name of the testing agency. Furnish a shipping bill or memorandum of each shipment of finished pieces or members to the project site, giving the designation mark and weight of each piece, the number of pieces, and the total weight. Submit material records before the beginning of fabrication.

6.4 Welded Connections

a. Welding Procedure.

(1) Welding shall conform to the applicable provisions of AWS D1.5M/D1.5. Prior to the start of production welding, submit a complete schedule of welding procedures for a typical structure. The schedule shall conform to the requirements specified in the provisions of AWS D1.5M/D1.5. The schedule shall provide detailed procedure specifications and tables or diagrams showing the procedures to be used for each required joint.

(2) Submit to the Government Representative, a Welding Procedure Specification for each weld to be made. Submit Welding Procedure Specifications and Procedure Qualification Records (PQR) to the Government Representative/Contracting Officer for approval before fabrication is commenced. Copies of the Welding Procedure specification and the results of the procedure qualification test for each type of welding which requires procedure qualification shall be submitted for approval. Submit the WPS and PQR with the shop drawings. Each WPS shall be prepared and qualified in accordance with the applicable provisions of AWS D1.5M/D1.5. Welding procedures shall show types and locations of welds designated or specified to receive nondestructive examination and identify the weld as FCM when applicable. A WPS is always required, even if the procedure is considered prequalified in accordance with AWS D1.5M/D1.5. Properly documented evidence of compliance with all requirements of these specifications for previous qualification tests shall establish the welding procedure as prequalified. Each procedure shall be clearly identified as being either prequalified or qualified by tests.

Approval of any procedure, however, will not relieve the Contractor of the responsibility for producing a finished structure meeting all requirements of these specifications.

Copies of the WPS shall be made available for reference to the welders, welding operators, and tack welders. A CWI meeting the specified qualifications shall approve all WPS’s and PQR’s.

a. Welder Performance Qualification 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 D1.5M/D1.5.

Before assigning any welder, welding operator, or tacker to work under this contract, submit the names of the welders, welding operators, and tackers to be employed, and certification that each individual is qualified as specified. The certification shall state the type of welding and positions for which the welder, welding operator, or tacker is qualified, the code and procedure under which the individual is qualified, the date qualified, and the name of the firm and person certifying the qualification tests. Copies of the Performance Qualification records shall be submitted to the Government Representative and approved before fabrication is commenced. Require the welder and welding operators to repeat the qualifying tests when, in the opinion of the Government Representative/Contracting Officer's Representative/Engineer, the work indicates a reasonable doubt as to proficiency. In such cases, the welder shall be recertified, as above, after successfully passing the retest; otherwise, he/she shall be disqualified until successfully passing a retest. The period of effectiveness for all welder and welding operator performance qualifications shall be in accordance with AWS D1.5M/D1.5. Keep the certification current for the duration of the Contract. All expenses in connection with qualification and requalification shall be borne by the Contractor.

b. Welding Process. Welding of structural steel shall be by an electric arc welding process using a method which excludes the atmosphere from the molten metal and shall conform to the applicable provisions of AWS D1.5M/D1.5 for all welds. Welding shall be such as to minimize residual stresses, distortion and shrinkage.

c. Welding Technique.

(1) 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 or shall be as shown where a specific choice of AWS specification allowable is required. Weld metal toughness shall meet the requirements of AWS D1.5M/D1.5, Tables, 4.1, 4.2, or 12.1 as applicable. The AWS designation of the electrodes to be used shall be included in the schedule of welding procedures. Only low hydrogen electrodes shall be used for manual shielded metal-arc welding regardless of the thickness of the steel. A controlled temperature storage oven shall be used at the job site as prescribed by AWS D1.5M/D1.5, Subsection 12.6 to maintain low moisture of low hydrogen electrodes. Controlled temperature storage ovens shall be powered at all times. FCAW filler metal shall be subjected to the storage and handling requirements defined in AWS D1.5M/D1.5 section 12.6.7.4. Filler metals and processes shall not be combined in the same joint or weld.

(2) Preheat and Interpass Temperature - Preheating shall be performed as required by the applicable provisions of AWS D1.5M/D1.5 for all welds except that the temperature of the base metal shall be at least 70 degrees F. Preheat for fracture critical welds shall be as defined in Table 12.3 and in accordance with the PQR/WPS. 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 as required and in accordance with the approved WPS in order to prevent cracking or distortion.

d. Workmanship for welding shall be in accordance with AWS D1.5M/D1.5, Section 3 for all welds and other applicable requirements of these specifications

(1) Preparation of Base Metal. Prior to welding, inspect surfaces to be welded to assure compliance with the applicable sections of AWS D1.5M/D1.5.

(2) Tack and Temporary Welds. Tack and temporary welds required for fabrication and erection shall be made in accordance with AWS D1.5M/D1.5 under the controlled conditions prescribed herein for permanent work. Tack welds that are to be incorporated into the permanent work shall be subject to the same quality requirements as the permanent 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. All welds shall be made using low-hydrogen welding electrodes and by welders qualified for permanent work as specified elsewhere in these specifications. Preheat shall be as required by AWS D1.5M/D1.5 for permanent tack welds except that the minimum temperature shall be 70 degrees F in any case, regardless of electrode used. All tack welds which will be incorporated into the final weldment shall be a maximum of 1/8 inch with a minimum length of 1 inch long spaced at a maximum of 6 inch on center. In making temporary welds, arc strikes shall not be struck in other than weld locations. Each temporary weld shall be removed as required by AWS D1.5M/D1.5, Subsection 3.3.8. All arc strikes struck outside the weld zone shall be ground out, filled, and inspected in accordance with AWS D1.5M/D1.5.

(3) Weld Access Holes. Weld access holes shall be provided as shown on the shop drawings. If the oversite of intersecting out-of-plane welds is encountered, the fabricator shall notify the Contracting Officer for the approval of weld access hole additions in such locations. Payment for the addition of weld access holes not shown on plans will be the Contractor's responsibility.

(4) Weld Backing Removal. Unless otherwise indicated, all steel weld backing material shall be removed from welded joints prior to testing. All weld backing material that cannot be removed shall be identified on the shop drawings.

(5) Weld Backing Material Other Than Steel. All weld backing material, other than steel, shall be qualified by testing and shall be included in submitted PQR/WPS. Variation from approved weld backing material will not be permitted and will require the development and testing a new weld procedure which addresses the change in backing material.

6.5 Bolted Connections

(1) Bolts, Nuts, and Washers. All bolts shall conform to the requirements of ASTM A193 Grade B8M. Nuts shall conform to the requirements of ASTM A194.

(2) Bolt Holes. Bolt holes shall be accurately located, smooth, perpendicular to the member and cylindrical.

(1) 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.

(2) The provisions of AWS D1.5M/D1.5 Section 3.7.7 allowing misdrilled holes do not apply. All misdrilled holes shall be repaired as directed by the Engineer. Repair of mislocated or misdrilled holes shall be submitted for Government approval.

6.6 Miscellaneous Provisions

a. Weldments. Portions of the structure include thick weldments where locked in thermal stresses may make final dimensions unstable. The Contractor is required to sequence the work and thermally stress relieve subassemblies of thick weldments such that final machining achieves stable specified dimensions and tolerances.

b. Drain Holes. Locate drain holes as shown on the drawings, unless otherwise noted.

Drain holes shall be drilled. Flame cutting of holes will not be permitted.

c. Seal Welds. Seal welds are required to maintain water tightness. All seal welds shall be shown and made as indicated on the shop drawings. Seal welds, when called for on the drawings, shall be made the minimum size fillet weld as required in AWS D1.5M/D1.5.

In addition, seal welds may require weld wrapping around reentrant corners that is specifically prohibited in AWS D1.5M/D1.5. All seal welds on fracture critical members shall be subjected to the minimum preheat requirements of AWS D1.5M/D1.5 Table 12.3 as applicable. All seal welds shall be subjected to the same testing requirements required for a fillet weld made to any fracture critical member according to AWS D1.5M/D1.5 Chapter 12.

6.7 Shop Assembly

Perform fabrication and assembly in an indoor, climate controlled shop. Each item shall be closely checked to ensure that all necessary clearances have been provided and that binding does not occur in any moving part. Errors or defects disclosed shall be immediately remedied without cost to the Government.

VII. Test Reports Submit reports of tests, inspections, and verifications of all materials used under this Contract approved by the Government before incorporation into the stop logs and lifting beam. All steel used in this Contract shall be tested by an approved U.S. laboratory to ensure that it meets the required standards.

7.1 General

Have required material tests and analyses performed and certified by an approved laboratory, at the Contractor's expense, to demonstrate that materials are in conformity with the scope of work. Tests, inspections, and verifications shall conform to the requirements of the particular sections of these specifications for the respective items of work unless otherwise specified or authorized. Tests shall be conducted in the presence of the Contracting Officers Representative. Furnish specimens and samples for additional independent tests and analyses upon request by the Contracting Officer.

7.2 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, magnetic particle, 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 Contractor. Any defects will be cause for rejection and rejected parts shall be replaced and retested by the same test method that located the defect at the Contractor's expense.

7.3 Inspection of Structural Steel Welding

Maintain an approved inspection system and perform required inspections. Welding shall be subject to inspection to determine conformance with the requirements of AWS D1.5M/D1.5 and the approved welding procedures and provisions stated in other sections of these specifications. All completed welds shall be cleaned and carefully visually examined for insufficient throat or leg sizes, cracks, undercutting, overlap, excessive convexity or reinforcement and other surface defects to ensure compliance with the requirements of AWS D1.5M/D1.5, subsection 6.26 and the additional requirements of chapter 12 for the Fracture Control Plan. In addition, the Government may choose to hire a third party inspector to perform verification of this work. The Government's third party inspection will occur at various times throughout the duration of fabrication. The Contractor will be advised that third party inspection shall be coordinated with the GQAR and the Contractor for all verification inspections selected by the Government.

a. Visual Examination. Prior to any welding, a certified weld inspector (CWI) supplied by the Contractor shall visually inspect and document on the weld tracking log the preparation of material for welding at each weld or joint in order to assure compliance with AWS D1.5M/D1.5 and approved WPS. The CWI shall also perform VT inspection on all completed welds throughout the welding process to assure compliance with AWS D1.5M/D1.5 and approved WPS. All completed welds shall be cleaned free of oxide, flux, scale, paint spatter, or other foreign matter before inspection.

b. Nondestructive Examination. The nondestructive examination of welds shall be performed as specified or described on the drawings or as listed in the following paragraphs.

(1) Testing Agency. The nondestructive examination of welds and the evaluation of examination tests as to the acceptability of the welds shall be performed by a testing agency adequately equipped and competent to perform such services or by the Contractor using suitable equipment and qualified personnel. In either case written approval of the examination procedures is required and the examination tests shall be made in the presence of the Contracting Officer. The evaluation of examination tests shall be subject to Weld Inspectors (CWI) shall be qualified and certified in accordance with the provisions of AWS QC1 and shall be familiar with AWS D1.5M/D1.5 fracture critical member inspection as required in AWS D1.5M/D1.5 Section 12.16. The laboratory and all personnel performing nondestructive testing shall be qualified as specified. Only individuals qualified for NDT Level II or Level III may perform nondestructive testing. The Level III NDT inspector who supervises all NDT shall posses a currently valid American Society for Nondestructive Testing (ASNT) Level III certificate for each of the processes for which they are qualified. Copies of the certifications, including the ASNT certificate of Level III NDT Technician that certified the Level II Technicians shall be included in the submittals.

(1) Examination Procedure and Extent. All nondestructive testing shall comply with AWS

D1.5M/D1.5, Section 6 or section 12, as applicable. Testing shall be required as defined in the following paragraph.

(2) Acceptability of Welds. Welds will be unacceptable if shown to have defects prohibited by AWS D1.5M/D1.5.

(3) Examination Procedures. Examination procedures shall conform to the following requirements:

(4) Ultrasonic Testing (UT) - Ultrasonic testing of welds shall conform to the provisions of AWS D1.5M/D1.5. The ultrasonic equipment shall be capable of making a permanent record of the test indications. A record shall be made of each weld tested.

(5) Radiographic Testing (RT) - Making, evaluating and reporting radiographic testing of welds shall conform to the applicable requirements of AWS D1.5M/D1.5.

(6) Magnetic Particle Inspection (MT) - Magnetic particle inspection of welds shall conform to the provisions of ASTM E709 and AWS D1.5M/D1.5, Section 6 and Subsection 12.16 where applicable. Requirements of AWS D1.5M/D1.5 section 6.7.2.3 shall not apply to these specifications, such that secondary members shall be subjected to MT sampling as required. MT by the prod method is prohibited.

(7) Dye Penetrant Inspection (PT) - Dye penetrant inspection (PT) of welds shall conform to the applicable provisions of ASTM E165.

7.4 Welds to be Subject to Nondestructive Examination

a. Structural Steel Non-Fracture Critical Members - Full Penetration Welds. Welds shall be inspected in conformance with AWS D1.5M/D1.5, Section 6.7. 100 per cent of all Full Penetration welds on non-fracture critical members shall be tested.

b. Structural Steel Non-Fracture Critical Member Fillet Welds and Partial Penetration Welds. 100 per cent of all fillet welds and partial penetration welds shall be examined by magnetic particle and or dye Penetrant testing procedures described previously.

c. Structural Steel Fracture Critical Member Welds. All welds on FCM shall be tested in accordance with AWS D1.5M/D1.5, Subsection 12.16. 100 per cent of all fracture critical full-penetration welds on fracture critical members shall be subjected to ultrasonic testing. Butt joints in tension shall be inspected by UT. The testing shall be done as early in the project as possible to ensure the quality of the procedure and process. Weld backing shall be removed from all fracture critical welds prior to all NDE unless the weld backing member is permanent. The UT report for all butt welds shall include non-rejectable indications with defect severity ratings within 5 db of being rejectable and shall be fully recorded as to indication, rating, size, and location. In accordance with AWS D1.5M/D1.5 Section 12.16.5.3, all discontinuities found by UT must be recorded.

7.5 Structural Steel Welding Rehabilitation Work

Defective welds in the structural steel should be defined as critical repairs or non-critical repairs and shall be repaired in accordance with AWS D1.5M/D1.5, Subsection 3.7 for non-FCM and section 12 for FCM. Make separate submittals for Welding Repairs - Non-Fracture Critical Members and Welding Repairs - Fracture Critical Members. Submit welding repair plans for steel and for fracture critical welds, approved prior to making repairs. Welding repair plans shall address weld repairs within the weld as well as weld repairs for base metal discontinuities. All weld repairs to fracture critical members shall be considered critical welds in accordance with AWS D1.5M/D1.5 Section 12.17.3 and shall be approved by the Engineer of Record. Approval by the Government shall be obtained for weld repairs to mill defects in the base metal, repair of cracks, or a revised design to compensate for deficiencies. The Contractor may prepare procedures and specifications for the repair of anticipated routine problems and submit them for approval before fabrication begins. Critical weld repairs require a WPS specific to the weld repair. Defective weld metal shall be removed to sound metal by use of air carbon-arc gouging.

Oxygen gouging for purposes of weld repair shall not be permitted. The surfaces shall be thoroughly cleaned before welding. Inadequate removal of welds that damages the base metal shall be subject to replacement of the base metal, or compensation for the deficiency in a manner approved by the Contracting Officer. Welds that have been repaired shall be retested by the same methods used in the original inspection. Except for the repair of members cut to remove test coupons and found to have acceptable welds, costs of repairs and retesting shall be borne by the Contractor.

VIII. Painting

All exposed surfaces of the structure shall be painted as specified in Section 09965: PAINTING - HYDRAULIC STRUCTURES ( located under Appendix F of this Statement of Work). ). All edges of plate shall be ground prior to coating. Grinding plate edges shall be accomplished before paint preparation in order to remove hardness as a result of flame cutting. All square edges and holes other than bolt holes shall be broken and ground to a 1/16 inch radius prior to painting.

IX. Option Work

Option work will include the Contractor providing rehabilitation work for the stoplogs and lifting beam as needed to include but not limited to welding, reinstallation of nuts / bolts, installation of epoxy seals, replacement and re-greasing of rollers, replacement of wood planking on stop logs.

Rehabilitation work will be dependent on the Contractors NDT Report for both the stop logs and lifting beam and cannot be carried out without written approval from either the Government Representative or the Contracting Officer.

Table 1 (located below) provides an approximate estimate for rehabilitation work for the stop logs and lifting beam. The stoplogs and lifting beam can be viewed and photographed at time of site visit prior to the bid closing, a site visit is highly recommended.

The sand blast cleaning and repainting of the stop logs and lifting beam is not considered option work and is required to be performed by the Contractor.

Table 1

Option Work Quantity Estimate

X. Deliverables

The Contractor shall provide the draft report in electronic Adobe Portable Document Format (PDF to the Government Representative and Contracting Officer. The final report shall be provided to the USIBWC in both written (2 copies) and electronic formats (2 CDs). All report drawings shall be computer generated, clear and legible on 8.5 inch x 11 inch or 11 inch x 17 inch sized paper.

Appendices shall include the figures, logs, profiles, completion diagrams, and personnel certifications and licenses. The Contractor shall adhere to the following timeframes for the Scope of Work deliverables:

Project schedule based on critical path method outlining scope of work milestones (to be provided to the Government Representative and Contracting officer within one (1) month of Contract award).

Personnel Certificates and Professional Credentials for individuals who will be carrying out this scope of work (to be provided to the Government Representative and Contracting Officer within one (1) month of Contract award).

Inspection logs, notes, photographs and measurements obtained during the condition assessment for both the stop logs and lifting beam (to be provided to the Government Representative and Contracting Officer within three (3) months of Contract award).

Draft Condition Assessment Report (to be provided to the Government Representative and Contracting Officer within four (4) months of Contract award).

Item # Description Unit Not to Exceed Amount

1 Welding of Stop Logs LF 280

2 Welding of Lifting Beam LF 100

Replacement of Nuts / Bolts for Stop Logs

(one pair = bolt + nut)

EA 75

Replacement of Nuts / Bolts for Lifting Beam

(one pair = bolt + nut)

EA 35

Replacement of Wood Planking on Stop Logs

(one plank approx. = 25' x 1 'x 2')

EA 40

Replacement of rubber seals on Stop Logs

(one rubber seal approx. 50' x 6"x6")

EA 50

7 Replacement of Rollers on Stop Logs EA 50

8 Replacement of Rollers on Lifting Beam EA 10

Final Condition Assessment Report (to be provided to the Government Representative and Contracting Officer within five (5) months of Contract award).

Submit reports of tests, inspections, and verifications of all materials used under this Contract approved by the Government before incorporation into the stop logs and lifting beam rehabilitation work (to be provided to the Government Representative and Contracting Officer within six (6) months of Contract award).

Delivery/Shipping Plan for stop logs and lifting beam:

Phase I - Condition Assessment does not recommend any rehabilitation Phase II - Condition Assessment recommends rehabilitation (to be provided to the Government Representative within seven (7) to nine (9) months of Contract award).

Notify the Contracting Officer and Contracting Officer’s Representative at least 28 days in advance of delivery of the stoplogs and lifting beam (structures). Shipping of the structures shall be at the Contractor's expense. All structures shall be delivered as indicated. Contractor coordination for delivery shall be through the Contracting Officer and Contracting Officer’s Representative. The structures shall be arranged on the delivery vehicles such that no damage occurs during shipping.

All sling lifting lugs shall be directed up. Submit a Delivery/Shipping Plan showing orientation and locations of structures on the delivery vehicles prior to shipment for Government approval. Submit drawings providing descriptions of methods of delivering the completed structural units, including details for support during shipment to prevent distortion or other damages, and orientation and location of the structures on transport equipment.

XI. Payments

The Contractor shall invoice monthly (the last Friday of every month) for services provided in accordance with this SOW.

1.0 Invoices will be sent to USIBWC Finance and Accounting Division (FAD) via e-mail to invoices@ibwc.gov. A copy shall be furnished to the Contracting Officer and Contracting Officer Representative.

1.1 Payment shall be made in accordance per FAR Clause 52.232-1.