J.06_Appendix_E.pdf

SECTION 05 59 13

FABRICATION OF HYDRAULIC STEEL STRUCTURES

08/09

PART 1 GENERAL

1.1 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.

AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING (ASNT)

ASNT SNT-TC-1A (2012) Recommended Practice for Personnel Qualification and Certification in Nondestructive Testing

AMERICAN WELDING SOCIETY (AWS)

AWS D1.5M/D1.5 (2010) Bridge Welding Code

AWS QC1 (2007) Standard for AWS Certification of Welding Inspectors

AMERICAN SOCIETY FOR TESTING ANF MATERIALS (ASTM)

ASTM A193 (2012a) Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High Temperature or High Pressure Service and Other Special Purpose Applications

ASTM A194 (2012) Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High Pressure or High Temperature Service, or Both

ASTM A709/A709M (2011) Standard Specification for Structural Steel for Bridges

ASTM E165 (2009) Standard Test Method for Liquid Penetrant Examination

ASTM E709 (2008) Standard Guide for Magnetic Particle Examination

ASTM F 436 (2011) Hardened Steel Washers

U.S. ARMY CORPS OF ENGINEERS (USACE)

EM 385-1-1 (2008; Errata 1-2010; Changes 1-3 2010; Changes 4-6 2011) Safety and Health Requirements Manual

1.2 SYSTEM DESCRIPTION

Provide a detailed Work Plan for fabrication, including descriptions of shop facilities, equipment, number of personnel, and related information, and procedures for safe conduct of the work, Include in the procedures a detailed description of the methods and equipment to be used for each operation, and the sequence of operations in accordance with EM 385-1-1. The Work Plan shall include the recommended measuring system for ensuring dimensional tolerances.

a. Material with welds will not be accepted unless the welding is specified or indicated on the drawings or otherwise approved. Welding shall not be started until welding procedures, inspectors, nondestructive testing personnel, welders, welding operators, and tackers have been qualified and approved. Each Contractor performing welding shall maintain records of the test results obtained in welding procedure, and welder, welding operator, and tacker performance qualifications.

b. As it is used in these specifications, "The Engineer" refers to the District engineer of record.

The AWS D1.5M/D1.5 definition of "The Engineer" as specified in AWS D1.5M/D1.5 section

1.1.3 shall refer to the District engineer of record in lieu of the state bridge engineer as specified in section 1.1.3 of AWS D1.5M/D1.5.

1.2.1 Weld Tracking Log Template

Submit for approval a weld tracking log template, a minimum of 5 days prior to commencement of fabrication, to identify all necessary components to be addressed in the tracking of all welds for the structures in question. A weld-tracking log will be developed and maintained as described in the following paragraphs.

1.2.2 Weld Tracking Log

Submit a log capable of individually identifying and tracking every weld on the project.

Member identification shall follow the numbering scheme shown on the shop drawings. The log shall include the member to be welded, member type (FCM and Non-FCM), type of weld including temporary and tack welds, welding position, applicable WPS reference, AWS joint preparation designation, name or stamping designation of welder, welding operator or tacker, date and time of completion of welding and/or tacking, name and date of CWI visual inspection, NDT testing performed, including the type of inspection, date(s) of inspection, inspector name, and the acceptance criteria used, description of defects found and reason for non-compliance, corrective action taken, or whether the weld is acceptable. Weld identification on the shop drawing shall match weld tracking log identification. A completed log shall be bound together and two copies shall be submitted to the Contracting Officer immediately upon completion of fabrication. Draft copies of NDT testing shall be furnished to the Contracting Officer upon request and shall be available on the shop floor during any inspection.

1.2.3 Welding Procedure Specifications (WPS)

Submit a Welding Procedure Specification (WPS), with attached PQR and supporting test documentation on forms similar or equivalent to the sample forms in AWS D1.5M/D1.5, Annex III, for each weld, including prequalified welds, in accordance with paragraph Welded Connections approved before fabrication is commenced. Welding Procedure Specifications shall be individually identified and shall be referenced on the shop drawings. In case of conflict between this specification and AWS D1.5M/D1.5 as applicable, this specification governs.

1.2.4 Fracture Critical Members (FCM)

FCM are shown on the Contract Drawings and include all attachments and connections to these members as defined in AWS D1.5M/D1.5. All materials to be welded shall be ASTM A709/A709M, grade as specified or shown on the drawings, using killed fine-grain mill practice, unless otherwise shown or specified. Mill repairs of base metal are prohibited.

Toughness shall meet the requirements of ASTM A709/A709M, Table 10, for Zone [2], unless otherwise indicated or specified. All materials used for the construction of fracture critical components shall meet the requirements of section 10 of ASTM A709/A709M and shall include mill certification showing that the material meets the necessary toughness requirements. Welding for fracture critical members shall meet all requirements of AWS D1.5M/D1.5 Section 12, including:

a. 12.5 Welding Processes. All procedures shall be qualified as required.

b. 12.6 Consumable Requirements. All welding consumables shall be heat or lot-tested by the manufacturer to determine conformance with the requirements of the Fracture Control Plan (FCP). Exceptions are not allowed. Toughness test results shall meet the values specified in Table 12.1 of AWS D1.5M/D1.5. Submit a Fracture Control Plan (FCP) for welding on all Fracture Critical Members (FCM) in accordance with AWS D1.5M/D1.5, Section 12. Welding Procedures, qualifications, and certifications shall be submitted showing compliance with FCP requirements

c. 12.7 Welding Procedure Specifications (WPS). All procedures, including repair welds, shall be prequalified or qualified by test as required and documented in the WPS and Procedure guidelines of AWS D1.5M/D1.5.

d. 12.8 Certification and Qualification. Welders and welding operators shall meet the applicable requirements of AWS D1.5M/D1.5.

e. Material handling and preparation, including thermal cutting, preparation of base metal, and straightening, curving, cambering shall meet the applicable requirements.

f. 12.13 Tack Welds and Temporary Welds. All welds shall be located within the joint and shall meet the requirements of AWS D1.5M/D1.5, Table 12.2. Temporary welds on FCM are not permitted.

g. Welding processes, including preheat, interpass temperatures, and postweld thermal treatment shall meet the applicable requirements.

h. 12.16 Weld Inspection. The Quality Control inspection program shall be documented in the FCP. All inspectors and NDT technicians shall be qualified as required. All butt joints shall be tested with UT. Inspection procedures and documentation are as specified in the applicable sections of AWS D1.5M/D1.5. Cooling times must be strictly adhered to.

i. 12.17 Repair Welding. Repair welds must be classified as "critical repairs" or "non-critical repairs" for all repair welding. Repair procedures shall follow the minimum provisions unless specified otherwise. Repair procedures must be qualified and approved and subject to the same QA/QC inspection requirements as other welds. Minimum preheat for repair welding shall be as defined in AWS D1.5M/D1.5 section 12.17.6. 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.

1.3 SUBMITTALS

Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for information only. Submit the following in accordance with Section

01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Welding Procedure Specifications (WPS) G; Fracture Control Plan (FCP) G; Weld Tracking Log Template I

SD-02 Shop Drawings

Shop Drawings:

Welding Repairs - Non-Fracture Critical Members I

Welding Repairs - Fracture Critical Members G

Delivery/Shipping Plan I

SD-03 Product Data

Materials Disposition Record

SD-06 Test Reports

I

Certified Test Reports G; Weld Tracking Log I

SD-07 Certificates

Work Plan G; Qualification of Welders and Welding Operators G; Inspector Qualifications G; Qualification of Structural Steel Fabricator G

1.4 QUALITY ASSURANCE

Magnetic Particle Inspection of 100% of All Welds on Gate and Ultrasonic Testing of 100% of Any Butt or Bevel Welds That are Accessible and of a Material Thickness of 5/16'' or Greater. Magnetic Particle of 100% of All Repair Welds and in Material in the Heat Effected Zone. Ultrasonic Testing of 100% of all Butt and Bevel Welds that Have Been Made During the Repair Process.

Intermediate QA Inspections will be conducted on an as needed basis and at the discretion of the Government. All QA inspections will follow AWS D1.5M/D1.5 and AASHTO/NSBA Steel Bridge Collaboration S 4.1 - 2002 Steel Bridge Fabrication QC/QA Guide Specification.

Provide unpainted components for each QA NDT and Visual Inspection. At these stages of construction, give the Contracting Officer three working days to inspect the structure. The QA Inspection period shall not commence until after a minimum period of 72 hours after any welding. After the Contracting Officer and the Engineer of Record has inspected the structure, make any changes required to the structure as directed by the Contracting Officer before proceeding with any additional welding.. Each structure fabricated is subject to a Final Fabrication Inspection prior to painting. . Give the Contracting Officer a minimum notice of one week prior to the Final Fabrication Inspection.

1.4.1 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.

1.4.2 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.

1.4.3 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.

1.4.4 Testing by the Government

Material component parts may be subjected to any form of nondestructive testing, as directed by the Contracting Officer. This may include ultrasonic, magnetic partial, dye Penetrant 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 materials or parts shall be replaced and retested at the Contractor's expense.

1.4.5 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.

1.5 DELIVERY, STORAGE, AND HANDLING

Notify the Contracting Officer at least 28 days in advance of delivery of the 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 IBWC Contracting Officer. 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 structure on transport equipment.

PART 2 PRODUCTS

2.1 FABRICATION

2.1.1 Structural Fabrication

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.

2.1.2 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.

2.1.3 Materials Disposition Record

Submit three copies of all purchase and mill orders, shop orders for materials and work orders, including all new orders placed by Contractors 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. Additional requirements for this submittal are listed below.

2.1.4 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 Engineer, 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. 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.

2.1.5 Bolted Connections

a. 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.

b. 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.

2.1.6 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.

2.1.7 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. All shop testing for assembly shall be witnessed by the

Government Representative. Errors or defects disclosed shall be immediately remedied without cost to the Government.

2.1.8 Seals

Rubber seals shall be of the mold type only, compounded of natural rubber, synthetic polyisoprene, or a blend of both, and shall contain reinforcing carbon black, zinc oxide, accelerators, antioxidants, vulcanizing agents, and plasticizers. The surfaces of finished splices shall be smooth and free of irregularities. Bolt holes in the rubber seals shall be match-drilled with the seal support and clamping bars, as applicable; to insure proper fit and spacing between holes of the completed seal assembly. Seal support and clamping bars shall conform to the configurations shown on the drawings and shall be machine finished. The seals and blocks shall be installed after painting has been completed.

TEST METHOD

PHYSICAL TEST TEST VALUE SPECIFICATION

Tensile Strength 2500 psi (min.) ASTM D 412

Elongation at Break 450 percent (min.) ASTM D 412

300 percent Modulus 900 psi (min.) ASTM D 412

Durometer Hardness 60 to 70 ASTM D 2240 (Shore Type A)

*Water Absorption 5% by weight (max.) ASTM D 471

Compression Set 30% (max.) ASTM D 395

Tensile Strength 80% tensile ASTM D 572 (after aging 48 hrs) strength (min.)

* The "Water Absorption" test shall be performed with distilled water. The washed specimen shall be blotted dry with filter paper or other absorbent material and suspended by means of small glass rods in the oven at a temperature of 70 degrees C plus or minus 2 degrees for 22 plus or minus 1/4 hour. The specimen shall be removed, allowed to cool to room temperature in air, and weighed. The weight shall be recorded to the nearest 1 mg as M subscript 1 (M subscript 1 is defined in ASTM D 471). The immersion temperature shall be 70 degrees C plus or minus one (1) degree and the duration of immersion shall be 166 hours.

2.2 CERTIFIED TEST REPORTS

Submit reports of tests, inspections, and verifications of all materials used under this contract approved by the Government before incorporation into the structure. All steel used in this contract shall be tested by an approved U.S. laboratory to ensure that it meets the required standards.

2.2.1 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 specifications. 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 Officer. Furnish specimens and samples for additional independent tests and analyses upon request by the Contracting Officer.

2.2.2 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 Government. 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.

2.2.3 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.

(2) 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.

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

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

(5) 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.

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

(7) 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.

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

2.2.4 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.

2.2.5 Structural Steel Welding Repairs

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.

PART 3 EXECUTION

3.1 INSTALLATION

3.1.1 Cleaning

All parts to be installed shall be thoroughly cleaned. Packing compounds, rust, dirt, grit and other foreign matter shall be removed. Holes and grooves for lubrication shall be cleaned.

Enclosed chambers or passages shall be examined to make sure that they are free from damaging materials. Where units or items are shipped as assemblies they will be inspected prior to installation. Non-Structural bolts and screws shall be tightened firmly and uniformly but care shall be taken not to overstress the threads. Threads of corrosion-resisting steel bolts and nuts shall be coated with an approved antigalling compound. Driving and drifting bolts or keys will not be permitted.

3.1.2 Alignment and Setting

Each structural unit attached to structurals fabricated according to this specification shall be accurately aligned by the use of steel shims or other approved methods so that no binding in any moving parts or distortion of any member occurs before it is fastened in place. The alignment of all parts with respect to each other shall be true within the respective tolerances required.

3.2 PROTECTION OF FINISHED WORK

Machined surfaces shall be thoroughly cleaned of foreign matter. All finished surfaces shall be protected by suitable means. Unassembled pins and bolts shall be oiled and wrapped with moisture resistant paper or protected by other approved means. Finished surfaces of ferrous metals to be in bolted contact shall be washed with an approved rust inhibitor and coated with an approved rust resisting compound for temporary protection during fabrication, shipping and storage periods. Finished surfaces of metals shall be painted as specified in specification SECTION 09 97 02: PAINTING - HYDRAULIC STRUCTURES.

3.3 PAINTING

All exposed surfaces of the structure shall be painted as specified in Section 09 97 02:

PAINTING - HYDRAULIC STRUCTURES. 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.

-- End of Section -

SECTION TABLE OF CONTENTS - PAGE 1

SECTION TABLE OF CONTENTS

DIVISION 09-FINISHES

SECTION 09965 – PAINTING: HYDRAULIC STRUCTURES

PARAGRAPH TITLE PAGE No

PART 1 - GENERAL

1.1 SCOPE OF WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09965-01

1.2 DEFINITIONS AND NOMENCLATURE . . . . . . . . . . . . . . . . . . . . 09965-01

1.3 REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09965-01

1.4 SUBMITTALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09965-03

1.5 PACKAGING, LABELING, DELIVERY,

AND STORAGE OF PAINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 09965-03

1.6 SAFETY PROVISIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09965-03

1.7 PAYMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09965-07

PART 2 - PRODUCTS

2.1 SPECIAL PAINT FORMULATIONS NOT

COVERED BY STANDARD SPECIFICATIONS . . . . . . . . . . . . . .09965-07

PART 3 - EXECUTION

3.1 CLEANING AND PREPARATION

OF SURFACES TO BE PAINTED . . . . . . . . . . . . . . . . . . . . . . . 09965-08

3.2 PAINT APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09965-09

3.3 PAINT SYSTEMS TO BE APPLIED--

NUMBER OF COATS AND FORMULAS. . . . . . . . . . . . . . . . . . . 09965-12

3.4 PAINT SYSTEMS AND PAINTING SCHEDULE . . . . . . . . . . . . . . 09965-13