Solicitation Amendment W9128F26QA0040001 SF 30.pdf

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Performance Work Statement (PWS) Draft Tube Bulkhead Seal Replacement at Fort Randall Dam

1.0 General Information

1.1 Background

The Fort Randall powerhouse is located on the Missouri River at Pickstown, South Dakota. Fort Randall currently has nine (9) draft tube bulkheads onsite, eight (8) of which were fabricated in 1949, and the other was fabricated in 2020. The seals and leaf springs were last replaced during a 1996 contract. The seals on eight (8) bulkheads are now in need of replacement again. They show signs of cracking, deformation, and erosion which are leading to an increase in leakage through the bulkheads. The bulkheads are maneuvered with a lifting beam by a 25-ton draft tube gantry crane.

Three (3) bulkheads are required to unwater a single unit. An ongoing unit rehabilitation project will require new seals and ancillary items to be delivered so that three (3) bulkheads can be serviced in time to un-water the next unit of the rehabilitation project. The next unit to be un-watered is estimated to start October 11, 2026.

1.2 Objective

This project will supply rubber seal assemblies, side retaining bars, leaf springs, and ancillary materials for the eight (8) draft tube bulkheads.

1.3 Scope

The contractor shall supply items listed in the table.

Quantity Description 9 Complete Rubber Seal Assemblies

12 Side Seal Retaining Bars 4 Side Seal Retaining Bars

32 Leaf Springs 175 Top Seal Brass Countersunk Bolt Assemblies 100 Side and Bottom Seal Brass Bolt Assemblies 128 Leaf Spring Brass Countersunk Bolt Assemblies

1.4 Period and Place of Performance

1.4.1 Period of Performance

The work must be completed 190 days after the date of contract award. Delivery schedule will be in accordance with Section 2.0.2, Time of Delivery.

1.4.2 Place of Performance

The supplies requested under this contract will be delivered to:

United States Army Corps of Engineers Fort Randall Dam

399 Powerhouse Road Pickstown, SD 57367

1.5 Quality Control

The contractor shall designate, in writing, an employee who shall serve as the contact for matters involving quality and performance or nonperformance of the required work stated in this PWS. The employee(s) shall be qualified and fully competent with full authority to act for, and on behalf of, the contractor as necessary to ensure that the required work is performed in accordance with the standards contained herein. The contractor shall furnish the above written designation to the Contracting Officer Representative (COR) no later than the first day of work. The contractor shall include the name(s), address(s), and telephone number(s) of the responsible individual(s).

The Contracting Officer reserves the right to disapprove any individual whom he considers incompetent to perform the work required. The Contracting Officer will provide a written notice of any disapproval to the contractor.

1.6 Quality Assurance

The government will ensure that the contractor is performing the work required by this PWS in an acceptable manner.

The government has the right to inspect all items called for by the contract, to the extent practicable at all times and places during the term of the contract.

If any of the work does not conform to contract requirements, the government may require the contractor to re-perform the work in conformity with contract requirements and at no increase cost to the Government.

1.7 Hours of Operation

The contractor will have access to the facility for work during the hours of 0700-1600 Monday thru Thursday except Federal holidays or when the Government facility is closed due to local or national emergencies, administrative closings, or similar Government directed facility closings. Draft tube crane support from Government is unavailable on Fridays without special request by the contractor 10 business days prior to the need of crane.

The following Federal legal holidays are observed by this installation:

New Year’s Day 1 January Martin Luther King’s Birthday Third Monday in January President’s Day Third Monday in February Memorial Day Last Monday in May Juneteenth 19 June Independence Day 4 July Labor Day First Monday in September Columbus Day Second Monday in October Veterans Day 11 November Thanksgiving Day Fourth Thursday in November Christmas Day 25 December

1.8 Kick-off Meeting

Prior to commencing any activities, the Contracting Officer Representative (COR) will schedule a Kick-off Meeting with the contractor. The meeting shall establish methods of communication, set clear expectations, discuss the work requirements, scheduling, and submittal process. The Contractor will be responsible to schedule periodic meetings to ensure all milestones are being met according to the agreed upon schedule. At least one (1) week prior to commencing work, the Contractor shall coordinate their proposed work schedule with the COR.

1.9 Submittals

Prior to commencement of the work, the Contractor will submit the following documents to the COR for review and approval. Government approval is required for submittals with a "G" classification. Submittals not having a "G" classification are for Contractor Quality Control approval. When used, a code following the "G" classification identifies the office that will review the submittal for the Government. Submit the following electronically to the Contracting Officer Representative (COR):

Note: For all submittals to be reviewed by the Hydroelectric Design Center (HDC), so indicated by a "G HDC" designation, submittals and cover sheets and forms must be sent via FTP or e-mail in Adobe Acrobat .pdf format.

a. Fabricator’s Quality Control Plan; G, HDC

b. Shop Drawings; G, HDC

c. Nonconformance Reports; G, HDC

d. Test and Inspection Report; G, HDC

e. NDT Equipment Calibration Records

f. Material Test Report; G, HDC

g. Inspector Qualifications; G, HDC

h. Seal Manufactures Recommended Storage; G, HDC

i. Seal Manufactures Recommended Delivery; G, HDC

j. Seal Shop Drawings; G, HDC

k. Material Test Report; G, HDC

l. Fluorocarbon Adhesion Bond Test Report; G, HDC

m. Existing Side Seal Retaining Bar Drawings; G HDC

n. Quality Control Manual (QCM); G

o. Safety and Health Provisions; G

p. Waste Classification, Handling, and Disposal; G

q. Paint Formulas; G

r. Solvent and Thinners; G

s. Inspection Reports; G

t. Coating Thickness Gage Qualification; G

u. Qualified Paint Applicator; G

v. Qualify Control Personnel; G

w. Qualified Painting Contractor; G

Additional submittal details are listed in Section 2. All submittals requiring Government approval will be reviewed and approved within 30 business days unless otherwise stated.

1.10 Standards and Regulations

The Contractor shall perform to the standards in the contract and comply with all Local, State, and Federal Regulations during the services performed. The Contractor is responsible for ascertaining the extent to which these regulations affect the operations resulting from this contract. The Contractor shall comply will all applicable regulations. Applicable regulations include, but are not limited to the following:

a. AISC 325 (2017) Steel Construction Manual

b. ANSI/ASNT CP-189 (2016) ASNT Standard for Qualification and Certification of

Nondestructive Testing Personnel (ANSI/ASNT CP-105-2006)

c. AWS A2.4 (2012) Standard Symbols for Welding, Brazing and Nondestructive Examination

d. AWS A3.0M/A3.0 (2010) Standard Welding Terms and Definitions

e. ASME B4.1 (1967; R 2009) Preferred Limits and Fits for Cylindrical Parts

f. ASTM B21/B21M (2014) Standard Specification for Naval Brass Rod, Bar, and Shapes

g. ASTM D395 (2014) Standard Test Methods for Rubber Property - Compression Set

h. ASTM D412 (2006a; R 2013) Standard Test Methods for Vulcanized Rubber and Thermoplastic

Elastomers – Tension

i. ASTM D413 (1998; R 2017) Standard Test Methods for Rubber Property - Adhesion to Flexible

Substrate

j. ASTM D471 (2012a) Standard Test Method for Rubber Property - Effect of Liquids

k. ASTM D572 (2004; R 2010) Rubber Deterioration by Heat and Oxygen

l. ASTM D2137 (2011) Standard Test Methods for Rubber Property - Brittleness Point of Flexible

Polymers and Coated Fabrics

m. ASTM D2240 (2005; R 2010) Standard Test Method for Rubber Property - Durometer Hardness

n. ASTM D1045 (2019) Standard Test Methods for Sampling and Testing Plasticizers Used in

Plastics

o. ASTM D1152 (2006; R 2012) Methanol (Methyl Alcohol)

p. ASTM D1153 (2012) Methyl Isobutyl Ketone

q. ASTM D1200 (2010; R 2014) Viscosity by Ford Viscosity Cup

r. ASTM D1210 (2005; R 2014) Fineness of Dispersion of Pigment-Vehicle Systems by Hegman-

Type Gage

s. ASTM D153 (1984; R 2014) Specific Gravity of Pigments

t. ASTM D281 (2012; R 2016) Standard Test Method for Oil Absorption of Pigments by Spatula

Rub-Out

u. ASTM D2917 (2007; R 2013) Methyl Isoamyl Ketone

v. ASTM D3465 (2014) Standard Test Method for Purity of Monmeric Plasticizers by Gas

Chromatography

w. ASTM D3721 (2005; R 2011) Synthetic Red Iron Oxide Pigment

x. ASTM D4228 (2005; R 2017) Standard Practice for Qualification of Coating Applicators for

Application of Coatings to Steel Surfaces

y. ASTM D4417 (2019) Field Measurement of Surface Profile of Blast Cleaned Steel

z. ASTM D520 (2000; R 2011) Zinc Dust Pigment

aa. ASTM D561 (1982; R 2014) Carbon Black Pigment for Paint

bb. ASTM D7091 (2013) Standard Practice for Nondestructive Measurement of Dry Film Thickness of Nonmagnetic Coatings Applied to Ferrous Metals and Nonmagnetic, Nondestructive Coatings Applied to Non-Ferrous Metals

cc. ASTM D740 (2011) Methyl Ethyl Ketone

dd. ASTM D841 (2019) Standard Specification for Nitration Grade Toluene

ee. ASTM E1347 (2006; R 2020) Standard Test Method for Color and Color Difference

Measurement by Tristimulus (Filter) Colorimetry

ff. FED-STD-595 (Rev C; Notice 1) Colors Used in Government Procurement

gg. 29 CFR 1910 Occupational Safety and Health Standards

hh. 29 CFR 1910, Subpart I Personal Protective Equipment

ii. 29 CFR 1910.134 Respiratory Protection

jj. 29 CFR 1910.146 Permit-required Confined Spaces

kk. 29 CFR 1910.94 Ventilation

ll. 29 CFR 1926 Safety and Health Regulations for Construction

mm. 40 CFR 261 Identification and Listing of Hazardous Waste

nn. 40 CFR 262.22 Number of Copies

oo. RCSC S348 (2014; Errata 2015) RCSC Specification for Structural Joints Using High-strength

Bolts

pp. SSPC PA 17 (2012; E 2015) Procedure for Determining Conformance to Steel Profile/Surface

Roughness/Peak Count Requirements

qq. SSPC PA 2 (2015; E 2018) Procedure for Determining Conformance to Dry Coating Thickness

Requirements

rr. SSPC QP 1 (2019) Standard Procedure for Evaluating the Qualifications of Industrial/Marine

Painting Contractors (Field Application to Complex Industrial Steel Structures and Other Metal Components)

ss. SSPC QP 3 (2010) Standard Procedure for Evaluating Qualifications of Shop Painting Applicators

tt. SSPC SP 1 (2015) Solvent Cleaning

uu. SSPC SP 5/NACE No. 1 (2007) White Metal Blast Cleaning

vv. EM 385-1-1 (2014) Safety and Health Requirements Manual

1.11 Payment

The government will make payment once unit is received. Payment will be made based on the completion of CLIN items 1 thru 7. Once the government has inspected and accepted the work, and the government has reviewed, approved, and processed the contractor’s invoice. The contractor shall submit the invoice to the COR and/or any other person that has been designated in the contract to receive the invoice. Payments will be made for the performance listed below:

a. Delivery of nine (9) complete rubber seal assemblies.

b. Delivery of twelve (12) side seal retaining bars.

c. Delivery of four (4) side seal retaining bars.

d. Delivery of 32 leaf springs.

e. Delivery of 175 top seal countersunk bolts assemblies.

f. Delivery of 100 side and bottom seal bolt assemblies.

g. Delivery of 128 leaf spring countersunk bolt assemblies.

The contractor must provide the contractor’s name, address, contract number, CLIN number and specific quantities of work performed (i.e., 1 Month, 40 days, 100 acres, etc.), and total requested, for an invoice to be considered proper.

2.0 Specific Tasks

Work requirements associated with this contract include the supplying of the following but is not limited to:

a. Supply nine (9) complete rubber seal assemblies.

b. Supply side seal retaining bars, sixteen (16) in total.

i. Contractor is responsible for determining the bolt hole spacing for each individual side seal retaining bar and the length of the side seal retaining bars on each bulkhead.

ii. Measurements will be accomplished within 30 calendar days of the appropriate Required Delivery Schedule from Section 2.0.2. Contractor will coordinate with the Government to determine access to each bulkhead. Coordination will be in accordance with Section 1.8, Hours of Operation.

c. Supply 32 leaf springs.

d. Top Seal Countersunk Bolt Assemblies.

i. Supply of 175 brass countersunk bolt assemblies to be used for the top seal assembly.

e. Side and Bottom Seal Bolt Assemblies.

i. Supply of 100 brass bolt assemblies to be used for the side and bottom seal assembly.

f. Leaf Spring Countersunk Bolt Assemblies.

i. Supply of 128 brass countersunk bolt assemblies to be used for the leaf spring assembly.

2.0.2 Time of Delivery

The Government requires delivery to be made according to the following schedule:

Required Delivery Schedule:

a. Award to 190 calendar days for the following items

i. Nine (9) rubber seal assemblies

ii. Twelve (12) side seal retaining bars

iii. 32 leaf springs

iv. 175 top seal brass countersunk bolt assemblies

v. 100 side and bottom brass bolt assemblies

vi. 128 leaf spring brass countersunk bolt assemblies

b. Notification of access to last two bulkhead plus 90 days

i. Four (4) side seal retaining bars

2.0.1 Drawings

The Contract Drawings that accompany this PWS are a part thereof.

Contractor shall immediately check furnished Reference Drawings and Contract Drawings and notify the Government of any discrepancies.

2.1 Bulkhead Seals

2.1.1 Quality Assurance

Specify and show on the drawings all requirements for tests, workmanship, and other measures for quality assurance. Provide continuous inspection of all operations for quality control and record the results for submitting to the Government to show compliance with Contract requirements.

2.1.2 Seal Shop Drawings

Prior to any manufacturing submit detailed shop drawings of the seals to the CO and Engineer of Record for approval. Show complete details of materials (including teflon coverage), tolerances, connections, and bolting hardware on shop drawings. Include catalog cuts, templates, fabrication and assembly details, and type of materials, as appropriate on shop drawings. Utilize AWS A2.4, AWS A3.0M/A3.0, AISC 303, AISC 325, and AISC 326 for shop drawing preparation. Provide shop drawings to scale and readable on an 11x17 printed copy. Fabricator is required to provide an 11x17 printed copy of the approved set of fabrication drawings to the Government Quality Assurance Representative prior to the start of fabrication.

2.1.3 Delivery and Storage

Seals must be stored and shipped in accordance with seal manufactures guidelines. Seals must be shipped flat and fully vulcanized. Submit seal manufactures recommended storage methods and seal manufacturer recommended delivery method for review. Storing and shipping seals coiled is not allowed and will be replaced at the contractor’s expense.

2.1.4 Existing Bulkhead Field Measurements

Measure the side seal bar bolt spacings for both side seal retaining bars on all eight (8) existing draft tube bulkheads. Provide findings on existing side seal retaining bar drawings. Detail side seal bar geometry including but not limited to thickness and length. Provide on center seal bolt spacings found in the field on the drawings. Provide a drawing for each existing draft tube bulkhead.

2.1.5 Materials

2.1.5.1 Rubber Seals

Provide rubber seals that are of the fully molded type only and are compounded of natural rubber/Polyisoprene. Provide fully molded seal corners with splices a minimum of 12 inches from the vertical and horizontal seal intersection or as indicated on the drawing. All splices must be factory vulcanized. Provide rubber seals which include reinforcing carbon black, zinc oxide, accelerators, antioxidants, vulcanizing agents, and plasticizers. Do not provide rubber compounds made of reclaimed polymers. Properly cure the rubber seal profile into a homogeneous form and keep free of oils, grease, or other materials which would deteriorate the rubber. Meet the following requirements for the physical characteristics of the seals:

Physical Test Specification Test Value Test Method

Tensile Strength 3,000 psi (min.) ASTM D412 Elongation at Break 450 % (min.) ASTM D412

300% Modulus 900 psi (min.) ASTM D412 Durometer Hardness, Shore

Type A 60 to 70 ASTM D2240

Water Absorption 5% by weight (max.) ASTM D471 Immersed at 70 C for

166 hours Compression Set 30% (max.) ASTM D395

Method B Tensile Strength After Oxygen Bomb Aging

80% of strength (min.) ASTM D572 48 hours of aging

Low Temperature Brittleness

Non-brittle after 3’ @ -40 degrees F

ASTM D2137

Method A

Perform the "Water Absorption" test with distilled water. Blot dry the washed specimen with filter paper or other absorbent material and suspended by means of small glass rods in the oven at a temperature of 70°C plus or minus 2°C for 22 plus or minus 1/4 hour. Remove the specimen, allow to cool to room temperature in air, and weigh. Record the weight to the nearest 1 mg as W1 (W1 is defined in ASTM D471). The immersion must be 70°C + 1°C and the duration of immersion must be 166 hours.

2.1.5.2 Fluorocarbon (PTFE) Clad Rubber Seals

Provide a fluoro-carbon film vulcanized and bonded to the sealing surface of the bulb on the top and side rubber seals. Provide film that is 0.060-inch-thick Huntington Abrasion Resistant Fluorocarbon Film No.

4508, or equal, having the following physical properties:

Tensile strength ............... 2,000 psi (min.)

Elongation ..................... 250 percent (min.)

The outside surface of the rubber seal and must be free of adhering or bonded rubber. Provide strips and corner seals molded in lengths suitable for obtaining the finish lengths shown and with sufficient excess length to provide test specimens for testing the adequacy of the adhesion bond between the film and bulb of the seal as specified in Testing below.

2.1.5.2.1 Testing

Test the fluorocarbon film for adhesion bond in accordance with ASTM D413, using either the machine method or the deadweight method. Submit a Fluorocarbon Adhesion Bond Test Report prior to shipping of the structures. At one end of each strip or corner seal to be tested, mask the fluorocarbon film during bonding to prevent a bond for a length sufficient to hold the film securely during testing. Use a 1" piece of seal cut from the end of the seal which has been masked and subjected to tension at an angle relative to the dimensions of the rubber surface. There must be no separation between the fluorocarbon film and the rubber when subjected to the following loads:

Thickness of Fluorocarbon Film

Machine Method at 2 inches Per Minute

Deadweight Method

0.060 30 lbs per inch width 30 lbs per inch width

2.1.6 Material Test Report

Contractor to 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. Reports of tests, inspections, and verifications of all materials used under this contract are to be approved by the Government before incorporation into the structure. Conform tests, inspections, and verifications to the requirements of the particular sections of these specifications for the respective items of work unless otherwise specified or authorized. Government may request that tests be conducted in the presence of the Government. Furnish specimens and samples for additional independent tests and analyses upon request by the Government.

2.2 Steel Fabrication and Machine Work

2.2.1 Quality Assurance

2.2.1.1 Fabricator’s Welding Quality Control Plan

Before the start of work, submit a Fabricator's Quality Control Plan for approval. Ensure the plan describes the methods, equipment, and procedures utilized to ensure quality control including but not limited to material tracking, NDT equipment calibration, non-conformance reports, and inspection witness points.

2.2.1.2 Shop Drawings

Prior to fabrication submit detailed shop drawings of the seal retainer bars and leaf springs to the CO and Engineer of Record for approval. Show complete details of materials, tolerances, connections, and bolting hardware on shop drawings. Include catalog cuts, templates, fabrication and assembly details, and type of materials, as appropriate on shop drawings. Utilize AWS A2.4, AWS A3.0M/A3.0, AISC 303, AISC 325, and AISC 326 for shop drawing preparation. Provide shop drawings to scale and readable on an 11x17 printed copy. Fabricator is required to provide an 11x17 printed copy of the approved set of fabrication drawings to the Government Quality Assurance Representative prior to the start of fabrication.

Provide a table containing a list of all members and a reference to each material certificate and test report that applies to that member.

2.2.2 Materials

2.2.2.1 Structural Steel

Provide structural steel for the side seal retaining bars conforming to ASTM A36/A36M.

2.2.2.2 Top Seal Bolts

Provide .625" diameter 3.25" long flat head half-hard naval brass conforming to ASTM B21/B21M UNS C46400. Provide brass washers and brass nylon locking nuts.

2.2.2.3 Side and Bottom Seal Bolts

Provide .625" diameter 3.00" long hex head half-hard naval brass conforming to ASTM B21/B21M UNS C46400. Provide brass washers and brass nylon locking nuts.

2.2.2.4 Leaf Spring Bolts

Provide .75" diameter 4" long flat head half-hard naval brass conforming to ASTM B21/B21M UNS C46400. Provide brass washers and brass nylon locking nuts. Provide isolation sleeves as detailed on the drawings.

2.2.2.5 Leaf Spring

Provide Leaf Springs made from Alloy 5160H meeting the requirements of ASTM A322. Provide a minimum hardness of 55 HRC conforming to ASTM A304/A304M.

2.2.3 Material Test Reports

Contractor to 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. Reports of tests, inspections, and verifications of all materials used under this contract are to be approved by the Government before incorporation into the structure. Conform tests, inspections, and verifications to the requirements of the particular sections of these specifications for the respective items of work unless otherwise specified or authorized. Government may request that tests be conducted in the presence of the Government. Furnish specimens and samples for additional independent tests and analyses upon request by the Government.

2.2.4 Fabrication

2.2.4.1 Structural Fabrication

Material must be straight before being laid off or worked. If necessary, straighten by methods that will not impair the metal. Sharp kinks or bends are cause for rejection of the material. Make bends by approved dies, press brakes or bending rolls. Finished members must be free of twists, bends, and open joints.

Where heating is required, take precautions to avoid overheating the metal and allow to slowly cool in still air in a manner that will not adversely impair the original properties of the metal.

Cut structural steel to meet the dimensions as required on the approved shop drawings and to obtain an accurate profile with a surface that is smooth and free from cracks and notches. Limit flame cutting to low carbon, non-heat-treated steels used for structural application with the exception of structural bolt hole installation. Approve all other flame cutting prior to use and clearly indicate locations on shop drawings. Shearing must be accurate, and all portions of the work neatly finished. Corners must be square and true unless otherwise shown. Fillet re-entrant cuts with a minimum radius of 19 mm 3/4 inch, unless otherwise approved. Cut steel and fabricate steel plates and splice plates for major structural components so the primary direction of rolling is parallel to the direction of the main tensile or compressive stresses.

Break all cut edges and corners with 1/16-inch radius to eliminate sharp edges. Bolts, nuts, and screws must be tight.

2.2.4.2 Dimensional Tolerance and Alignment for Structural Fabrication

Measure dimensions by an approved measuring system. Submit the measuring system for approval with the work plan. The overall dimensions of an assembled structural unit are required to 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 on drawings, a variation of 0.8 mm 1/32 inch is permissible in the overall length of component members with both ends milled and component members without milled ends are not permitted deviate from the dimensions shown by more than 1.6 mm 1/16 inch for members 9 m 30 feet or less in length and more than 3 mm 1/8 inch for members over 9 m 30 feet in length based on a structure temperature of 20 degrees C 70 degrees F. In all cases, completed members must be free of twists (except as allowed by ASTM standards), bends and open joints. Sharp kinks or sharp bends will be cause for rejection.

For straight structural members other than compression members, the variation in straightness is not permitted to exceed that specified for structural shapes in the applicable ASTM standards.

For straight compression members, the variation in straightness must be equal to or less than 1/1000 of the axial length between points that are to be laterally supported.

For beams that are detailed without specified camber, fabricate the member so that, after erection, any incidental camber due to rolling or shop fabrication is upward.

The accumulation of the mill tolerances and fabrication tolerances must not cause the erection tolerances to be exceeded.

2.2.5 Bolted Connections

2.2.5.1 General

Provide bolts, nuts, and washers of the type specified or indicated on the drawings. Equip all bolt heads and nuts with washers except for high-strength bolts. Use beveled washers where bearing faces have a slope of more than 1:20 with respect to a plane normal to the bolt axis. Ribbed bolts will not be acceptable.

2.2.5.2 Bolt Holes

2.2.5.2.1 Regular Bolts

Drill or sub-drill and ream holes for regular bolts. Holes must be accurately located, smooth, perpendicular to the member, cylindrical and not more than 1/16-inch larger than the diameter of the bolt, unless shown or noted otherwise.

2.2.5.2.2 Fitted Bolts

Holes for fitted bolts must be match-reamed or drilled. Holes must be smooth, perpendicular to the member and cylindrical. Remove burrs resulting from reaming. The threads of the bolt must be entirely outside of the holes. Tolerances for the body diameter of the bolt conform to recommendations in ASME B4.1 for the class to fit specified. Fitted bolts must be fitted in reamed holes by selective assembly to provide an LC 7 or closer tolerance fit.

2.2.6 Machine Work

2.2.6.1 General

For tolerances, allowances and gages for metal fits between plain, non-threaded, cylindrical parts, conform to ASME B4.1 for the class of fit shown or to the dimensions shown. Where fits are not shown comply with good industrial practice for the intended application and obtain approval prior to beginning work. Provide tolerances for machine-finished surfaces designated by non-decimal dimensions within 1/64-inch unless otherwise specified. Provide tolerances for machine-finished surfaces designated by decimal dimensions as follows, unless otherwise specified or shown on the contract or reference drawings. Note that these tolerances are for general machine work for non-critical components.

One (1) place....... +/- 0.030 Two (2) places...... +/- 0.010 Three (3) places...... +/- 0.001

Allow for sufficient excess material stock on surfaces requiring machining to ensure true surfaces of solid material while maintaining the specified minimum or finished plate thickness. Finished contact or bearing surfaces must be true and exact to secure full contact. Finish all surfaces in accordance with the contract drawings to ensure proper operation when assembled. Accurately machine parts and make all like parts interchangeable. Accurately locate all drilled bolt holes to ensure interchangeability.

2.2.6.2 Finished Surfaces

Provide surface finishes as indicated on drawings or specified in accordance with ASME B46.1. Values of required roughness heights are arithmetical average deviations expressed in micro inches. These values are maximum. Lesser degrees will be satisfactory unless otherwise indicated. Compliance with surface requirements is determined by sense of feel and visual inspection of the work compared to Roughness Comparison Specimens in accordance with the provisions of ASME B46.1. Values of roughness width and waviness height must be consistent with the general type of finish specified by roughness height.

Where the finish is not indicated or specified, provide a surface finish that is most suitable for the particular surface, provides the class of fit required and indicate the finish on the shop drawings by a symbol which conforms to ASME B46.1 when machine finishing is provided. Flaws such as scratches, ridges, holes, peaks, cracks, or checks which will make the part unsuitable for the intended use will be cause for rejection.

2.2.6.3 Unfinished Surfaces

Lay out all work to secure proper matching of adjoining unfinished surfaces unless otherwise directed.

Where there is a discrepancy between adjoining unfinished surfaces, grind the discrepancy smooth or machine to secure proper alignment. Unfinished surfaces must be true to the lines and dimensions shown.

Grind free all projections and rough spots. Fill in depressions or holes not affecting the strength or usefulness of the parts using an approved method.

2.2.7 Inspection/Nondestructive Examination (NDE)

2.2.7.1 Inspection

Maintain an approved inspection system and perform required inspections. Document nonconformances in writing and submit a Nonconformance Reports documenting any deviation from the QCP, approved shop drawings, code, Work Plan and/or specifications.

Perform fabrication/erection inspection to ensure that materials and workmanship meet the minimum requirements of the Contract documents.

When doubt exists as to the soundness of any material part; such part may be subjected to any form of nondestructive testing that will thoroughly investigate the part in question as determined by the CO. Any defects may be cause for rejection and rejected parts are required to be replaced and retested at the Contractor's expense.

2.2.8 Shop Inspection

Inspect each structural unit prior to assembly to determine the correctness of the fabrication and machining of the component parts. Do not exceed tolerances shown. Closely check each unit inspected to ensure that dimensions and tolerances are met. Maintain an inspection record for review by the Government for each item inspected.

2.2.9 Protection of Machined Surfaces

For machined surfaces, thoroughly clean of foreign matter and protect by suitable means. For un-assembled pins and bolts, oil and wrap with moisture-resistant paper or protect by other approved means.

2.3 Painting - Hydraulic Structures

2.3.1 Quality Control Manual

Before the start of work, the fabricator is to supply a Quality Control Manual (QCM) to the Government for approval. The QCM will clearly address differences between the Quality Management System (QMS) and with these Specifications. These Specifications will govern between any discrepancies. The QCM will include, at a minimum, the following items in addition to the requirements outlined in the joint AISC 420/SSPC QP 3 Quality Management System Standard for Coatings Application:

a. Inspection plan.

b. Method for verification of accuracy of inspection measuring and test equipment.

c. Nonconformance control procedures.

d. Corrective action procedures.

e. Coating defect repair procedures.

f. Handling, storage and delivery of product and materials

2.3.2 Pre-Painting Conference

Prior to any painting, schedule and hold a pre-painting conference. Include in the pre-painting conference, at a minimum, the Prime Contractor, Painter, the primary paint quality control representative, the COR, and the Government Quality Assurance Representative. The pre-painting conference is required to occur either at the painters facility or a similar location as deemed appropriate. Include, at a minimum, discussions of the painters QCM and identification of roles and responsibilities including roles and responsibilities of painting subcontractors. Prepare for this meeting by reviewing plans and specifications and code concerns prior to this meeting and be prepared to discuss any issues regarding the painting including application requirements and required witnessing of testing. In addition, hold points/witness points are required to be established during the pre-painting conference. At minimum, hold points will include, but are not limited to, the following:

a. Blast Profile for each structure.

b. Primer dry film thickness (DFT) for each structure.

c. Complete coating system for each structure.

2.3.3 Coating Thickness Gage Qualification

Submit documentation of manufacturer's certification for all coating thickness gages and dew point meters. Submit dry film thickness gauge calibration records for Government approval. Calibrate all gauges annually. Use type 2 gauges as described in ASTM D7091 to make all coating thickness measurements on ferrous metal substrates. Use eddy current thickness gages as described in ASTM D7091 to measure coating thickness on all nonferrous metal substrates. Use gages with an accuracy of +/-three percent or better. Use gages certified by the manufacturer as meeting these requirements on the job.

Calibrate gages on an annual basis and submit the current calibration.

2.3.4 Sampling and Testing

Allow at least 30 days for sampling and testing. Sampling may be at the jobsite or source of supply.

Notify the Contracting Officer (CO) when the paint and thinner are available for sampling. Sampling of each batch will be witnessed by a Government representative unless otherwise specified or directed.

Submit samples of all special paint formula, Military, Master Painter Institute, and SSPC paints and samples of solvents or thinners used to reduce the viscosity of the paint. Submit a 1 L 1-quart product samples of paint and thinner for each batch proposed for use. Label the sample to indicate formula or specification number and nomenclature, batch number, batch quantity, color, date made, and applicable project Contract number. Test all paint formulas at U.S. Army Construction Engineering Research Laboratory (CERL). Testing will be performed by the Government. Costs associated with sampling and shipping are to be borne by the Contractor. Costs for retesting rejected material will be deducted from payments to the Contractor at the rate of $2,500 for each paint sample retested and $400 for each thinner retested. Send all paint formulas to be tested to:

U.S. Army Construction Engineering Research Laboratory

ATTN: Paint Laboratory 2902 Newmark Dr.

Champaign, IL 61826-9005

2.3.5 Qualifications

Comply with the following for qualifications and experience.

2.3.5.1 Quality Control Personnel

Quality Control personnel are to be certified by SSPC as a Protective Coating Inspector level 2, NACE Coating Inspection Personnel level 2, or AMPP Certified Coating Inspector level 2. Quality control personnel can be assigned to more than one task, provided they are qualified and able to fully perform the duties of each position. Individual(s) responsible for quality assurance/quality control may not serve as or report to production management. If the ability of QC is in doubt, the Government reserves the right to have QC personnel removed from the project.

2.3.5.2 Qualified Painting Contractor

Provide a certified SSPC QP 1 Painting Contractor for field applications.

Provide a certified SSPC QP 3 or AISC Complex Coatings Endorsement - Enclosed for shop applied coatings.

2.3.5.3 Qualified Paint Applicator

Submit records of qualification tests and third-party certification for each Qualified Paint Applicator.

Paint applicators who have previously qualified in the last 12 months on the specified paint system are exempt from testing provided their qualification certificates are submitted and approved by the Government. Prior to the initiation of any work, test and certify all paint applicators as meeting the requirements of the qualified paint applicator. Administration of the certification will be by the Government approved third party Test Agency. Do not apply any paint from applicators failing the certification test.

2.3.5.4 Test Plate

Use the standard test plate in accordance with ASTM D4228. Paint the test plate in the near vertical position (15 degree maximum from vertical). Use a minimum test plate thickness of 3/8-inch unless otherwise instructed. Provide half of the bolts with the heads exposed and half with the threads exposed.

Do not alter the test plate design without prior approval from the Government.

2.3.5.5 Certification Test Procedure

Conduct certification testing of paint applicators at the painting facility where these components will be coated in coordination with the CO. Only one applicator is permitted to test an individual panel. Supply the fabricated test plates to be used for the tests and provide crane service, rigging, and any other work necessary to provide accessibility for the certification testing and inspection. In preparation, clean and prepare the test plates in accordance with the requirements of the contracted work. Perform abrasive blasting with the blast media to be used in the Contract. Provide paints and materials to be applied from the same batch numbers as to be used on this project. Apply paints as specified in the Contract. The painter being tested is required to mix and thin the paints to be used in the test and set up and adjust the application equipment for use. Apply each of the types of paint comprising the specified system by each painter. Paint the test plate in a near vertical position.

2.3.5.6 Certification Criteria

Evaluation of the paint applicator will be based on the conformance of the applied paint system to the requirements of the specifications. Deficiencies in the coatings, improper mixing or improper application methods are basis for failure. The Government Representative will be the sole judge as to the acceptability of each paint applicator's performance. If during production painting the painter's ability is brought into question, the Government reserves the right to remove the painter from the project.

2.3.6 Ambient Conditions

Apply paint only to surfaces that are a minimum of 5 degrees above the dew point temperature and that are completely free of moisture and contaminants as determined by sight and touch. Do not apply paint to surfaces upon which there is detectable frost or ice. Except as otherwise specified, the temperature of the surfaces to be painted and of air in contact therewith must be not less than 9 degrees C 45 degrees F during paint application nor must paint be applied if the surfaces can be expected to drop to 0 degrees C 32 degrees F or lower before the film has dried to a reasonably firm condition. During periods of inclement weather, painting may be continued by enclosing the surfaces and applying artificial heat, provided the minimum temperatures and surface dryness requirements prescribed previously are maintained. Do not apply paint to surfaces heated by direct sunlight or other sources to temperatures that will cause detrimental blistering pin holing, or porosity of the film.

2.3.7 Warranty

Any visible signs of coating failure on the side seal retainer bars within 1 year of final acceptance will be corrected by the Contractor at no additional cost to the Government, to include paint system repair.

2.3.8 Paint Formulas

Submit manufacturer's product data sheet for each type of paint used; for products that are specified to be applied in accordance with the manufacturer's recommendations, submit the paint manufacturer's product data sheet or other written instructions for those products. Include test reports on the paint formula by CERL as required in paragraph SAMPLING AND TESTING. Provide paints with the composition as indicated herein. Where so specified, package certain components of a paint formulation in separate containers for mixing on the job. If not specified or otherwise prescribed, use the color naturally obtained from the required pigmentation.

2.3.8.1 Formula V-766e

This formula is for Vinyl-Type White (or Gray) Impacted Immersion Coating, the ingredients are shown below.

INGREDIENTS PERCENT BY MASS

Vinyl Resin, Type 3 5.6 Vinyl Resin, Type 4 11.6 Titanium Dioxide and (for Gray) Carbon Black

13.0

Diisodecyl Phthalate 2.9

Methyl Isobutyl Ketone 32.0 Toluene 34.7 Ortho-Phosphoric Acid 0.2

Total 100.0

Accomplish the dispersion of pigment by means of pebble mills or other approved methods to produce a fineness of grind (ASTM D1210) of not less than 7 on the Hegman scale. Grinding in steel-lined or steel-ball mills will not be permitted. No grinding aids, antisettling agents, or any other materials except those shown in the formula will be permitted. The paint must show the proper proportions of specified materials when analyzed by chromatographic and/or spectrophotometric methods. Measure the ortho-phosphoric acid accurately and dilute with at least four parts of ketone to one part of acid and slowly incorporate into the finished paint with constant and thorough agitation.

Provide paint with a viscosity between 60- and 90-seconds using ASTM D1200 and a No. 4 Ford cup.

Provide white and gray paints in the volume ratio designated by the purchaser. Provide gray paint containing no pigments other than those specified. Provide enough carbon black to produce a dry paint film having a reflectance of 20-24 (ASTM E1347). The resulting gray color must approximate color 26231 of FED-STD-595.

2.3.8.2 Formula VZ-108d

This formula is for Vinyl-Type Zinc-Rich Impacted Immersion Coating, the ingredients are shown below.

INGREDIENTS PERCENT BY

WEIGHT

KILOGRAMS/POUNDS LITERS/GALLONS

COMPONENT A

Vinyl Resin, Type 3 16.6 49.5/109.2 36.5/39.65 Methyl Isobutyl Ketone

80.6 239.9/528.9 300.1879.30

Suspending Agent E 0.7 2.1/4.6 1.06/0.28 Suspending Agent F 0.4 1.2/2.7 0.72/0.19 Methanol 0.5 1.5/3.3 1.89/0.50 Synthetic Iron Oxide (Red)

1.2 3.6/7.9 0.72/0.19

Total 100.0 297.8/656.6 341.1/090.11

COMPONENT B

Silane B 100.0 4.1 1.78/0.47

COMPONENT C

Zinc Dust 100.0 550.0 35.66/9.42 Total Volume 378.54/100.0

(mixed paint)

Disperse iron oxide and suspending agents into the vehicle (Component A) to a fineness of grind of not less than 4 on the Hegman scale (ASTM D1210). Grinding in steel-lined containers or using steel-grinding media will not be permitted. The paint must show the proper proportions of specified materials when analyzed by chromatographic and/or spectrophotometric methods. The sole purpose of the iron oxide pigment is to produce a contrasting color. A red iron oxide-type 3 vinyl resin vehicle paste may be used in place of dry iron oxide provided compensating adjustment are made in the additions of Type 3 resin and methyl isobutyl ketone. Provide a finished product with zinc dust added that produces a paint which has a red tone upon drying and a reflectance of not more than 16 (ASTM E1347).

Apply VZ-108d paint as a kit. Each kit consists of 17 L 4.5 gal (15 kg 33.1 pounds) of Component A in a 20 L 5-gallon lug closure type pail, 12 kg 27.5 pounds of zinc dust (Component C) packaged in a 4 L 1-gal plastic pail, and 89 mL 3 fluid ounces of silane (Component B) packaged in a glass bottle of suitable size having a polyethylene lined cap. Place the bottle of silane on the zinc dust in the 4 L 1-gal pail. In addition to standard labeling requirements, properly identify each container of each component as to component type and each container label of Component A must carry the following: MIXING AND

APPLICATION INSTRUCTIONS: WARNING - THIS PAINT WILL NOT ADHERE TO STEEL

SURFACES UNLESS COMPONENT B IS ADDED. Remove the 89 mL 3 ounces of bottled Component B (silane) from the Component C (zinc dust) container and add to the base paint Component A) with thorough stirring. Then sift the zinc dust into the base paint while it is being vigorously agitated with a power-driven stirrer and continue the stirring until the zinc dust has been dispersed.