Specifications draft.pdf

MAX24 RESTOCK MITER GATE PARTS

SPECIFICATIONS

1. SCOPE. This specification is for the manufacture and supply of various miter gate parts with contract line item numbers (CLIN), material requirements, and quantities as follows:

CLIN Part Name Mark Number

Stock Part Number

Quantity

001 Miter Contact Block 21/6-1 0470 30 002 Quoin Contact Block 21/6-5 0502 30 003 15” Pintle Ball 21/8-5 0238 2 004 Anchor Arm Perp 21/10-1 P138 4 005 Anchor Arm Parallel 21/10-3 P139 4 006 Stud 21/10-5 n/a 8 007 Gudgeon Pin 21/10-6 n/a 4 008 Bushing 21/10-7 n/a 4 009 Wedge Pin 1 Convex 21/10-8 0431 2 010 Gudgeon Link 21/10-12 P135 8 011 Link Pin 21/10-13 n/a 4

Keeper Plate (including 8 cap screws)

21/10-17 n/a 4

These items shall be supplied in accordance with the following specifications and details supplied on the drawings.

2. MATERIALS. The materials shall conform to the following requirements.

2.1. CLIN 001 – Miter Contact Block – Stainless Steel, ASTM A240, Type 304.

2.2. CLIN 002 – Quoin Contact Block – Stainless Steel, ASTM A240, Type 304.

2.3. CLIN 003 – 15” Pintle Ball - Steel Forging, ASTM A668, Class D, carbon content not to exceed 0.35 percent. Corrosion Resisting Welding Rod, AWS A5.4, E309 Series Electrode.

2.4. CLIN 004 – Anchor Arm Perp – Steel Forging, ASTM A668, Class D, carbon content not exceeding 0.35 percent of overall chemical composition which results in satisfactory weldability.

2.5. CLIN 005 – Anchor Arm Parallel – Steel Forging, ASTM A668, Class D, carbon content not exceeding 0.35 percent of overall chemical composition which results in satisfactory weldability.

2.6. CLIN 006 – Stud – Stainless Steel, ASTM A240, Type 304.

2.7. CLIN 007 – Gudgeon Pin – Steel Forging, ASTM A668, Class K.

2.8. CLIN 008 – Bushing – Aluminum Bronze, ASTM B148, B271, or B505 UNS C95400.

2.9. CLIN 009 – Wedge Pin 1 Convex – Steel Forging, ASTM A668, Class K.

2.10. CLIN 010 – Gudgeon Link – Steel Forging, ASTM A668, Class D, carbon content not exceeding 0.35 percent of overall chemical composition which results in satisfactory weldability.

2.11. CLIN 011 – Link Pin – Steel Forging, ASTM A668, Class K.

2.12. CLIN 012 – Keeper Plate – Structural Steel, ASTM A36.

Also includes 8 cap screws – SAE Grade 8.

3. MACHINE WORK REQUIREMENTS. All workmanship shall be of the highest grade in accordance with the best modern practices to conform to the specifications for the item to be furnished. All similar parts shall be interchangeable. All sharp edges and corners shall be broken.

3.1. Dimensions and Tolerances. Tolerances for machine-finished surfaces designated by non-decimal dimensions shall be within +/- 0.010-inch unless otherwise noted on the drawings.

3.2. Unfinished Surfaces. Unfinished surfaces shall be true to the lines and dimensions given on the drawing and shall be chipped or ground free of all projections and rough spots.

Tolerances shall conform to the standard foundry and/or industry practices.

3.3. Finished Surfaces. Surfaces indicated on the drawings or specified herein, the symbols used or finishes specified shall be in accordance with ANSI B46.1, “Surface Texture (Surface Roughness, Waviness and Lay)”. Values of required roughness heights are arithmetical average deviation expressed in micro inches. These values are maximums. Lesser degrees will be satisfactory unless otherwise indicated on the drawings. Compliance with surface requirements shall be determined by sense of feel and visual inspection of the work compared to Roughness Comparison Specimens in accordance with the provisions of ANSI B46.1.

Values of roughness width and waviness height shall be consistent with the general type of finish specified by roughness height. Where the finish is not indicated or specified, it shall be that which is most suitable for the particular surface, provide the class of fit required, and be indicated on the shop drawing by a symbol which conforms to ANSI B46.1 when machined finishing is provided. Flaws such as scratches, ridges, holes, peaks, cracks or checks which will make the part unsuitable for the intended purpose will be cause for rejection.

3.4. Protection of Finished Work. Machined surfaces shall be thoroughly cleaned of foreign matter. All finished surfaces shall be protected by suitable means.

4. CERTIFICATION OF COMPLIANCE. Certificates of compliance shall be submitted for all items demonstrating compliance of materials with the specification requirements. The certificate(s) shall verify that the supplied material complies with the established standards for both the physical and chemical properties of the material specified. Each certification shall be signed by an official authorized to certify on behalf of the manufacturing company and shall contain the name and address of the contractor, the contract number and the quantity and date(s) of shipment or delivery to which the certifications apply.

4.1. Material Test Reports. Material Certification testing shall be performed and reports shall be submitted for all items supplied under the contract. The reports shall include a description of material, specifications, chemical properties and mechanical properties of the material used to manufacture the contract parts.

Information shall be included which renders the reports identifiable and traceable with the specific parts manufactured for the contract.

5. NONDESTRUCTIVE TESTING. CLINs 003, 004, 005, 007, 009, 010, and 011 shall be subjected to nondestructive testing, including ultrasonic and magnetic particle tests. NDT testing (UT and MT) for CLIN 003 pintle ball shall be conducted prior to performing weld cladding for corrosion resistance. See Section 7 herein for additional NDT and destructive testing required for CLIN 003. An approved independent testing laboratory shall perform all nondestructive testing. Ultrasonic Testing shall be in accordance with ASTM A388 and ASTM A788, Supplementary Requirement S20, Acceptance Level BR. Magnetic Particle Testing shall be in accordance with ASTM A275 and ASTM 788 Supplementary Requirement S18. All welds shall be Magnetic Particle Tested in accordance with ASTM E709 and AWSD 1.1 Section 6, Part C and D. Certified test reports shall be submitted for all tests.

6. MARKING REQUIREMENTS. Each part shall be legibly marked with a paint marker and/or tag with the Mark Number and Stock Part Number (if applicable) shown in the table above.

7. WELDING. Welding shall conform to the following provisions.

7.1. For CLIN 003 Pintle Ball, the weld procedure and qualification shall be in accordance with NAVSEA S9074-AQ-GIB-010/248 “Requirements for Welding and Brazing Procedure and Performance Qualification” dated 01-August-1995. The requirements pertaining to weld cladding for corrosion resistance (paragraph 4.4.2.1) shall be met, including guided bend, macro-etch, and liquid penetrant testing in accordance with Table VII. The base metal (ASTM A668 Class D) shall be assumed to fall into base metal category S-1 in Table I. The welding rod (AWS A5.4, E309 electrode) shall be assumed to fall into filler material category A-8A in Table II.

7.2. For CLIN 006 Stud, welding shall conform to the provisions of AWS D1.6 Structural Welding Code for Stainless Steel. Filler material shall meet AWS A5.4, E309 electrode classification.

7.3. For CLIN 010 Gudgeon Link, welding shall conform to the provisions of AWS D1.1 Structural Welding Code for Steel. Filler material shall meet AWS A5.1, E7018 electrode classification.

7.4. Welding Procedure. Complete schedules of welding procedures and other required procedures must be submitted and approved before fabrication is commenced. The schedule shall conform to the provisions outlined above for CLINS 003, 006, and

010. Filler metal, preheat, interpass temperature, and stress relief heat treatment requirements must be included in the procedures. Procedures shall be such as to minimize residual stresses, distortion, and shrinkage. Procedure shall be qualified by test except for prequalified procedures described in AWS. Properly documented evidence of compliance with all requirements for these specifications for previous qualifications tests shall establish the joint welding procedure as being prequalified or qualified by tests. Application of any procedure will not relieve the contractor of the responsibility for producing a finished structure meeting all requirements of these specifications. Forged samples used for all testing shall be separate pieces forged from the same material which is incorporated into the final product.

7.5. Welders’ Qualification. Welding operators, welders, and tack welders shall be qualified and requalified if necessary for the particular type of work to be done. The contractor shall certify by name the welders and welding operators qualified, the date of qualification, and code procedures under which qualified.

7.6. Filler Metal. The electrode, electrode-flux combination and grade of weld metal shall conform to the appropriate specification for the base metal and welding process being used. The designation of 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 to maintain low moisture of low hydrogen electrodes.

7.7. Preheat and Interpass Temperature. Preheating shall be performed as required by AWS, except that the temperature of the base metal shall be at least 70 degrees Fahrenheit. The weldments to be preheated shall be slowly and uniformly heated by approved means to the prescribed temperature, held at that temperature until the welding is completed, and then permitted to cool slowly in still air.

7.8. Preparation of Base Metal. Prior to welding, the contractor shall inspect surfaces to be welded to assure compliance with AWS.

7.9. Stress Relief Heat Treatment. Stress relief heat treatment shall be in accordance with the requirements of AWS unless otherwise authorized or directed by the contracting officer.

8. CASTINGS. These requirements pertain to CLIN 008 Aluminum Bronze Bushing.

Dimensions of castings shown on the drawings shall be finished dimensions. Castings that are warped or otherwise distorted or that are oversized to an extent that will interfere with proper fit with other parts will be rejected. The structure of metal in castings shall be homogenous and free from excessive nonmetallic inclusions. Excessive segregation of impurities or alloys at critical points in castings will be cause for rejection. Repairs to castings shall not be made prior to approval and shall be made at no additional cost to the Government.

9. ASSEMBLY. CLINS 004, 005, 008, 010, 011, and 012 are required to be assembled per the provided assembly drawing. Ensure the inside diameter (ID) of CLIN 008 meets the tolerances on the drawing after being press fit (ensures CLIN 007 Gudgeon Pin can be installed through the bushing after press fit is completed). The all-around fillet weld shown on the assembly drawing will be performed by others in the future. However, tack welding shall be performed to the extent necessary to maintain the proper angles during handling and shipment.

10. PACKAGING. All items shall be protected to the extent necessary to prevent damage during shipment. The contractor shall repair all damage incurred due to inadequate protection. The contractor shall provide all materials required for protection during shipment.

11. SHIPPING. The contractor shall deliver all items to the Pittsburgh Engineering

Warehouse and Repair Shops (PEWARS) located at 3500 Grand Avenue. Neville Island, PA 15225-1584. Delivery shall occur between 0800 and 1430 hours Monday through Friday; excluding Federal Holidays.

12. POINT OF CONTACT. If there are any questions related to the information shown in these specifications, the technical point of contact is Timothy O’Loughlin, timothy.o’loughlin@usace.army.mil, 412-395-7606 (office), 412-290-1207 (cell).