Statement_Of_Work.pdf

Specifications for

FABRICATION OF

AUXILIARY LOCK NEEDLE

BEAMS FOR MARMET

LOCKS AND DAM,

BELLE, WV

DEPARTMENT OF THE ARMY

HUNTINGTON DISTRICT, CORPS OF ENGINEERS

HUNTINGTON, WEST VIRGINIA

September 2019

RTA-CERTIFIED FINAL DOCUMENTS

This page was intentionally left blank for duplex printing.

KRLMAR06

BIDDING SCHEDULE

ITEM

NO. DESCRIPTION

ESTIMATED

QUANTITY UNIT

UNIT

PRICE

ESTIMATED

AMOUNT

1 Final "As-Built" Documents 1 Job Sum

Fabrication of Two (2) Auxiliary Lock Needle

Beams 1 Job Sum

3 Shipment and Delivery 1 Job Sum

Total Bid Items 1 thru 3 $

GENERAL FEATURES: The Contract shall consist of the fabrication and delivery of two (2) auxiliary lock needle beams to Winfield Locks and Dam in Eleanor, West Virginia. Delivery shall be made via truck transportation as described in these specifications.

Fabrication of Auxiliary Lock Needle Beams KRLMAR06

PROJECT TABLE OF CONTENTS

DIVISION 01 - GENERAL REQUIREMENTS

01 11 01 SECTION C-PART B 01 11 01 GENERAL REQUIREMENTS

01 38 10 SECTION C-PART D 01 38 10 PROGRESS PHOTOGRAPHS

01 78 00 SECTION C-PART F 01 78 00 CLOSEOUT SUBMITTALS

DIVISION 05 - METALS

05 59 20 SECTION C-PART G 05 59 20 FABRICATION OF HYDRAULIC STEEL

STRUCTURES

DIVISION 09 - FINISHES

09 97 02 SECTION C-PART H 09 97 02 PAINTING: HYDRAULIC STRUCTURES

DIVISION 31 - EARTHWORK

31 46 00 SECTION C-PART I 31 46 00 AUXILIARY LOCK NEEDLE BEAM

-- End of Project Table of Contents --

PROJECT TABLE OF CONTENTS Page 1

SECTION TABLE OF CONTENTS

DIVISION 01 - GENERAL REQUIREMENTS

SECTION C-PART B 01 11 01 GENERAL REQUIREMENTS

PART 1 GENERAL

1.1 SUMMARY

1.2 REFERENCES

1.3 SUBMITTALS

1.4 SCOPE

1.5 DRAWINGS

1.6 PACKAGING AND MARKING

1.7 INSPECTIONS AND ACCEPTANCE OF WORK

1.8 CONTRACTOR QUALITY CONTROL

1.9 GOVERNMENT WITNESS POINT INSPECTIONS

PART 2 PRODUCTS

2.1 PRODUCTS AND PARTS OF STANDARD MANUFACTURE

PART 3 EXECUTION

3.1 COMBINED PRODUCTION SCHEDULE AND PROGRESS CHART

3.2 SEQUENCE OF WORK

3.3 PROJECT RECORDS

3.4 DELIVERY

3.5 PAYMENT

-- End of Section Table of Contents --

SECTION 01 11 01 Page 1

SECTION C-PART B

01 11 01

GENERAL REQUIREMENTS

PART 1 GENERAL

1.1 SUMMARY

This section covers general requirements applicable to the performance of the work under this contract. These requirements are in addition to those specified in other sections of the contract.

1.2 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to in the text by basic designation only.

AMERICAN WELDING SOCIETY (AWS)

AWS D1.5M/D1.5 (2015) Bridge Welding Code

1.3 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only or as otherwise designated. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. The following shall be submitted in accordance with Section C-Part C 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Prefabrication Submittals

Production Schedule; G|CM

Production schedule shall be submitted for approval.

Updated Progress Charts; G|CM

Updated progress charts shall be submitted monthly for approval.

SD-07 Certificates

Contractor Quality Control Plan; G|CM

The Contractor shall submit a written quality control plan for approval in accordance with paragraph "INSPECTIONS AND ACCEPTANCE

OF WORK".

1.4 SCOPE

The work covered by this section consists of the fabrication, assembly, and delivery of two needle beams, and appurtenant items as specified and shown on the drawings. The needle beams shall be complete, welded, structural steel structures with fabrication and assembly performed in a fabrication shop. Each needle beam consists of a box beam with lifting lugs, an attached composite bearing block assembly, and a personnel walkway. The box

SECTION 01 11 01 Page 2 beam shall be 60’-0” long with a flange width of 2’-0” and section depth of 5’-2-1/4. The composite bearing block and the channel which it is installed into shall be installed as shown on the contract drawings. The personnel walkway shall consist of steel framing members, steel (galvanized) pipe handrailing, and composite grating. All features shall be dimensioned and connected as shown on the contract drawings.

Due to the critical nature of this structure, and the fact that some members are "Fracture Critical", all welding is required to be performed to AWS D1.5M/D1.5 welding code standard by a steel fabricator certified under the AISC Quality Certification Program for "Fabricators of Hydraulic Steel Structures" (HYD) or Steel Bridge Fabricators (AISC 207-16) for "Advanced Bridges" (ABR) meeting supplemental requirements for "Fabricators of Bridges with Fracture-Critical Members" (FC). The Contractor shall possess five (5) years documented experience on projects of similar scope.

Individuals that work for the Contractor, or whom are hired by the Contractor, that will require access to the Marmet Locks and Dam (MAR) will need to meet the security requirements and AT/OPSEC requirements as specified in Section C-Part A 00 80 00 SPECIAL CONTRACT REQUIREMENTS. This shall include the delivery truck personnel and the Contractor's representative(s) that will perform the final inspection once the needle beams have been delivered to the project.

1.5 DRAWINGS

The Drawings reflect the work to be performed under this contract. In accordance with Section C-Part A 00 80 00 SPECIAL CONTRACT REQUIREMENTS, Paragraph CONTRACT DRAWINGS AND SPECIFICATIONS, the Contractor shall check all drawings immediately upon receipt, and verify the figures, dimensions, and the representation of the work, and shall promptly notify the Contracting Officer of any discrepancies. Any omissions from the drawings or misdescription of details of the work which are manifestly necessary to carry out the intent of the drawings, or which are customarily performed, shall not relieve the Contractor from performing such omitted or misdescribed details of work.

1.6 PACKAGING AND MARKING

The Contractor shall prepare and load the needle beams on a truck for shipment in accordance with SECTION D, PACKAGING AND MARKING. Any damage incurred during handling, packaging, loading and shipping shall be repaired and/or replaced by the Contractor as directed by the Contracting Officer without additional cost to the Government.

1.7 INSPECTIONS AND ACCEPTANCE OF WORK

Items furnished under this contract order shall be inspected in accordance with SECTION E, INSPECTION AND ACCEPTANCE. The Contracting Officer or his authorized representative shall be the individual(s) solely authorized to reject materials, disapprove or approve any work in progress, or order or direct any revision or change to the plans and specifications as presently shown and stated.

When all the work for the needle beams and appurtenant items specified under this contract have been completed and the needle beams and appurtenant items have been delivered f.o.b. destination, the Contracting Officer will make a thorough examination of the needle beams and appurtenant items to assure that no damage occurred during shipment. If the

SECTION 01 11 01 Page 3 needle beams and appurtenant items are found to be in good condition, they will be accepted and the Contractor will be so notified.

1.8 CONTRACTOR QUALITY CONTROL

The Contractor shall be responsible for quality control and shall establish and maintain an effective quality control system in accordance with SECTION H, SPECIAL REQUIREMENTS. The quality control system shall consist of plans, procedures, and organization necessary to produce an end product which complies with the requirements of this contract. The system shall cover all fabrication, painting and delivery operations.

1.9 GOVERNMENT WITNESS POINT INSPECTIONS

The Government will conduct witness point inspections throughout the fabrication process and upon delivery to the Government facility. The Contractor shall notify the Government 14 calendar days prior to the defined witness points to allow for scheduling of Government personnel and travel. See Section 05 59 20 FABRICATION OF HYDRAULIC STEEL STRUCTURES for detailed witness point requirements.

PART 2 PRODUCTS

2.1 PRODUCTS AND PARTS OF STANDARD MANUFACTURE

All materials, supplies and articles furnished so as to be incorporated into the work under this contract shall, whenever so specified and otherwise practicable, be standard products of recognized reputable manufacturers. All products specified by "similar or equal to" a particular brand name are for descriptive purposes only and are not to imply that the product is available from only that source.

PART 3 EXECUTION

3.1 COMBINED PRODUCTION SCHEDULE AND PROGRESS CHART

The Contractor shall, within 15 days after receipt of Notice of Award, submit a proposed Production Schedule showing how the Contractor proposes to perform the work, the dates on which he will start the several salient features, including procurement of materials, fabrication, assembly, testing, cost breakdown and the contemplated dates for completion and shipment. The schedule shall be in the form of a bar graph of suitable scale to indicate appropriately the percentage of work scheduled for completion at any time on the salient features as well as the completion of all work. The Contractor shall enter on the graph the actual progress at the end of each month, and shall immediately deliver a copy to the Contracting Officer or his authorized representative. These Updated Progress Charts reflecting actual progress will be considered "Production Progress Reports".

3.2 SEQUENCE OF WORK

The work shall be prosecuted in such order of precedence as best suits the Contractor's fabrication schedule. The Contractor shall perform the work in a diligent, effective manner, and shall schedule his operations in such a manner that the work is completed on time.

SECTION 01 11 01 Page 4

3.3 PROJECT RECORDS

The Contractor shall maintain and submit "As-Built" drawings, As-Built Record of Equipment and Materials, and Data Book in accordance with Section C-Part F 01 78 00, CLOSEOUT SUBMITTALS.

3.4 DELIVERY

The Contractor shall prepare, load and ship the needle beams and the appurtenances items in accordance with SECTION F, DELIVERIES AND

PERFORMANCE.

3.5 PAYMENT

No separate payment will be made under this section and all costs in connection therewith, shall be included in the applicable contract price to which the work pertains.

-- End of Section --

SECTION 01 11 01 Page 5

DIVISION 01 - GENERAL REQUIREMENTS

SECTION C-PART D 01 38 10 PROGRESS PHOTOGRAPHS

PART 1 GENERAL

1.1 SUMMARY

1.2 GENERAL REQUIREMENTS

1.2.1 Description

1.3 SUBMITTALS

PART 2 PRODUCTS

2.1 CONTRACTOR-FURNISHED EQUIPMENT

2.1.1 Digital Camera

2.1.2 Digital Photographs

PART 3 EXECUTION

3.1 PHOTOGRAPHY

3.2 PAYMENT

SECTION 01 38 10 Page 1

SECTION C-PART D

01 38 10

PROGRESS PHOTOGRAPHS

PART 1 GENERAL

1.1 SUMMARY

The work under this section includes furnishing progress photographs, consisting of digital photographs showing the progress of the fabrication operations throughout the contract period. The digital photographs shall be furnished in electronic form.

1.2 GENERAL REQUIREMENTS

1.2.1 Description

The Contractor shall, during the progress of the project (including progress of fabrications), furnish the Contracting Officer progress photographs to depict progress of fabrication, throughout the life of contract. The photographs shall be taken using digital photography equipment furnished by the Contractor. Electronic copies of approved photographs shall be furnished on compact disk, or other storage media as approved by the Contracting Officer.

1.3 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only or as otherwise designated. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. The following shall be submitted in accordance with Section C-Part C 01 33 00 SUBMITTAL PROCEDURES:

SD-03 Product Data

Electronic Copy of Selected Official Progress Images; G|DS Electronic Copy of All Other Progress Images; G|DS

Copies of digital progress images in electronic form shall be submitted monthly for approval in accordance with Paragraph PHOTOGRAPHY. Progress images shall be submitted in a timely manner as coordinated with the Contracting Officer.

PART 2 PRODUCTS

2.1 CONTRACTOR-FURNISHED EQUIPMENT

The Contractor shall be responsible for furnishing all photographic equipment to perform the work specified by the section. If the camera becomes unusable for three (3) calendar days or more due to defects in materials or workmanship, the Contractor shall be responsible for furnishing a temporary replacement for the period it is out of service.

2.1.1 Digital Camera

The Contractor shall use a minimum of one digital camera for his use to

SECTION 01 38 10 Page 2 take the official progress photos for this contract. Progress photos shall include progress during all phases of fabrication. The digital camera shall conform to the following minimum requirements. The camera shall have a CCD resolution no less than 16.0 million pixels per image. The camera shall also have picture overlay capability, which allows the user to overlay the time and the date over the digital image. The camera shall come with software that allows the user to download the images onto an IBM-compatible personal computer running Windows 10 or higher, and allow the images to be saved in one of the following graphic formats: JPG (Joint Photographic Experts Group).

2.1.2 Digital Photographs

Digital Photographs shall be submitted at full resolution, not compressed.

The Contractor shall furnish, in Adobe PDF format, a document with each month's photographs which lists the following identifying information for each photographic image:

Name and Location of project Contract number Contractor (and subcontractor if applicable) Date taken File Name Orientation of view and brief description of work depicted

Each photograph shall be sequentially numbered. The identifying data shall be placed in the document accompanying the photographs. No identifying data, except the date stamp, shall appear on the electronic digital photographs. Electronic images shall be recorded with a minimum of 24 bit color and no reduction in actual picture size.

PART 3 EXECUTION

3.1 PHOTOGRAPHY

The Contractor shall, during the progress of the work, furnish the Contracting Officer digitally produced progress photographs to depict the progress of the work. All progress images shall be taken at the camera's highest resolution. In coordination with the Contracting Officer, at least thirty (30) progress photographs per month shall be taken over the full duration of this contract. Electronic copies shall be furnished on compact disk (CD-ROM) with file of required photographic information. At least thirty (30) digital photographs shall be taken continuously throughout each month in which work is in progress. Unless otherwise directed by the Contracting Officer, photographs will not be required for periods of time in which work is not being performed. Additional sets of photographs shall be taken as directed by the Contracting Officer. Enough digital photographs shall be taken to adequately depict each phase of the work and shall show progress made during those phases and at the completion of the project. Digital photographs shall show work accomplished since the previous photographs. Progress photographs shall be submitted as specified herein and in Paragraph SUBMITTALS.

SECTION 01 38 10 Page 3

3.2 PAYMENT

No separate payment will be made for these services, and all costs in connection thereto shall be considered incidental to the listed Contract Line Item price most closely associated with the work involved.

SECTION 01 38 10 Page 4

DIVISION 01 - GENERAL REQUIREMENTS

SECTION C-PART F 01 78 00 CLOSEOUT SUBMITTALS

PART 1 GENERAL

1.1 SUBMITTALS

1.2 PROJECT RECORD DOCUMENTS

1.2.1 As-Built Drawings

1.2.1.1 Government Furnished Materials

1.2.1.2 Working As-Built and Final As-Built Drawings

1.2.1.3 Drawing Preparation

1.2.1.4 Final As-Built Drawings

1.2.2 As-Built Record of Equipment and Materials

1.2.3 Data Book

1.2.4 Electronic CADD Files

1.3 PAYMENT

1.3.1 Final Project Record Documents

PART 2 PRODUCTS (NOT USED)

PART 3 EXECUTION (NOT USED)

SECTION 01 78 00 Page 1

SECTION C-PART F

01 78 00

CLOSEOUT SUBMITTALS

PART 1 GENERAL

1.1 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. The following shall be submitted in accordance with Section C-Part C 01 33 00 SUBMITTAL PROCEDURES:

SD-11 Closeout Submittals

As-Built Drawings; G|DS

Drawings showing final as-built conditions of the project. The manually prepared drawings shall consist of the approved marked working as-built prints.

As-Built Record of Equipment and Materials

Two (2) copies of the record listing the as-built materials and equipment incorporated into the fabrication of the project.

Data Book; G|DS Electronic CADD Files

1.2 PROJECT RECORD DOCUMENTS

1.2.1 As-Built Drawings

This paragraph covers as-built drawings complete, as a requirement of the contract. The terms "drawings," "contract drawings," "drawing files," "working as-built drawings" and "final as-built drawings" refer to contract drawings which are revised to be used for final as-built drawings.

1.2.1.1 Government Furnished Materials

Three (3) sets of drawings revised to reflect all amendments will be provided by the Government at the pre-fabrication conference.

1.2.1.2 Working As-Built and Final As-Built Drawings

The Contractor shall revise 2 sets of paper drawings by red-line process to show the as-built conditions during the prosecution of the project. These working as-built marked drawings shall be kept current on a weekly basis and at least one set shall be available on the jobsite at all times.

Changes from the contract plans which are made in the work or additional information which might be uncovered in the course of fabrication shall be accurately and neatly recorded as they occur by means of details and notes.

Final as-built drawings shall be prepared after all fabrication activities have been completed. If the Contractor fails to maintain the working and final as-built drawings as specified herein, the Contracting Officer will deduct from the contract total representing the estimated cost of

SECTION 01 78 00 Page 2 maintaining the as-built drawings. This monthly deduction will continue until an agreement can be reached between the Contracting Officer and the Contractor regarding the accuracy and completeness of updated drawings. The working and final as-built drawings shall show, but shall not be limited to, the following information:

a. Changes in details of design or additional information obtained from working drawings specified to be prepared and/or furnished by the Contractor; including but not limited to fabrication, erection, assembly, etc.

b. Changes or modifications which result from the final inspection.

c. Where contract drawings or specifications present options, only the option selected for fabrication shall be shown on the final as-built prints.

d. Modifications (change order price shall include the Contractor's cost to change working and final as-built drawings to reflect modifications) and compliance with the following procedures.

(1) Directions in the modification for posting descriptive changes shall be followed.

(2) A Modification Circle shall be placed at the location of each deletion.

(3) For new details or sections which are added to a drawing, a Modification Circle shall be placed by the detail or section title.

(4) For minor changes, a Modification Circle shall be placed by the area changed on the drawing (each location).

(5) For major changes to a drawing, a Modification Circle shall be placed by the title of the affected plan, section, or detail at each location.

(6) For changes to schedules or drawings, a Modification Circle shall be placed either by the schedule heading or by the change in the schedule.

(7) The Modification Circle size shall be 1/2-inch diameter unless the area where the circle is to be placed is crowded.

Smaller size circle shall be used for crowded areas.

1.2.1.3 Drawing Preparation

The as-built drawings shall be modified as may be necessary to correctly show the features of the project as it has been fabricated by bringing the contract set into agreement with approved working as-built prints, and adding such additional drawings as may be necessary. These working as-built marked prints shall be neat, legible and accurate. These drawings are part of the permanent records of this project and shall be returned to the Contracting Officer after approval by the Government. Any drawings damaged or lost by the Contractor shall be satisfactorily replaced by the Contractor at no expense to the Government.

SECTION 01 78 00 Page 3

1.2.1.4 Final As-Built Drawings

Only personnel proficient in the preparation of manually prepared drawings shall be employed to make corrections to the contract drawings. Using the third set of Government furnished drawings, final as-built drawings shall be red-line mark-ups of the original plans created from the working as-built drawings in office setting. Thus being a much neater version of the working set. As-Built Drawings shall also be submitted in PDF format to the Government. Additions and corrections to the contract drawings shall be neat, clean and legible, and shall be done to the same level of detail as the original drawings. All corrections/ dimensions shall be shown in red ink on the original drawings. Corrections, changes, additions, and deletions required shall meet these standards.

a. When final revisions have been completed, each drawing shall be lettered or stamped with the words "RECORD DRAWING AS-BUILT" followed by the name of the Contractor in letters at least 3/16-inch high.

Original contract drawings shall be marked either "As-Built" drawings denoting no revisions on the sheet or "Revised As-Built" denoting one or more revisions All original contract drawings shall be dated in the revision block.

b. The Contractor shall submit a color copy draft set of Final As-built Drawings for review and approval within fifteen (15) calendar days following the completion of fabrication activities. Within thirty

(30) calendar days of receipt of the Final As-built Drawings, the Government will return one set annotated with any necessary corrections. Within fourteen (14) calendar days the Contractor shall revise the drawings accordingly at no extra cost and submit two final sets to the Government. Approval and acceptance of the Final As-built Drawings shall be accomplished before final payment is made to the Contractor.

1.2.2 As-Built Record of Equipment and Materials

The Contractor shall furnish three copies of preliminary record of equipment and materials used on the project fifteen (15) calendar days prior to final inspection. This preliminary submittal will be reviewed and returned fifteen (15) calendar days after final inspection with Government comments. Three sets of final record of equipment and materials shall be submitted thirty (30) calendar days after final inspection, two (2) hard copies and one (1) additional copy on CD-ROM. The designations shall be keyed to the related area depicted on the contract drawings. The record shall list the following data:

RECORD OF DESIGNATED EQUIPMENT AND MATERIALS DATA

Description Specification Manufacturer Composition Where Section and Catalog, and Size Used Model, and Serial Number

1.2.3 Data Book

The Contractor shall compile and maintain a "Data Book" throughout the duration of the contract. The "Data Book" shall consists of copies of all Requests for Information (RFI's) with Government responses, copy of Contractor's AISC Quality Certification, Fracture Control Plan (FCP), SECTION 01 78 00 Page 4

Welding Procedure Specifications (WPS's), Procedure Qualification Records (PQR's), Qualifications of Welders and Welding Operators, Inspector Qualifications, Distortion and Shrinkage Control Plan, Weld Tracking Log, Non-Destructive Examination Reports, Welding Repairs (both FCM's and Non-FCM's), Record of Control Dimensions, Record of Stress Relieving, Painting Contractor Qualifications, documentation of Government Approval of Vinyl Paint and Thinner Samples, Paint Reports, Material Orders, Mill Certification Reports and Manufacturer's Certification Letter's. The "Data Book" shall be neatly prepared with tabs separating each specific item identified above and a Table of Contents identifying which tab corresponds to which item. The in-progress "Data Book" shall be available to the Government to review during shop inspections of the project.

a. When final revisions have been completed, The Contractor shall prepare a "Certificate of Conformance" on their company letterhead certifying that: 1) all materials and workmanship included in the project were detailed, manufactured, tested, inspected and documented as specified in the contract requirements; and 2) the requirements of applicable codes, standards, specifications and drawings have been complied with and that all required quality assurance documentation verify conformance to the contract documents have been submitted. The "Certificate of Conformance" shall be signed by the Contractor's Quality Control System Manager.

b. The Contractor shall submit a draft copy of Final "Data Book" for review and approval within fifteen (15) calendar days following the completion of fabrication activities. Within thirty (30) calendar days of receipt of the Final "Data Book", the Government will return one copy annotated with any necessary corrections. Within fourteen (14) calendar days the Contractor shall revise the "Data Book" accordingly at no extra cost and submit the Final Copy of the Final "Data Book" including the "Certificate of Conformance" to the Government. Approval and acceptance of the Final "Data Book" shall be accomplished before final payment is made to the Contractor.

1.2.4 Electronic CADD Files

All 2D and 3D Computer Aided Drafting and Design (CADD) or any Digital Representations of Design created by the fabricator shall be submitted after acceptance of as-built drawings. Electronic copies shall be furnished on compact disk (CD-ROM). Files shall be submitted as specified herein and in Paragraph SUBMITTALS.

1.3 PAYMENT

1.3.1 Final Project Record Documents

Payment for all costs in connection with the work specified in this section will be made at the contract Line Item price for "Final Project Record Documents", which price shall not be less than $10,000. Failure of the Contractor to update project record documents may result in a retainage held by the Contracting Officer in an amount prorated to the number of weeks during which the Contractor fails to update said drawings.

SECTION 01 78 00 Page 5

PART 2 PRODUCTS (NOT USED)

PART 3 EXECUTION (NOT USED)

SECTION 01 78 00 Page 6

DIVISION 05 - METALS

SECTION C-PART G 05 59 20 FABRICATION OF HYDRAULIC STEEL STRUCTURES

PART 1 GENERAL

1.1 REFERENCES

1.2 SYSTEM DESCRIPTION

1.2.1 Weld Tracking Log Template

1.2.2 Weld Tracking Log

1.2.3 Welding Procedure Specifications (WPS)

1.2.4 Fracture Critical Members (FCM)

1.2.4.1 Fracture Control Plan (FCP)

1.2.4.2 Welding Processes

1.2.4.3 Consumable Requirements

1.2.4.4 Welding Procedure Specifications (WPS)

1.2.4.5 Certification and Qualification

1.2.4.6 Material Handling

1.2.4.7 Tack Welds and Temporary Welds

1.2.4.8 Welding Processes

1.2.4.9 Weld Inspection

1.2.4.10 Repair Welding

1.3 SUBMITTALS

1.4 QUALITY ASSURANCE

1.4.1 Test of Materials

1.4.2 Qualification of Welders and Welding Operators

1.4.3 Inspector Qualifications

1.4.4 Qualification of Structural Steel Fabricator

1.4.5 Testing by the Government

1.4.6 Shop Drawings

1.5 DELIVERY, STORAGE, AND HANDLING

1.6 SYMBOLS AND SAFETY

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Structural Steel

2.1.1.1 Non-Fracture Critical Structural Steel

2.1.1.2 Fracture Critical Structural Steel

2.1.1.3 Structural Steel Plate

2.1.2 Bolts, Nuts and Washers

2.2 COMPOSITE BEARING BLOCK

2.2.1 General

2.2.2 Ultra-High Molecular Weight Polyethylene

2.3 HANDRAILING

2.4 GRATING

2.5 WELDING EQUIPMENT AND MATERIALS

2.6 FABRICATION

2.6.1 Structural Fabrication

2.6.1.1 Dimensional Tolerances for Structural Work

2.6.1.2 Structural Steel Fabrication

2.6.1.3 Thermal Cutting of Structural Steels with 50,000 psi

Minimum Yield Strength or Higher

2.6.1.4 Sheared Edges

2.6.1.5 Control of Distortion and Shrinkage

2.6.1.6 Thermal Stress Relief (TSR)

SECTION 05 59 20 Page 1

2.6.2 Assembly

2.6.3 Materials Disposition Record

2.6.4 Welded Connections

2.6.4.1 Welding Procedure

2.6.4.2 Welder Performance Qualification of Welders and Welding

Operators

2.6.4.3 Welding Process

2.6.4.4 Welding Technique

2.6.4.4.1 Filler Metal

2.6.4.4.2 Preheat and Interpass Temperature

2.6.4.5 Workmanship

2.6.4.5.1 Preparation of Base Metal

2.6.4.5.2 Tack and Temporary Welds

2.6.4.5.3 Weld Access Holes

2.6.4.5.4 Weld Backing Removal

2.6.4.5.5 Weld Backing Material Other Than Steel

2.6.5 Bolted Connections

2.6.5.1 Bolts, Nuts, and Washers

2.6.5.2 Bolt Holes and Pin Holes

2.6.5.2.1 Bolt Holes

2.6.5.2.2 Pin Holes

2.6.5.3 Rotational Capacity Tests

2.6.6 Miscellaneous Provisions

2.6.6.1 Weldments

2.6.6.2 Vent Holes and Drain Holes

2.6.6.3 Seal Welds

2.6.7 Shop Assembly

2.7 CERTIFIED TEST REPORTS

2.7.1 General

2.7.2 Nondestructive Testing

2.7.3 Inspection of Structural Steel Welding

2.7.3.1 Visual Examination

2.7.3.2 Nondestructive Examination

2.7.3.2.1 Testing Agency

2.7.3.2.2 Examination Procedure and Extent

2.7.3.2.3 Acceptability of Welds

2.7.3.2.4 Examination Procedures

2.7.3.2.4.1 Ultrasonic Testing (UT)

2.7.3.2.4.2 Radiographic Testing (RT)

2.7.3.2.4.3 Magnetic Particle Inspection (MT)

2.7.3.2.4.4 Dye Penetrant Inspection (PT)

2.7.4 Welds to be Subject to Nondestructive Examination

2.7.4.1 Structural Steel Non-Fracture Critical Members Complete

Joint Penetration Groove Welds

2.7.4.2 Structural Steel Non-Fracture Critical Member Fillet Welds and Partial Penetration Groove Welds

2.7.4.3 Structural Steel Fracture Critical Member Welds

2.7.5 Test Coupons

2.7.6 Supplemental Examination

2.7.7 Structural Steel Welding Repairs

2.7.8 Control Dimensions

PART 3 EXECUTION

3.1 INSTALLATION

3.1.1 Cleaning

3.1.2 Alignment and Setting

3.2 PROTECTION OF FINISHED WORK

3.3 PAINTING

SECTION 05 59 20 Page 2

3.4 GOVERNMENT WITNESS POINT INSPECTIONS

3.4.1 Witness Point 1

3.4.2 Witness Point 2

3.4.3 Witness Point 3

3.4.4 Witness Point 4

3.4.5 Witness Point 5

3.5 PAYMENT

3.5.1 Auxiliary Lock Needle Beams

SECTION 05 59 20 Page 3

SECTION C-PART G

05 59 20

FABRICATION OF HYDRAULIC STEEL STRUCTURES

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 INSTITUTE OF STEEL CONSTRUCTION (AISC)

AISC 303 (2016) Code of Standard Practice for Steel Buildings and Bridges

AISC 325 (2017) Steel Construction Manual

AISC 326 (2009) Detailing for Steel Construction

AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING (ASNT)

ANSI/ASNT CP-189 (2016) ASNT Standard for Qualification and Certification of Nondestructive Testing Personnel (ANSI/ASNT CP-105-2006)

AMERICAN WELDING SOCIETY (AWS)

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

AWS D1.5M/D1.5 (2015) Bridge Welding Code

AWS QC1 (2016) Specification for AWS Certification of Welding Inspectors

AWS Z49.1 (2012) Safety in Welding and Cutting and Allied Processes

ASME INTERNATIONAL (ASME)

ASME B18.2.1 (2012; Errata 2013) Square and Hex Bolts and Screws (Inch Series)

ASME B18.2.2 (2015) Nuts for General Applications:

Machine Screw Nuts, Hex, Square, Hex Flange, and Coupling Nuts (Inch Series)

ASME B18.21.1 (2009; R 2016) Washers: Helical Spring-Lock, Tooth Lock, and Plain Washers (Inch Series)

ASTM INTERNATIONAL (ASTM)

ASTM A193/A193M (2016) Standard Specification for Alloy-Steel and Stainless Steel Bolting

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Materials for High-Temperature Service and Other Special Purpose Applications

ASTM A194/A194M (2017a) Standard Specification for Carbon Steel, Alloy Steel, and Stainless Steel Nuts for Bolts for High-Pressure or High-Temperature Service, or Both

ASTM A307 (2014; E 2017) Standard Specification for Carbon Steel Bolts, Studs, and Threaded Rod 60 000 PSI Tensile Strength

ASTM A449 (2014) Standard Specification for Hex Cap Screws, Bolts, and Studs, Steel, Heat Treated, 120/105/90 ksi Minimum Tensile Strength, General Use

ASTM A500 (2010a) Standard Specification for Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and Shapes

ASTM A53/A53M (2012) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

ASTM A563 (2015) Standard Specification for Carbon and Alloy Steel Nuts

ASTM A578/A578M (2007; R 2012) Standard Specification for Straight-Beam Ultrasonic Examination of Rolled Steel Plates for Special Applications

ASTM A6/A6M (2017a) Standard Specification for General Requirements for Rolled Structural Steel Bars, Plates, Shapes, and Sheet Piling

ASTM A709/A709M (2017) Standard Specification for Structural Steel for Bridges

ASTM D2240 (2015; E 2017) Standard Test Method for Rubber Property - Durometer Hardness

ASTM D256 (2010) Determining the Izod Pendulum Impact Resistance of Plastics

ASTM D4020 (2011) Ultra-High-Molecular-Weight Polyethylene Molding and Extrusion Materials

ASTM D570 (1998; E 2010; R 2010) Standard Test Method for Water Absorption of Plastics

ASTM D792 (2013) Density and Specific Gravity (Relative Density) of Plastics by Displacement

ASTM E165/E165M (2012) Standard Practice for Liquid

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Penetrant Examination for General Industry

ASTM E709 (2015) Standard Guide for Magnetic Particle Examination

ASTM F3125/F3125M (2015a) Standard Specification for High Strength Structural Bolts, Steel and Alloy Steel, Heat Treated, 120 ksi (830 MPa) and 150 ksi (1040 MPa) Minimum Tensile Strength, Inch and Metric Dimensions

ASTM F436 (2011) Hardened Steel Washers

ASTM F436/F436M (2016) Standard Specification for Hardened Steel Washers Inch and Metric Dimensions

RESEARCH COUNCIL ON STRUCTURAL CONNECTIONS (RCSC)

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

U.S. ARMY CORPS OF ENGINEERS (USACE)

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

1.2 SYSTEM DESCRIPTION

Submit a detailed Work Plan for fabrication, including descriptions of shop facilities, equipment, number of personnel, and related information prior to the Prefabrication Conference, and procedures for safe conduct of the work, careful removal and disposition of materials, protection of property that is to remain undisturbed, and coordination with other work in progress. 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 for all work that occurs on federal property. Include the recommended measuring system for ensuring dimensional tolerances in the Work Plan. Perform the fabrication of the following listed structures under this contract in accordance to this section of the specifications:

1. Auxiliary Lock Needle Beams

a. Material with welds will not be accepted unless the welding is specified or indicated on the drawings or otherwise approved. Do not begin welding until welding procedures, inspectors, nondestructive testing personnel, welders, welding operators, and tackers have been qualified and approved. Each Contractor performing welding must 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 Application Clause refers to the District engineer of record in lieu of the state bridge engineer as specified in the Application Clause of AWS D1.5M/D1.5.

c. Schedule a Prefabrication Conference as soon as possible after award and prior to any fabrication. The Prefabrication Conference shall

SECTION 05 59 20 Page 6 include, at a minimum, the Prime Contractor, Fabricator, the Fabricator's primary QC representatives, the COR, the GQAR, and the Engineer of record for the structure or structures being fabricated.

The Prefabrication Conference shall occur at the Fabrication Facility.

The Prefabrication Conference may also serve as Government Witness Point Inspection #1.

1.2.1 Weld Tracking Log Template

Submit for approval a weld tracking log template, a minimum of 30 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 must follow the numbering scheme shown on the shop drawings. Include in the log 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 must match weld tracking log identification. Bind together a completed log for each structure and submit two copies to the Contracting Officer immediately upon completion of the fabrication of each structure. Furnish draft copies of NDT testing to the Contracting Officer upon request and have a copy available on the shop floor during any inspection.

1.2.3 Welding Procedure Specifications (WPS)

Submit a Welding Procedure Specification (WPS), with supporting PQR and supporting test documentation on forms similar or equivalent to the sample forms in AWS D1.5M/D1.5, for each weld, including prequalified welds, in accordance with paragraph Welded Connections approved before fabrication is commenced. Individually identify each Welding Procedure Specification and reference it on the shop drawings. In case of conflict between this specification and AWS D1.5M/D1.5 as applicable, this specification governs. There are no ancillary items as defined in AWS D1.5M/D1.5 Welding Processes Clause contained in item 1 of Paragraph SYSTEM DISCRIPTION of this specification section.

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 as specified in Part 2 of this specification section, using killed fine-grain mill practice, unless otherwise shown or specified.

Mill repairs of base metal are prohibited. Welding for fracture critical members must meet all requirements of AWS D1.5M/D1.5 AASHTO/AWS Fracture Control Plan (FCP) for Nonredundant Members Clause.

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1.2.4.1 Fracture Control Plan (FCP)

Submit a Fracture Control Plan (FCP) for welding on all Fracture Critical Members (FCM) in accordance with AWS D1.5M/D1.5, AASHTO/AWS Fracture Control Plan (FCP) for Nonredundant Members Clause. Submit welding Procedures, qualifications, and certifications showing compliance with FCP requirements.

1.2.4.2 Welding Processes

All procedures shall be qualified as required.

1.2.4.3 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 AWS D1.5M/D1.5.

1.2.4.4 Welding Procedure Specifications (WPS)

Prequalify or qualify all procedures, including repair welds, by test as required and documented in the WPS and Procedure guidelines of

AWS D1.5M/D1.5.

1.2.4.5 Certification and Qualification

Welders and welding operators shall meet the applicable requirements of

AWS D1.5M/D1.5.

1.2.4.6 Material Handling

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

1.2.4.7 Tack Welds and Temporary Welds

Locate all welds within the joint and meet the requirements of AWS D1.5M/D1.5. Temporary welds on FCM are not permitted.

1.2.4.8 Welding Processes

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

1.2.4.9 Weld Inspection

Document the Quality Control inspection program in the FCP. Qualify all inspectors and NDT technicians as required. Test all butt joints with UT and RT. Inspection procedures and documentation are as specified in the applicable sections of AWS D1.5M/D1.5. Strictly adhere to cooling times.

1.2.4.10 Repair Welding

Classify repair welds as "critical repairs" or "non-critical repairs" for all repair welding. Unless specified otherwise, follow the minimum

SECTION 05 59 20 Page 8 provisions for repair procedures. Repair procedures must be qualified and approved and subject to the same QA/QC inspection requirements as other welds. Follow minimum preheat requirements, as defined in AWS D1.5M/D1.5 AASHTO/AWS Fracture Control Plan (FCP) for Nonredundant Members Clause, for repair welding. Consider all weld repairs to fracture critical members critical welds in accordance with AWS D1.5M/D1.5 AASHTO/AWS Fracture Control Plan (FCP) for Nonredundant Members Clause and must 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. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Prefabrication Submittals

Performance Qualification Records; G|DS Welding Procedure Specifications (WPS); G|DS Fracture Control Plan (FCP); G|DS Weld Tracking Log Template; G|DS Distortion And Shrinkage Control Plan; G|DS Qualification of Welders and Welding Operators; G|DS Inspector Qualifications; G|DS Qualification of Structural Steel Fabricator; G|DS NDT Inspector Certification; G|DS

SD-02 Shop Drawings

Shop Drawings; G|DS Shop Assembly Drawings; G|DS Welding Repairs - Non-Fracture Critical Members; G|DS Welding Repairs - Fracture Critical Members; G|DS Delivery/Shipping Plan; G|DS

SD-03 Product Data

Materials Disposition Record; G|DS

SD-06 Test Reports

Certified Test Reports; G Weld Tracking Log; G Witness Points Repair of Mislocated or Misdrilled Holes;; G|DS Schedule of Random Testing; G|DS Manufacturer Certified Test Reports; G|DS Distributor Certified Test Reports; G|DS

SD-07 Certificates

Work Plan; G|DS

SD-09 Manufacturer's Field Reports

Control Dimensions; G|DS

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1.4 QUALITY ASSURANCE

Establish Government Witness Point Inspections as required Part 3 - Execution below. Supplemental QA Inspections will be conducted on an as needed basis and at the discretion of the Government. Provide unpainted components for each QA NDT and Visual Inspection. At these stages of fabrication, give the Contracting Officer to working days to inspect each 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 have inspected the structure, make any changes required to the structure(s) as directed by the Contracting Officer before proceeding with any additional work. Proceed with the fabrication until the next witness point is reached, unless it is waived in writing by the Contracting Officer.

1.4.1 Test of Materials

Requirements for tests, workmanship, and other measures for quality assurance shall be as specified herein and shown on the drawings. All of the required material tests and analyses shall be performed and certified by an approved laboratory to demonstrate that the required mechanical properties and chemical compositions of the materials are in conformity with the specifications. The Contractor shall provide continuous inspection of all operations for quality control and record the results for submitting to the Contracting Officer or his authorized representative to show compliance with contract requirements.

1.4.2 Qualification of Welders and Welding Operators

Submit welder, welding operator, and tack welder performance qualification records (WPQR) for each welder, welding operator, or tack welder for approval before fabrication is commenced in accordance with paragraph Welded Connections. An AWS Certified Welding Inspector (CWI) meeting the specified qualifications must approve all welder qualifications. Limit welders, welding operators, and tack welders to welding procedures for which they are certified. Prepare, weld, and test welds 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 and certification that each individual is qualified as specified. 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 on the certification. Keep the certification current for the duration of the contract. Submit welder and welding operator qualification test records on forms similar or equivalent to the sample forms in AWS D1.5M/D1.5, Annex. All welders must be qualified in accordance with the Qualification Clause of AWS D1.5M/D1.5.

Welders performing fracture critical welds must meet the additional requirements of the AASHTO/AWS Fracture Control Plan (FCP) for Nonredundant Members Clause of AWS D1.5M/D1.5. Verify all qualifications are 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.

1.4.3 Inspector Qualifications

All inspectors, performing structural steel visual inspection in accordance with these specifications, must be qualified and certified in conformance with AWS QC1. Provide an AWS Certified Welding Inspector (CWI) with an

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AWS D1.5M/D1.5 Bridge Code Endorsement as the primary point of contact for quality control of welding. Designate one individual as having primary responsibility for all quality control in accordance with AWS D1.5M/D1.5 Inspection Clause when several CWI and NDT technicians are working. Do not use non-certified inspectors and certified associate weld inspectors (CAWI) for inspection under these specifications. All personnel who perform NDT must be qualified in accordance with: ANSI/ASNT CP-189 NDT Level II or III. Provide supervision by personnel possessing a Level III ASNT NDT certification for all personnel performing NDT, in accordance with AWS D1.5M/D1.5 Inspection Clause and the AASHTO/AWS Fracture Control Plan (FCP) for Nonredundant Members Clause. Submit copies of certificates showing evidence of qualifications or certifications for welding inspectors and NDT personnel.

1.4.4 Qualification of Structural Steel Fabricator

The fabricating plant and fabricator must be certified under the AISC (American Institute of Steel Construction) Quality Certification Program, with one of the following certifications and with a Fracture Critical Endorsement (F), Category CBR: Major Bridge Fabrication, IBR: Certified Bridge Fabricator - Intermediate, ABR: Certified Bridge Fabricator - Advanced or HYD: Certified Hydraulic Fabricator at time of bid. The fabricator or fabrication plant must 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.

1.4.5 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, radiographic, 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. Replace and retest all defects that are cause for rejection and rejected materials or parts at the Contractor's expense. The government reserves the right to perform quality assurance at any point during fabrication.

1.4.6 Shop Drawings

Prepare all shop drawings in accordance with AISC 326 and AISC 325. Shop drawings shall not be reproductions of contract drawings. Return elements of fabricated items inadvertently omitted on contract drawings to the Engineer of Record for detailing unless they are to be detailed by the fabricator and so indicated on the shop drawings. Cloud any and all details developed by the fabricator on the shop drawings for separate approval by the Engineer of Record. Any items designed by the Contractor must be prepared and sealed by a Registered Professional Engineer. No splices shall be included in the structure without approval of the Engineer of Record. Identify all field welds on the shop drawings. Provide a unique identifier to permit tracking on the weld tracking log for each weld, both shop and field welds.