11285.pdf

Miter Gate Supply Contract - Pike Island Locks & Dam

SECTION TABLE OF CONTENTS

DIVISION 11 - EQUIPMENT

SECTION 11285

MITER GATES

PART 1 GENERAL

1.1 REFERENCES

1.2 SUBMITTALS

1.3 QUALIFICATION OF WELDERS AND WELDING OPERATORS

1.4 DELIVERY, STORAGE, AND HANDLING

1.4.1 Rubber Seals

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Metals

2.1.1.1 Structural Steel

2.1.1.2 Structural Steel Plates

2.1.1.3 Steel Pipe

2.1.1.4 Stainless Steel Bars and Shapes

2.1.1.5 Stainless Steel Plate, Sheet, and Strip

2.1.2 Rubber Seals

2.1.2.1 Physical Characteristics

2.1.2.2 Fabrication

2.1.3 Bumpers and Fenders

2.1.3.1 Physical Characteristics of Rubber

2.1.3.2 Physical Characteristics of UHMW-PE

2.1.4 Asphalt Saturated Preformed Filler Strips

2.1.5 Asphalt Cement

2.1.6 Asphalt Mastic

2.1.7 Cast Magnesium Anodes

2.1.7.1 Single Stud Mounting Provisions for Water Immersed Anodes

2.1.8 Spare Parts

2.2 MANUFACTURED UNITS

2.2.1 Bolts, Nuts and Washers

2.2.2 Screws

2.2.3 Torquenut

2.3 FABRICATION

2.3.1 Detail Drawings

2.3.1.1 Fabrication Drawings

2.3.1.2 Shop Assembly Drawings

2.3.1.3 Delivery Drawings

2.3.2 Structural Fabrication

2.3.3 Welding

2.3.4 Bolted Connections

2.3.5 Machine Work

2.3.6 Miscellaneous Provisions

2.3.7 Fabrications

2.3.7.1 Gate Leaf

2.3.7.2 Quoin and Miter Contact Blocks

SECTION 11285 Page 1 W911WN-08-B-0009 Revised by Amendment 0003

2.3.7.3 Pintle Assembly

2.3.7.4 Gudgeon Anchorage

2.3.7.5 Seal Assemblies

2.3.7.6 Appurtenant Items

2.3.8 Shop Assembly

2.4 TESTS, INSPECTIONS, AND VERIFICATIONS

2.4.1 Testing of Rubber Seals

PART 3 EXECUTION

3.1 ASSEMBLY

3.1.1 Gate Leaf

3.1.2 Diagonals

3.1.3 Miter Guide

3.1.4 Weight Labeling Of Gate Leaves

3.1.5 Painting

3.1.6 Seal Assemblies

3.2 CAST MAGNESIUM ANODE INSTALLATION

3.2.1 Welding Connection

3.2.2 Bolted Connections

3.2.3 Field Inspection

3.3 TESTS AND INSPECTIONS

3.3.1 Skin Plate Watertightness Test

3.3.2 Acceptance

3.4 SHIPPING

3.5 PROTECTION OF FINISHED WORK

-- End of Section Table of Contents --

SECTION 11285 Page 2

SECTION 11285

MITER GATES

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 WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2006; Errata 2006) Structural Welding Code - Steel

AWS D1.2/D1.2M (2003; Errata 2004) Structural Welding Code - Aluminum

ASTM INTERNATIONAL (ASTM)

ASTM A 167 (1999; R 2004) Standard Specification for Stainless and Heat-Resisting Chromium-Nickel Steel Plate, Sheet, and Strip

ASTM A 176 (1999; R 2004) Standard Specification for Stainless and Heat-Resisting Chromium Steel Plate, Sheet, and Strip

ASTM A 240/A 240M (2007e1) Standard Specification for Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications

ASTM A 276 (2006) Standard Specification for Stainless Steel Bars and Shapes

ASTM A 307 (2007b) Standard Specification for Carbon Steel Bolts and Studs, 60 000 PSI Tensile Strength

ASTM A 320/A 320M (2007a) Standard Specification for Alloy/Steel Bolting Materials for Low-Temperature Service

ASTM A 325 (2007a) Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength

ASTM A 53/A 53M (2007) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

SECTION 11285 Page 3

ASTM A 564/A 564M (2004) Standard Specification for Hot-Rolled and Cold-Finished Age-Hardening Stainless Steel Bars and Shapes

ASTM A 572/A 572M (2007) Standard Specification for High-Strength Low-Alloy Columbium-Vanadium Structural Steel

ASTM A 668/A 668M (2004) Standard Specification for Steel Forgings, Carbon and Alloy, for General Industrial Use

ASTM A 709/A 709M (2007) Standard Specification for Structural Steel for Bridges

ASTM A 992/A 992M (2006a) Standard Specification for Structural Steel Shapes

ASTM B 843 (2007) Standard Specification for Magnesium Alloy Anodes for Cathodic Protection

ASTM D 1751 (2004) Standard Specification for Preformed Expansion Joint Filler for Concrete Paving and Structural Construction (Nonextruding and Resilient Bituminous Types)

ASTM D 2240 (2005) Standard Test Method for Rubber Property - Durometer Hardness

ASTM D 256 (2006a) Determining the Izod Pendulum Impact Resistance of Plastics

ASTM D 3019 (1994; R 2007) Lap Cement Used with Asphalt Roll Roofing Non Fibered, Asbestos Fibered, and Non Asbestos Fibered

ASTM D 395 (2003) Standard Test Methods for Rubber Property - Compression Set

ASTM D 412 (2006a) Standard Test Methods for Vulcanized Rubber and Thermoplastic Elastomers - Tension

ASTM D 413 (1998; R 2002e1) Rubber Property - Adhesion to Flexible Substrate

ASTM D 471 (2006) Standard Test Method for Rubber Property - Effect of Liquids

ASTM D 572 (2004) Rubber Deterioration by Heat and Oxygen

ASTM D 638 (2003) Standard Test Method for Tensile Properties of Plastics

ASTM D 792 (2000) Density and Specific Gravity (Relative Density) of Plastics by

SECTION 11285 Page 4

Displacement

THE SOCIETY FOR PROTECTIVE COATINGS (SSPC)

SSPC Paint 12 (1982; E 2000) Paint Specification No. 12 Cold-Applied Asphalt Mastic (Extra Thick Film)

1.2 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 01330 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Detail Drawings; G

Detail drawings shall be submitted as specified herein and in Section 05055 METALWORK FABRICATION, MACHINE WORK, MISCELLANEOUS

PROVISIONS.

SD-03 Product Data

Materials

System of identification which shows the disposition of specific lots of approved materials and fabricated items in the work shall be submitted before completion of the contract.

Materials orders, materials lists and materials shipping bills shall be submitted as specified in Section 05055 METALWORK

FABRICATION, MACHINE WORK, MISCELLANEOUS PROVISIONS.

Welding

Schedules of welding procedures for structural steel shall be submitted as specified in Section 05055 METALWORK FABRICATION, MACHINE WORK, MISCELLANEOUS PROVISIONS.

SD-04 Samples

Materials; G

Samples shall be submitted and approved prior to use of the represented materials or items in the work. Samples of standard and shop fabricated items shall be full size and complete as required for installation in the work. Approved samples may be installed in the work provided each sample is clearly identified and its location recorded.

SD-06 Test Reports

Tests, Inspections, and Verifications

Certified test reports for material tests shall be submitted with all materials delivered to the site.

SECTION 11285 Page 5

SD-07 Certificates

The Contractor shall submit manufacturer signed certification that the miscellaneous items, materials and standard articles incorporated into fabricated parts or the finished structure conform to these specifications.

Structural Steel; G RE

Stainless Steel; G RE

Steel Pipe; G RE

Steel Castings; G RE

Steel Forgings; G RE

Bronze; G RE

Bolts, Nuts, and Washers; G RE

Pins; G RE

Torque Nuts; G RE

Magnesium Alloy Slab Anodes; G RE

Gudgeon anchorage; G RE

1.3 QUALIFICATION OF WELDERS AND WELDING OPERATORS

Qualification of welders and welding operators shall conform to the requirements of Section 05055 METALWORK FABRICATION, MACHINE WORK, MISCELLANEOUS PROVISIONS.

1.4 DELIVERY, STORAGE, AND HANDLING

Delivery, handling, and storage of materials and fabricated items shall conform to the requirements specified herein and in Section 05055METALWORK FABRICATION, MACHINE WORK, MISCELLANEOUS PROVISIONS. Materials and equipment delivered to the site by the Contracting Officer shall be unloaded by the Contractor. The Contractor shall verify the condition and quantity of the items delivered by the Contracting Officer and acknowledge receipt and condition thereof in writing to the Contracting Officer. If delivered items are damaged or a shortage is determined, the Contractor shall notify the Contracting Officer of such in writing within 24 hours after delivery.

1.4.1 Rubber Seals

Rubber seals shall be stored in a place which permits free circulation of air, maintains a temperature of 70 degrees F or less, and prevents the rubber from being exposed to the direct rays of the sun. Rubber seals shall be kept free of oils, grease, and other materials which would deteriorate the rubber. Rubber seals shall not be distorted during handling.

SECTION 11285 Page 6

PART 2 PRODUCTS

2.1 MATERIALS

Materials orders, materials lists and materials shipping bills shall conform with the requirements of Section 05055 METALWORK FABRICATION, MACHINE WORK, MISCELLANEOUS PROVISIONS.

2.1.1 Metals

Structural steel, steel forgings, steel castings, stainless steel, bronze, aluminum bronze and other metal materials used for fabrication shall conform to the requirements shown and specified herein and in Section 05502

METALS: MISCELLANEOUS, STANDARD ARTICLES, SHOP FABRICATED ITEMS FOR CIVIL

WORKS STRUCTURES.

2.1.1.1 Structural Steel

Structural steel shall conform to ASTM A 992/A 992M or ASTM A 572/A 572M, Grade 50. Structural steel for fracture critical members shall conform to ASTM A 709/A 709M Grade 50F, Zone 2. Supplementary Requirement S93 shall apply.

2.1.1.2 Structural Steel Plates

Structural steel plates shall conform to ASTM A 572/A 572M, Grade 50 or Grade 60. Structural steel plates for fracture critical members shall conform to ASTM A 709/A 709M Grade 50F, Zone 2. Supplementary Requirement S93 shall apply.

2.1.1.3 Steel Pipe

Steel pipe shall conform to ASTM A 53/A 53M, Type S, Grade B, seamless, black, nominal size and weight class or outside diameter and nominal wall thickness as shown, plain ends.

2.1.1.4 Stainless Steel Bars and Shapes

Stainless steel bars and shapes shall conform to ASTM A 276, UNS S 20910, Condition A, hot-finished or cold-finished, Class C; or ASTM A 564/A 564M, UNS S 17400, Type 630, Condition H1025, age-hardened heat treatment, hot-finished or cold-finished, Class C.

2.1.1.5 Stainless Steel Plate, Sheet, and Strip

Stainless steel plate, sheet, and strip shall conform to ASTM A 167, UNS S 30400; ASTM A 176, UNS S 40500 or UNS S 41008; and ASTM A 240/A 240M, UNS S 20910,. Plate finish shall be hot-rolled, annealed or heat-treated, and blast-cleaned or pickled. Sheet and strip finish shall be No. 1.

2.1.2 Rubber Seals

Rubber for bottom seal assemblies and J-seal assemblies shall be fluorocarbon (Teflon) clad rubber seals of the mold type only, shall be compounded of natural rubber, synthetic polyisoprene, or a blend of both, and shall contain reinforcing carbon black, zinc oxide, accelerators, antioxidants, vulcanizing agents, and plasticizers.

SECTION 11285 Page 7

2.1.2.1 Physical Characteristics

Physical characteristics of the seals shall meet the following requirements:

TEST METHOD

PHYSICAL TEST TEST VALUE SPECIFICATION

Tensile Strength 2,500 psi (min.) ASTM D 412

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

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

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

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

Compression Set 30% (max.) ASTM D 395

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

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

The immersion temperature shall be 70 degrees C plus or minus 1 degree and the duration of immersion shall be 166 hours.

2.1.2.2 Fabrication

Rubber seals shall have a fluorocarbon film vulcanized and bonded to the sealing surface of the bulb. The film shall be 0.060 inch thick Huntington Abrasion Resistant Fluorocarbon Film No. 4508, or equal, and shall have the following physical properties:

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

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

The outside surface of the bonded film shall be flush with the surface of the rubber seal and shall be free of adhering or bonded rubber. Strips and corner seals shall be 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. At one end of each strip or corner seal to be tested, the fluorocarbon film shall be masked during bonding to prevent a bond for a length sufficient to hold the film securely during testing.

2.1.3 Bumpers and Fenders

Fenders shall consist of an Ultra High Molecular Weight Polyethylene (UHMW-PE) facing bonded to a rubber backing with dimensions as shown on the drawings.

SECTION 11285 Page 8

2.1.3.1 Physical Characteristics of Rubber

The rubber backing shall be compounded of natural rubber, synthetic polyisoprene, or a blend of both, and shall contain reinforcing carbon black, zinc oxide, accelerators, antioxidants, vulcanizing agents, and plasticizers and shall be resistant to aging, water, abrasion and ultraviolet rays. Physical characteristics of the rubber shall meet the following requirements:

TEST METHOD

PHYSICAL TEST TEST VALUE SPECIFICATION

Tensile Strength 2,500 psi (min.) ASTM D 412

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

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

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

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

Compression Set 30% (max.) ASTM D 395

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

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

The immersion temperature shall be 70 degrees C plus or minus 1 degree and the duration of immersion shall be 166 hours.

2.1.3.2 Physical Characteristics of UHMW-PE

The UHMW-PE facing shall cover the entire front face of the rubber backing. The facing material shall be 5 inches thick, yellow in color and UV stabilized. Physical characteristics of the UHMW-PE shall meet the following requirements:

TEST METHOD

PHYSICAL TEST TEST VALUE SPECIFICATION

Tensile Strength at 2,600 psi (min) ASTM D 638 Yield 73 degrees F

Tensile Strength at 3,600 psi (min.) ASTM D 638 Break 73 degrees F

Density 58 lbs/cu-ft (min.) ASTM D 792

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

SECTION 11285 Page 9

TEST METHOD

PHYSICAL TEST TEST VALUE SPECIFICATION

IZOD Impact No Break ASTM D 256

2.1.4 Asphalt Saturated Preformed Filler Strips

ASTM D 1751.

2.1.5 Asphalt Cement

ASTM D 3019.

2.1.6 Asphalt Mastic

SSPC Paint 12.

2.1.7 Cast Magnesium Anodes

Cast magnesium bolt-on anodes shall be of a type AZ63C alloy (Grade B H-1 alloy) complying the ASTM B 843, and shall have the following composition in percent by weight:

Element Percent

Aluminum 5.3 to 6.7 Manganese 0.15 to 0.7 Zinc 2.5 to 3.5 Silicon 0.30 Maximum Copper 0.05 Maximum Nickel 0.003 Maximum Iron 0.003 Maximum Other 0.30 Maximum Magnesium Remainder

Cast magnesium anode specifics shall be as follows:

Galvotec Anode Style Dimensions Weight Core Special Features

GA-MG- 8.0 inches by 7.5 3/4 inch Plastisol coated on 7.5-S 8 inches by pounds steel pipe bottom and sides (Only

2.0 inches top side exposed)

GA-MG- 9.0 inches by 24 Two cast-in Plastisol coated on H-24W 18.0 inches by pounds 1/4 inch by bottom and sides (Only

2.0 inches 2 inch top side exposed) galvanized steel straps with 3/4 inch diameter mounting holes

Cast magnesium anodes shall be as manufactured by Mesa Products, Tulsa, Oklahome; Galvotec Alloys, Inc., Gretna, Louisiana; or acceptable equal.

Equivalent anodes shall be acceptable to Contracting Officer's Representative and Engineer and shall comply with this specification.

SECTION 11285 Page 10

All anodes of the same type shall be of the same materials and manufacturer in order to standardize appearance, maintenance, and replacement.

2.1.7.1 Single Stud Mounting Provisions for Water Immersed Anodes

Mounting provisions for water immersed cast magnesium anodes shall consist of the following parts and materials:

Item Material

1/2 inch - 13 UNC threaded rod, 304L stainless steel 3-5/16 inches long

1/2 inch flat washer 304 stainless steel

1/2 inch - 13 UNC heavy duty FLEXLOC 304 stainless steel self locking nut

Gasket washer for stud protector Rubber

Stud protector Plastic

Single stud mounting provisions for water immersed anodes shall be as manufactured by Brance-Krachy Co., Inc., Houston, Texas; Mesa Products, Inc., Tulsa, Oklahoma; or acceptable equal.

All anode mounting provisions of the same type shall be of the same materials and manufacturer in order to standardize appearance, maintenance, and replacement.

2.1.8 Spare Parts

Spare anodes (the type used in the original installation) shall be furnished to the Contracting Officer's representative. A minimum of 50 of each type installation component required for the original installation of the anodes shall be furnished.

2.2 MANUFACTURED UNITS

Bolts, nuts, washers, screws and other manufactured units shall conform with the requirements shown and specified herein and in Section 05502

METALS: MISCELLANEOUS, STANDARD ARTICLES, SHOP FABRICATED ITEMS FOR CIVIL

WORKS STRUCTURES.

2.2.1 Bolts, Nuts and Washers

High-strength bolts, nuts, and washers shall conform to ASTM A 325, Type N, .

Bolts, nuts, studs, stud bolts and bolting materials other than high-strength shall conform to ASTM A 307, Grade A, or ASTM A 320/A 320M, Austenitic Steel, Grade B8, Class 2. Bolts 1/2 inch and larger shall have hexagon heads. The finished shank of bolts shall be long enough to provide full bearing. Washers for use with bolts shall conform to the requirements specified in the applicable specification for bolts.

2.2.2 Screws

Screws shall be of the type indicated on the drawings.

SECTION 11285 Page 11

2.2.3 Torquenut

Torquenut shall be as manufactured by Superbolt, Inc., Carnegie, PA 15106 or approved equal.

2.3 FABRICATION

2.3.1 Detail Drawings

Detail drawings, including fabrication drawings, shop assembly drawings, and delivery drawings, shall conform to the requirements specified herein and in Section 05055 METALWORK FABRICATION, MACHINE WORK, MISCELLANEOUS

PROVISIONS.

2.3.1.1 Fabrication Drawings

Fabrication drawings shall show complete details of materials, tolerances, connections, and proposed welding sequences which clearly differentiate shop welds and field welds.

2.3.1.2 Shop Assembly Drawings

Shop assembly drawings shall provide details for connecting the adjoining fabricated components in the shop to assure satisfactory field installation.

2.3.1.3 Delivery Drawings

Delivery drawings shall provide descriptions of methods of delivering components to the site, including details for supporting fabricated components during shipping to prevent distortion or other damages.

2.3.2 Structural Fabrication

Structural fabrication shall conform with the requirements shown and specified herein and in Section 05055 METALWORK FABRICATION, MACHINE WORK, MISCELLANEOUS PROVISIONS. Components shall be shop-fabricated of the materials specified and shown. Dimensional tolerances shall be as specified and shown on the drawings. Splices shall occur only where shown or approved. Pin holes shall be bored in components after welding, straightening, stress-relieving, and threading operations are completed.

Brackets, eye bar sections, and other components requiring straightening shall be straightened by methods which will not damage the material.

Bronze bushings shall be press-fitted with supporting components. Bolt connections, lugs, clips, or other pick-up assembly devices shall be provided for components as shown and required for proper assembly and installation. Provisions shall be made for the installation of cathodic protection system devices and other appurtenances as required.

2.3.3 Welding

Welding shall conform with the requirements of AWS D1.1/D1.1M, AWS D1.2/D1.2M, the requirements specified herein and in Section 05055 METALWORK FABRICATION, MACHINE WORK, MISCELLANEOUS PROVISIONS. Welds shall be of the type shown on the contract drawings and approved detail drawings. Radiographic examination is required on the major shop and field welds of the type and location indicated on the drawings and as follows:

Splices in girder and diaphragm flanges and webs, and splices in diagonals. Welds which have been designated to receive radiographic examination and are found to be inaccessible to a radiation source or film, SECTION 11285 Page 12 or are otherwise so situated that radiographic examination is not feasible may be examined, with written approval, by dye penetrant, magnetic particle tests, or ultrasonic tests. Components shall be stress-relief heat treated after welding where shown. Stress-relieving of components shall be performed prior to the attachment of miscellaneous appurtenances.

2.3.4 Bolted Connections

Bolted connections shall conform with the requirements specified in Section

05055 METALWORK FABRICATION, MACHINE WORK, MISCELLANEOUS PROVISIONS.

2.3.5 Machine Work

Machine work shall conform with the requirements specified in Section 05055

METALWORK FABRICATION, MACHINE WORK, MISCELLANEOUS PROVISIONS.

2.3.6 Miscellaneous Provisions

Miscellaneous provisions for fabrication shall conform with the requirements specified herein and in Section 05055 METALWORK FABRICATION, MACHINE WORK, MISCELLANEOUS PROVISIONS.

2.3.7 Fabrications

2.3.7.1 Gate Leaf

Gate leaf shall be of welded structural steel fabrication consisting of horizontal girders, intercostals, diaphragms, quoin post, gudgeon pin hood, operating strut connections, skin plate, and adjustable diagonals. Gate leaf shall be shop-fabricated. Contractor proposed shop-fabrication of gate leaf in separate segments to facilitate handling and shipping must be approved by the Contracting Officer and shall be as shown on approved detail drawings. Such segments shall permit easy field-assembly and shall be as few as practicable to minimize the number of joints to be field-welded. The overall height of the gate leaf shall not vary from the nominal dimension or differ from the mating gate leaf by more than 3/16 inch.

The surfaces of framing elements to which skin plates are to be welded shall not vary from a true plane by more than 1/8 inch. The outside surfaces of skin plates welded to framing members shall not vary from a true plane by more than 3/16 inch. Splices in skin plates shall be located only where shown or approved. In addition to welds specifically indicated on the drawings for nondestructive testing, 50 percent of the welds in the girders, gudgeon pin hood, verticals and skin plate of the gate leaf shall receive nondestructive testing. The location of these additional welds for testing shall be as directed by the Contracting Officer. Gate leaf shall be provided complete with quoin and miter contact blocks, miter guide assembly, pintle assembly, gudgeon anchorage, seal assembly, lubrication system, fenders, anodes, and other appurtenant components as required for complete installation, specified herein and shown.

2.3.7.2 Quoin and Miter Contact Blocks

Quoin and miter contact blocks shall be of stainless steel bars conforming to ASTM A 564/A 564M, Type 630, condition H1025. Splices in contact blocks shall occur only at the centerlines of horizontal girders. Contact faces of contact blocks shall be milled at splices to assure watertight joints.

Contact blocks shall be provided with adjusting bolts as shown.

SECTION 11285 Page 13

2.3.7.3 Pintle Assembly

Pintle assembly shall consist of pintle socket and pintle as shown. Pintle socket shall be of cast nickel-alloy steel. Pintle socket shall be press-fitted with an aluminum bronze bushing with bearing surfaces finished truly hemispherical. Pintle shall be of ASTM A 743, Grade CF8 cast steel or ASTM A 27/A 27M, Grade 70 - 40, Class 1 cast steelASTM A 668 Class D forged steel with 1/8 inch minimum thickness of ASTM A 240/A 240M, Type 304, stainless steel cladding. Cladding shall be integrally and continuously bonded by welding or a similar process. Pintle ball shall receive a 8 microinch finish and shall be fitted into the bushing by scraping until uniform contact is attained over the entire bearing surface as determined by testing with carbon paper or other approved coloring. The pintle ball shall be match-marked with the bushing when fitted and so erected in the field. Bolt holes for attaching pintle socket to gate leaf shall be drilled and reamed after the pintle socket is assembled with gate leaf. Pintle socket shall be connected to the bottom of the lower girder web of the gate leaf with stainless steel bolts.

2.3.7.4 Gudgeon Anchorage

Gudgeon anchorage shall consist of gudgeon anchorage bars, links,wedge adjustment assembly and gudgeon pin. Gudgeon pin anchorages shall be made of structural steel plates conforming to ASTM A 588/A 588M or forged alloy steel plates conforming to ASTM A 668/A 668M, Class K and shall be fitted with a bronze bushing. Gudgeon anchorage links and gudgeon pin shall be of forged alloy steel conforming to ASTM A 668/A 668M. Gudgeon anchorage links shall be connected to the gudgeon embedded anchorage by means of the adjusting wedge assembly.

2.3.7.5 Seal Assemblies

Seal assemblies shall consist of rubber seals, stainless steel retainer and spacer bars, and fasteners. Rubber seals shall be continuous over the full length. Seals shall be accurately fitted and drilled for proper installation. Bolt holes shall be drilled in the rubber seals by using prepared templates or the retainer bars as templates. Splices in seals shall be fully molded, develop a minimum tensile strength of 50 percent of the unspliced seal, and occur only at locations shown. All vulcanizing of splices shall be done in the shop. The vulcanized splices between molded corners and straight lengths shall be located as close to the corners as practicable. Splices shall be on a 45 degree bevel related to the "thickness" of the seal. The surfaces of finished splices shall be smooth and free of irregularities. Stainless steel retainer bars shall be field-spliced only where shown and machine-finished after splicing.

2.3.7.6 Appurtenant Items

Fenders, seal plates and shapes, and other appurtenant items shall conform to details specified and shown.

2.3.8 Shop Assembly

Shop assembly requirements for miter gates and appurtenant items shall be as shown and specified herein and in Section 05055 METALWORK FABRICATION, MACHINE WORK, MISCELLANEOUS PROVISIONS. Miter gates and appurtenant items shall be assembled completely in the shop, unless otherwise approved by the Contracting Officer, to assure satisfactory field installation. Adjoining components shall be fitted and bolted together to facilitate field

SECTION 11285 Page 14 connections. The matchmarking of unassembled items shall be carefully preserved until the items are assembled. Mating surfaces and machined surfaces shall be covered with a rust preventive until assembly. Assembled components shall be shop-welded in their final positions as much as delivery and field installation conditions will permit. Rubber seals shall be fitted and drilled to match the seal retainers, match-marked, and removed for shipment. Shop assembly and disassembly work shall be performed in the presence of the Contracting Officer unless otherwise approved by the Contracting Officer. The presence of the Contracting Officer will not relieve the Contractor of any responsibility under this contract.

2.4 TESTS, INSPECTIONS, AND VERIFICATIONS

Tests, Inspections, and Verifications for materials shall conform to the requirements specified herein and in Section 05055 METALWORK FABRICATION, MACHINE WORK, AND MISCELLANEOUS PROVISIONS.

2.4.1 Testing of Rubber Seals

The fluorocarbon film of rubber seals shall be tested for adhesion bond in accordance with ASTM D 413 using either the machine method or the deadweight method. A 1 inch long piece of seal shall be cut from the end of the seal which has been masked and subjected to tension at an angle approximately 90 degrees to the rubber surface. There shall be no separation between the fluorocarbon film and the rubber when subjected to the following loads:

THICKNESS OF MACHINE METHOD AT DEADWEIGHT

FLUOROCARBON 2 INCHES PER MINUTE METHOD

FILM

0.060 inch 30 pounds per 30 pounds per inch width inch width

PART 3 EXECUTION

3.1 ASSEMBLY

Installation will be performed by the Government. Miter gates and appurtenant items shall be furnished assembled for installation in strict accordance with the contract drawings, and shop match-markings. Bearing surfaces requiring lubrication shall be thoroughly cleaned and lubricated with an approved lubricant before assembly. Components to be field-welded shall be in correct alignment before welding is commenced.

3.1.1 Gate Leaf

Gate leaf components not assembled in the shop shall be assembled in the field as required for installation. Pintle grease pipes shall be tapped into pintle bushing in correct register with bushing grease grooves.

Grease pipes shall be flushed prior to connecting to bearings. All necessary precautions shall be taken to avoid distortion of the gate leaf or any component parts.

3.1.2 Diagonals

Gate leaf diagonals shall be attached to the gate leaf.

SECTION 11285 Page 15

3.1.3 Miter Guide

Miter guide shall be installed by the Government after the contact blocks have been properly set.

3.1.4 Weight Labeling Of Gate Leaves

All gate leaves fabricated under this contract shall be given a label by the Contractor consisting of the size and weight of each leaf. Weight of each leaf shall be determined by the Contractor and listed in pounds. The Contractor shall determine weight of each leaf by utilizing a load indicating device on the lifting crane or by placing load cells under the four corners of each leaf. The label shall be placed on a plate and welded to each leaf. The identification plate and label shall be fabricated and attached to the leaf prior to painting. Letters shall be 4-inch high block letters formed with 1/4-inch stainless steel weld bead. The letters shall be placed on a suitably sized, 1/4-inch thick stainless steel plate.

Lettering shall be neat and easily readable. Each identification plate shall be placed at the top of each leaf on the skin plate, near the gudgeon pin. Each identification plate shall be welded to the skin plate with a fillet weld around the entire perimeter of the plate. The plate and welds shall be painted in accordance with Section 09964 PAINTING: HYDRAULIC

STRUCTURES.

3.1.5 Painting

Exposed parts of gates and appurtenances except machined surfaces, corrosion-resistant surfaces, surfaces of anchorages embedded in concrete, cathodic protection system anodes and attachments, and other specified surfaces shall be painted as specified in Section 09964 PAINTING:

HYDRAULIC STRUCTURES.

3.1.6 Seal Assemblies

Rubber seal assemblies shall be installed by the Government after the gate installation has been completed. Rubber seals shall be fastened securely to metal retainers.

3.2 CAST MAGNESIUM ANODE INSTALLATION

The mounting studs and mounting brackets for the cast magnesium anodes shall be installed prior to the surface preparation and coating of the miter gates. At the location of each anode mounting stud, the steel surface shall be cleaned to shiny metal by grinding or equivalent method prior to welding of the anode mounting provisions to the structure.

For each miter gate, after all the threaded mounting studs and brackets are welded to the steel members, the construction operations shall be scheduled in accordance with the following requirements and project scheduling requirements.

a. All threaded studs and mounting brackets shall be temporary protected from shot blasting and coating.

b. Temporary protection shall be removed from all the threaded mounting studs and brackets and then the cast magnesium anodes shall be installed in accordance with the drawings and as specified in this section. Any damaged studs shall be replaced at Contractor's expense and without any cost to the Government. Replaced stud(s) shall meet

SECTION 11285 Page 16 the specified coating and welding requirements.

3.2.1 Welding Connection

Welding shall be done in accordance to the welding requirements shown on the drawings. The miter gate coating system shall include all anode mounting weld areas. Coated welded area shall be subjected to inspection by the Contracting Officer's Representative.

3.2.2 Bolted Connections

Bolted connections shall be cleaned, lubricated and torqued in accordance with the anode installation details shown on the drawings.

3.2.3 Field Inspection

Cathodic protection system material, installation, and workmanship will be subject to continuous or daily inspection by the Contracting Officer's Representative. Upon the installation of all anodes at each miter gate, the Contracting Officer's Representative will inspect the entire installation for each miter gate. At each inspection time, the anode mounting provisions or anode installations will be visually inspected and, if defective, shall be replaced by the Contractor.

3.3 TESTS AND INSPECTIONS

3.3.1 Skin Plate Watertightness Test

Prior to painting and mounting of seals, skin plate welds shall be tested for watertightness by applying air pressure with a hose, using a minimum air pressure of 60 psi at the nozzle, to one face of the skin plate with a light coating of soapsuds on the opposite face. Disclosed leaks shall be sealed with light welds.

3.3.2 Acceptance

After completion of the gate(s), the Contracting Officer will examine the gates for final acceptance. The gates will be examined first to determine whether or not the workmanship conforms to the specification requirements.

Required repairs or replacements to correct defects, as determined by the Contracting Officer, shall be made at no cost to the Government.

3.4 SHIPPING

The gate leafs shall be shipped with the walkways removed. In addition, the gate leaves shall be shipped in a vertical position. The Contractor shall provide blocking as required to support the gates during shipping. A

Other miter gate components shall be shipped in a manner that protects them until installation. Components shall be grouped and readily accessible so a verification of receipt can be performed upon delivery and to. Small items such as the eyebar pins and the pintle shoe filler blocks shall be packaged together in a wooden crate/s and the crate(s) shall be labeled to identify the contents.

3.5 PROTECTION OF FINISHED WORK

Protection of finished work shall conform to the requirements of Section

05055 METALWORK FABRICATION, MACHINE WORK, MISCELLANEOUS PROVISIONS.

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SECTION 11285 Page 18

2.1.8 Spare Parts

2.3.8 Shop Assembly