05 50 14.pdf

Charleroi Locks and Dam - Upper and Lower Guard Walls

SECTION TABLE OF CONTENTS

DIVISION 05 - METALS

SECTION 05 50 14

STRUCTURAL METAL FABRICATIONS

PART 1 GENERAL

1.1 REFERENCES

1.2 SUBMITTALS

1.3 DETAIL DRAWINGS

1.4 QUALIFICATION OF WELDERS AND WELDING OPERATORS

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Materials Orders

2.1.2 Materials List

2.1.3 Shipping Bill

2.2 FABRICATION

2.2.1 Connections

2.2.2 Structural Fabrication

2.2.2.1 Dimensional Tolerances for Structural Work

2.2.2.2 Structural Steel Fabrication

2.2.2.3 Structural Aluminum Fabrication

2.2.3 Welding

2.2.3.1 Welding of Structural Steel

2.2.3.2 Welding of Steel Castings

2.2.3.3 Welding of Aluminum

2.2.3.4 Welding of Steel Studs

2.2.4 Bolted Connections

2.2.4.1 Bolted Structural Steel Connections

2.2.4.2 Bolted Aluminum Connections

2.2.5 Patterns

2.2.5.1 Fabrication of Patterns and Core Boxes

2.2.5.2 Disposition of Patterns, Core Boxes, and Templates

2.2.6 Castings

2.2.7 Machine Work

2.2.7.1 Finished Surfaces

2.2.7.2 Unfinished Surfaces

2.2.7.3 Pin Holes

2.2.8 Miscellaneous Provisions

2.2.8.1 Metallic Coatings

2.2.8.2 Cleaning of Corrosion-Resisting Steel

2.2.9 Shop Assembly

2.3 TESTS, INSPECTIONS, AND VERIFICATIONS

2.3.1 Nondestructive Testing

2.3.2 Tests of Machinery and Structural Units

2.3.3 Inspection of Structural Steel Welding

2.3.3.1 Visual Examination

2.3.3.2 Test Coupons

2.3.3.3 Supplemental Examination

SECTION 05 50 14 Page 1 W911WN-09-B-0004 Revised by Amendment No. 0002

2.3.4 Structural Steel Welding Repairs

2.3.5 Inspection and Testing of Steel Stud Welding

2.3.6 Inspection of Steel Castings

2.3.6.1 Castings to be Inspected

PART 3 EXECUTION

3.1 INSTALLATION

3.1.1 Alignment and Setting

3.1.2 Blocking and Wedges

3.1.3 Foundations and Grouting

3.2 PROTECTION OF FINISHED WORK

3.2.1 Machined Surfaces

3.2.2 Aluminum

3.3 TESTS

3.3.1 Workmanship

3.3.2 Production Welding

-- End of Section Table of Contents --

SECTION 05 50 14 Page 2

SECTION 05 50 14

STRUCTURAL METAL FABRICATIONS

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.

ALUMINUM ASSOCIATION (AA)

AA ADM1 (2005; Errata 2005) Aluminum Design Manual

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

AISC 317 (1992; Reprint 1999) ASD Manual of Steel Construction, Vol II: Connections

AISC 350 (2005) Load and Resistance Factor Design (LRFD)Specification for Structural Steel Buildings

AISC 360 (2005) Specification for Structural Steel Buildings, with Commentary

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2008) Structural Welding Code - Steel

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

ASME INTERNATIONAL (ASME)

ASME B4.1 (1967; R 2004) Preferred Limits and Fits for Cylindrical Parts

ASME B46.1 (2002) Surface Texture (Surface Roughness, Waviness and Lay)

ASME BPVC SEC IX (2007) Boiler and Pressure Vessel Code;

Section IX, Welding and Brazing Qualifications

ASTM INTERNATIONAL (ASTM)

ASTM A 123/A 123M (2008) Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products

ASTM A 325 (2007a) Standard Specification for Structural Bolts, Steel, Heat Treated, SECTION 05 50 14 Page 3

120/105 ksi Minimum Tensile Strength

ASTM A 380 (2006) Standard Practice for Cleaning, Descaling, and Passivation of Stainless Steel Parts, Equipment, and Systems

ASTM A 490 (2006) Standard Specification for Structural Bolts, Alloy Steel, Heat Treated, 150 ksi Minimum Tensile Strength

ASTM A 514/A 514M (2005) Standard Specification for High-Yield-Strength, Quenched and Tempered Alloy Steel Plate, Suitable for Welding

ASTM A 780 (2001; R 2006) Standard Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings

ASTM B 177 (2001; R 2006e1) Standard Guide for Engineering Chromium Electroplating

ASTM B 766 (1986; R 2003) Standard Specification for Electrodeposited Coatings of Cadmium

ASTM D 962 (1981; R 2003) Aluminum Powder and Paste Pigments for Paints

ASTM E 165 (2002) Standard Test Method for Liquid Penetrant Examination

ASTM E 446 (1998; R 2004e1) Radiographs for Steel Castings Up to 2 In. (51mm) in Thickness

ASTM E 94 (2004) Radiographic Examination

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 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Detail Drawings; G, ED

Detail drawings for metalwork and machine work, prior to fabrication, as specified and in Section 05 50 14 METALS:

MISCELLANEOUS, STANDARD ARTICLES, SHOP FABRICATED ITEMS.

SD-03 Product Data

Welding of Structural Steel; G, ED

Schedules of welding procedures for steel structures, prior to commencing fabrication.

Welding of Aluminum; G, ED

SECTION 05 50 14 Page 4

Schedules of welding processes for aluminum fabrications, prior to commencing fabrication.

Structural Steel Welding Repairs; G, ED

Welding repair plans for steel, prior to making repairs.

Materials Orders; G, RE

Copies of purchase orders, mill orders, shop orders and work orders for materials, prior to the use of the materials in the work.

Materials List; G, RE

Materials list for fabricated items, at the time of submittal of detail drawings.

Shipping Bill; G, RE

Shipping bill with the delivery of finished pieces to the site.

SD-06 Test Reports

Tests, Inspections, and Verifications

Certified test reports for materials with all materials delivered to the site.

SD-07 Certificates

Qualification of Welders and Welding Operators; G, RE

Certifications for welders and welding operators prior to commencing fabrication.

Application Qualification for Steel Studs; G, RE

Certified reports for the application qualification for steel studs prior to commencing fabrication.

Welding of Aluminum; G, RE

Certified report for aluminum welding qualification tests prior to commencing welding.

1.3 DETAIL DRAWINGS

Detail drawings for metalwork and machine work shall include catalog cuts, templates, fabrication and assembly details and type, grade and class of material as appropriate. Elements of fabricated items inadvertently omitted on contract drawings shall be detailed by the fabricator and indicated on the detail drawings.

1.4 QUALIFICATION OF WELDERS AND WELDING OPERATORS

The Contractor shall certify that the qualification of welders and welding operators and tack welders who will perform structural steel welding have

SECTION 05 50 14 Page 5 been qualified for the particular type of work to be done in accordance with the requirements of AWS D1.1/D1.1M, Section 5, or ASME BPVC SEC IX, Section IX, prior to commencing fabrication. The certificate shall list the qualified welders by name and shall specify the code and procedures under which qualified and the date of qualification. Prior qualification will be accepted if welders have performed satisfactory work under the code for which qualified within the preceding three months. The Contractor shall require welders to repeat the qualifying tests when their work indicates a reasonable doubt as to proficiency. Those passing the requalification tests will be recertified. Those not passing will be disqualified until passing. All expenses in connection with qualification and requalification shall be borne by the Contractor.

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Materials Orders

The Contractor shall furnish copies of purchase orders, mill orders, shop orders and work orders for all materials orders and items used in the work. Where mill tests are required purchase orders shall contain the test site address and the name of the testing agency.

2.1.2 Materials List

The Contractor shall furnish a materials list of the materials to be used in the fabrication of each item.

2.1.3 Shipping Bill

The Contractor shall furnish a shipping bill or memorandum of each shipment of finished pieces or members to the project site giving the designation mark and weight of each item, the number of items, the total weight, and the car initial and number if shipped by rail in carload lots. Duplicate copies of shipping bills shall be mailed promptly to the Contracting Officer.

2.2 FABRICATION

2.2.1 Connections

The Contractor shall be responsible for the design of connections that are not shown on the contract drawings, correctness of detailing, fabrication, and for the correct fitting of structural members. Connections, for any part of the structure that are not shown on the contract drawings, shall be designed and detailed in accordance with pertinent provisions of AISC 360 and AISC 350. Additionally the following minimum design criteria for connections shall be adhered to:

a. Connections shall be shop welded or shop bolted, and field bolted unless specifically designated on the contract drawings.

b. Design connection clip angles for the specified beam reaction forces and strut forces, that are shown on the contract drawings. Clip angles shall be a minimum of 5/16 inch thick. The Minimum connections shall have a load capacity equivalent to or greater than the load capacity of two (3/4) inch diameter high strength bolts in single shear. Welded connections shall develop at least (20,000) pounds.

SECTION 05 50 14 Page 6

When reactions forces are not indicated on the drawings a connection shall be provided that capable of supporting one half the uniform load capacity of the given beam, span and grade of steel specified from the "Allowable Loads on Beams" in Part 2 of AISC 317, but not less than the following minimum number of bolt rows for the beam depths indicated.

6 Rows - W44, W40, W36, W33 5 Rows - W30, W27 4 Rows - W24, W21 3 Rows - W18, W16, W14 2 Rows - W12, W10, W8 1 Row - W6

1. High strength bolted connections shall be fully pretensioned bearing type "N" with threads included in the shear plane unless otherwise indicated.

2. Use Table III "Framed Beam Connections" of AISC 317, for welded connections.

3. Bracing Connections: Design of bracing connections shall be based on the loads shown on the design drawings without any increase in allowable stresses. Design gusset plates to transfer the bracing forces to both the columns and beams and provide at least a 5/16 inch minimum thickness. Turn vertical element of angles or tees down. Back to back placement of elements is prohibited unless specifically indicated on contract drawings.

Substitution of sections or modification of connection details will not be accepted unless approved by the Contracting Officer. AISC 317 and AISC 350 shall govern the work. High-strength bolting shall be in accordance with

AISC 317.

2.2.2 Structural Fabrication

Material must be straight before being laid off or worked. If straightening is necessary it shall be done by methods that will not impair the metal. Sharp kinks or bends shall be cause for rejection of the material. Material with welds will not be accepted except where welding is definitely specified, indicated or otherwise approved. Bends shall be made by approved dies, press brakes or bending rolls. Where heating is required, precautions shall be taken to avoid overheating the metal and it shall be allowed to cool in a manner that will not impair the original properties of the metal. Proposed flame cutting of material other than structural steel shall be subject to approval and shall be indicated on detail drawings. Shearing shall be accurate and all portions of the work shall be neatly finished. Corners shall be square and true unless otherwise shown. Re-entrant cuts shall be filleted to a minimum radius of 3/4 inch unless otherwise approved. Finished members shall be free of twists, bends and open joints. Bolts, nuts and screws shall be tight.

Structural steel fabrication and erection shall be performed by an organization experienced in structural steel work of equivalent magnitude.

The Contractor shall be responsible for correctness of detailing, fabrication, and for the correct fitting of structural members.

2.2.2.1 Dimensional Tolerances for Structural Work

Dimensions shall be measured by an approved calibrated steel tape of

SECTION 05 50 14 Page 7 approximately the same temperature as the material being measured. The overall dimensions of an assembled structural unit shall be within the tolerances indicated on the drawings or as specified in the particular section of these specifications for the item of work. Where tolerances are not specified in other sections of these specifications or shown, an allowable variation of 1/32 inch is permissible in the overall length of component members with both ends milled and component members without milled ends shall not deviate from the dimensions shown by not more than 1/16 inch for members 30 feet or less in length and by more than 1/8 inch for members over 30 feet in length.

2.2.2.2 Structural Steel Fabrication

Structural steel may be cut by mechanically guided or hand-guided torches, provided an accurate profile with a surface that is smooth and free from cracks and notches is obtained. Surfaces and edges to be welded shall be prepared in accordance with AWS D1.1/D1.1M, Subsection 3.2. Where structural steel is not to be welded, chipping or grinding will not be required except as necessary to remove slag and sharp edges of mechanically guided or hand-guided cuts not exposed to view. Hand-guided cuts which are to be exposed or visible shall be chipped, ground or machined to sound metal.

2.2.2.3 Structural Aluminum Fabrication

Laying out and cutting of aluminum shall be in accordance with the AA ADM1, Section 6.

2.2.3 Welding

2.2.3.1 Welding of Structural Steel

a. Welding Procedures for Structural Steel - Welding procedures for structural steel shall be prequalified as described in AWS D1.1/D1.1M, Subsection 5.1 or shall be qualified by tests as prescribed in AWS D1.1/D1.1M, Section 5. Properly documented evidence of compliance with all requirements of these specifications for previous qualification tests shall establish a welding procedure as prequalified. For welding procedures qualified by tests, the test welding and specimen testing must be witnessed and the test report document signed by the Contracting Officer. Approval of any welding procedure will not relieve the Contractor of the responsibility for producing a finished structure meeting all requirements of these specifications. The Contractor will be directed or authorized to make any changes in previously approved welding procedures that are deemed necessary or desirable by the Contractor Officer. The Contractor shall submit a complete schedule of welding procedures for each steel structure to be welded. The schedule shall conform to the requirements specified in the provisions AWS D1.1/D1.1M, Sections 2, 3, 4, 7 and 9 and applicable provisions of Section 10. The schedule shall provide detailed procedure specifications and tables or diagrams showing the procedures to be used for each required joint. Welding procedures must include filler metal, preheat, interpass temperature and stress-relief heat treatment requirements. Each welding procedure shall be clearly identified as being prequalified or required to be qualified by tests.

Welding procedures must show types and locations of welds designated or in the specifications to receive nondestructive examination.

b. Welding Process - Welding of structural steel shall be by an

SECTION 05 50 14 Page 8 electric arc welding process using a method which excludes the atmosphere from the molten metal and shall conform to the applicable provisions of AWS D1.1/D1.1M, Sections 1 thru 7, 9, 10 and 11. Welding shall be such as to minimize residual stresses, distortion and shrinkage.

c. Welding Technique

(1) Filler Metal - The electrode, electrode-flux combination and grade of weld metal shall conform to the appropriate AWS specification for the base metal and welding process being used or shall be as shown where a specific choice of AWS specification allowables is required. The AWS designation of the electrodes to be used shall be included in the schedule of welding procedures.

Only low hydrogen electrodes shall be used for manual shielded metal-arc welding regardless of the thickness of the steel. A controlled temperature storage oven shall be used at the job site as prescribed by AWS D1.1/D1.1M, Subsection 4.5 to maintain low moisture of low hydrogen electrodes.

(2) Preheat and Interpass Temperature - Preheating shall be performed as required by AWS D1.1/D1.1M, Subsection 4.2 and 4.3 or as otherwise specified except that the temperature of the base metal shall be at least 70 degrees F. 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.

(3) Stress-Relief Heat Treatment - The Contractor shall include in the fabrication process a positive means of minimizing residual thermal stresses and distortions. The process shall contain a means of verifying that the relief has been achieved. Weld inspection shall be performed after the treatment. Acceptable processes:

a. A thermal stress relief as defined in AWS D1.1/D1.1M

b. A vibratory stress relief using subharmonic excitation as implemented by Bonal Technologies or an alternate equivalent.

d. Workmanship - Workmanship for welding shall be in accordance with AWS D1.1/D1.1M, Section 3 and other applicable requirements of these specifications.

(1) Preparation of Base Metal - Prior to welding the Contractor shall inspect surfaces to be welded to assure compliance with AWS D1.1/D1.1M, Subsection 3.2.

(2) Temporary Welds - Temporary welds required for fabrication and erection shall be made under the controlled conditions prescribed for permanent work. Temporary welds shall be made using low-hydrogen welding electrodes and by welders qualified for permanent work as specified in these specifications. Preheating for temporary welds shall be as required by AWS D1.1/D1.1M for permanent welds except that the minimum temperature shall be 120 degrees F in any case. In making temporary welds arcs shall not be struck in other than weld locations. Each temporary weld shall be removed and ground flush with adjacent surfaces after serving its purpose.

SECTION 05 50 14 Page 9

(3) Tack Welds - Tacks welds that are to be incorporated into the permanent work shall be subject to the same quality requirements as the permanent welds and shall be cleaned and thoroughly fused with permanent welds. Preheating shall be performed as specified above for temporary welds. Multiple-pass tack welds shall have cascaded ends. Defective tack welds shall be removed before permanent welding.

2.2.3.2 Welding of Steel Castings

Unsound material shall be removed from the surfaces of steel castings to be incorporated into welded connections by chipping, machining, air-arc gouging or grinding. Major connections designed for transfer of stresses shall not be welded if the temperature of the casting is lower than 100 degrees F. Castings containing over 0.35 percent carbon or over 0.75 percent manganese shall be preheated to a temperature not to exceed 450 degrees F and welding shall be accomplished while the castings are maintained at a temperature above 350 degrees F. Welding will not be permitted on castings containing carbon in excess of 0.45 percent except on written authorization. Castings requiring welding repairs after the first annealing and castings involving welding fabrication shall be stress-relieved annealed prior to receiving final machining unless otherwise permitted.

2.2.3.3 Welding of Aluminum

Welding of aluminum shall conform to AA ADM1 or AWS D1.2/D1.2M, Sections 1 through 7, 9 and 10. The welding process and welding operators shall be prequalified as required by AWS D1.2/D1.2M, Section 5 or AA ADM1, Subsection 7.2.4 in accordance with the methods described in ASME BPVC SEC IX, Section IX. A certified report giving the results of the qualifying tests shall be furnished for approval. A complete schedule of the welding process for each aluminum fabrication to be welded shall be furnished for approval.

2.2.3.4 Welding of Steel Studs

The procedures for welding steel studs to structural steel, including mechanical, workmanship, technique, stud application qualification, production quality control and fabrication and verification inspection procedures shall conform to the requirements of AWS D1.1/D1.1M, Section 7, except as otherwise specified.

a. Application Qualification for Steel Studs - As a condition of approval of the stud application process, the Contractor shall furnish certified test reports and certification that the studs conform to the requirements of AWS D1.1/D1.1M, Subsections 7.2 and 7.3, certified results of the stud manufacturer's stud base qualification test, and certified results of the stud application qualification test as required by AWS D1.1/D1.1M, Subsection 7.6, except as otherwise specified.

b. Production Quality Control - Quality control for production welding of studs shall conform to the requirements of AWS D1.1/D1.1M, Subsection 7.7, except as otherwise specified. Studs on which pre-production testing is to be performed shall be welded in the same general position as required on production studs (flat, vertical, overhead or sloping). If the reduction of the length of studs becomes

SECTION 05 50 14 Page 10 less than normal as they are welded, welding shall be stopped immediately and not resumed until the cause has been corrected.

2.2.4 Bolted Connections

2.2.4.1 Bolted Structural Steel Connections

Bolts, nuts and washers shall be of the type specified or indicated. All nuts shall be equipped with washers except for high strength bolts.

Beveled washers shall be used where bearing faces have a slope of more than 1:20 with respect to a plane normal to the bolt axis. Where the use of high strength bolts is specified or indicated the materials, workmanship and installation shall conform to the applicable provisions of ASTM A 325 or

ASTM A 490.

a. Bolt Holes - Bolt holes shall be accurately located, smooth, perpendicular to the member and cylindrical.

(1) Holes for regular bolts shall be drilled or subdrilled and reamed in the shop and shall not be more than 1/16 inch larger than the diameter of the bolt.

(2) Holes for fitted bolts shall be match-reamed or drilled in the shop. Burrs resulting from reaming shall be removed. The threads of bolts shall be entirely outside of the holes. The body diameter of bolts shall have tolerances as recommended by ASME B4.1 for the class of fit specified. Fitted bolts shall be fitted in reamed holes by selective assembly to provide an LN-2 fit.

(3) Holes for high strength bolts shall have diameters of not more than 1/16 inch larger than bolt diameters. If the thickness of the material is not greater than the diameter of the bolts the holes may be punched. If the thickness of the material is greater than the diameter of the bolts the holes may be drilled full size or subpunched or subdrilled at least 1/8 inch smaller than the diameter of the bolts and then reamed to full size. Poor matching of holes will be cause for rejection. Drifting occurring during assembly shall not distort the metal or enlarge the holes.

Reaming to a larger diameter of the next standard size bolt will be allowed for slight mismatching.

2.2.4.2 Bolted Aluminum Connections

Punching, drilling, reaming and bolting for bolted aluminum connections shall conform to the requirements of AA ADM1, Section 6.

2.2.5 Patterns

Care shall be taken to avoid sharp corners or abrupt changes in cross section and ample fillets shall be used in the construction of patterns.

Draft and increases in pattern thicknesses shall be added as required to conform to the standard foundry practice applied and as necessary to ensure that all metal thicknesses of the finished castings conform to the dimensions shown and are within the tolerances specified in paragraph INSPECTION OF STEEL CASTINGS. All patterns, including those for the corner castings identified on Drawing 037-LCH-20/G3, shall be furnished by the Contractor, become the property of the Government and not be used for work under any other contract unless specifically authorized.

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2.2.5.1 Fabrication of Patterns and Core Boxes

Patterns and core boxes that shall become the property of the Government shall be substantially made from thoroughly seasoned Grade B or better sugar pine, northern white pine or an approved equal. Built-up patterns and core boxes shall be securely glued and screwed together. Glue shall be of an approved high grade, water resistant and suitably treated for resistance to fungus and insect infestation. Only light sections are permitted to be nailed. Screw holes shall be counterbored and neatly filled with wood plugs. Loose pieces shall be dovetailed or fastened with pull-out dowels. Split patterns and core boxes shall have metal dowels at partings. Skeleton or sweep patterns will not be accepted unless specifically authorized. All nail and tool marks on molding surfaces shall be filled with beeswax. All surfaces shall be sanded with No. 0 grade sandpaper. Patterns shall be finished with not less than three coats of an approved phenolic-resin sealer colored in accordance with the standard trade practices for pattern colors. Each pattern, core box and loose piece shall be stamped with the part mark shown. Patterns shall be furnished complete with necessary core boxes and templates.

2.2.5.2 Disposition of Patterns, Core Boxes, and Templates

Boxes and crates for the packing and shipment of patterns, core boxes and templates shall be substantially made and put together with screws so that they can be used several times. Each box and crate shall be plainly marked to indicate its contents. All patterns, core boxes and templates used shall be thoroughly cleaned, crated and delivered in first-class condition with a list of same in duplicate to Pittsburgh Engineer Warehouse and Repair Shops, 3500 Grand Ave., Neville Island, Pittsburgh, PA 15225 before final payment is made. The Contracting Officer reserves the right to withhold payment for final parts made from any pattern until such pattern is delivered. Patterns and core boxes shall be varnished and all templates given a coat of an approved paint before being crated. Any pattern, core box or template lost in shipment or damaged by the Contractor shall be replaced by the Contractor without charge to the Government.

2.2.6 Castings

Each casting shall bear cast or stamped mark numbers. Castings weighing more than 500 required pounds shall also bear cast or stamped heat numbers. Deviations from the dimensions of castings shown shall not exceed amounts that will impair the strength of castings by more than 10 percent as computed from the dimensions shown. Dimensions of castings shown on approved detail drawings shall be finished dimensions. Castings that are warped or otherwise distorted or that are oversize to an extent that will interfere with proper fit with other parts of the machinery or structure will be rejected. The structure of metal in castings shall be homogeneous 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. Minor surface imperfections not affecting the strength of casting may be welded in the "green" if approved. Surface imperfections shall be considered minor when the depth of the cavity prepared for welding is the lesser of 20 percent of the actual wall thickness or 1 inch. Defects other than minor surface imperfections may be welded only when specifically authorized in accordance with the following requirements:

a. The defects have been entirely removed and are judged not to affect the strength, use or machineability of the castings when properly

SECTION 05 50 14 Page 12 welded and stress relieved.

b. The proposed welding procedure, stress relief and method of examination of the repair work have been submitted and approved.

2.2.7 Machine Work

Tolerances, allowances and gauges for metal fits between plain, non-threaded, cylindrical parts shall conform to ASME B4.1 for the class of fit shown or required unless otherwise shown on approved detail drawings.

Where fits are not shown they shall be suitable as approved. Tolerances for machine-finished surfaces designated by non-decimal dimensions shall be within 1/64 inch. Sufficient machining stock shall be allowed on placing pads to ensure true surfaces of solid material. Finished contact or bearing surfaces shall be true and exact to secure full contact. Journal surfaces shall be polished and all surfaces shall be finished with sufficient smoothness and accuracy to ensure proper operation when assembled. Parts entering any machine shall be accurately machined and all like parts shall be interchangeable except that parts assembled together for drilling or reaming of holes or machining will not be required to be interchangeable with like parts. All drilled holes bolts shall be accurately located.

2.2.7.1 Finished Surfaces

Surface finishes indicated or specified shall be in accordance with ASME B46.1. Values of required roughness heights are arithmetical average deviations expressed in microinches. These values are maximum. Lesser degrees will be satisfactory unless otherwise indicated. 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 ASME 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 detail drawings by a symbol which conforms to ASME B46.1 when machine finishing is provided. Flaws such as scratches, ridges, holes, peaks, cracks or checks which will make the part unsuitable for the intended use will be cause for rejection.

2.2.7.2 Unfinished Surfaces

All work shall be laid out to secure proper matching of adjoining unfinished surfaces unless otherwise directed. Where there is a large discrepancy between adjoining unfinished surfaces they shall be chipped and ground smooth or machined to secure proper alignment. Unfinished surfaces shall be true to the lines and dimensions shown and shall be chipped or ground free of all projections and rough spots. Depressions or holes not affecting the strength or usefulness of the parts shall be filled in an approved manner.

2.2.7.3 Pin Holes

Pin holes shall be bored true to gauges, smooth, straight and at right angles to the axis of the member. The boring shall be done after the member is securely fastened in position.

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2.2.8 Miscellaneous Provisions

2.2.8.1 Metallic Coatings

a. Zinc Coatings - Zinc coatings shall be applied in a manner and of a thickness and quality conforming to ASTM A 123/A 123M. Where zinc coatings are destroyed by cutting, welding or other causes the affected areas shall be regalvanized. Coatings 2 ounces or heavier shall be regalvanized with a suitable low-melting zinc base alloy similar to the recommendations of the American Hot-Dip Galvanizers Association to the thickness and quality specified for the original zinc coating.

Coatings less than 2 ounces shall be repaired in accordance with

ASTM A 780.

b. Cadmium Coatings - Cadmium coatings shall be of a quality and thickness conforming to the requirements of ASTM B 766 and inspection shall conform to the requirements of ASTM E 165.

c. Chromium Coatings - Chromium coatings for engineering use shall be applied in conformity with ASTM B 177.

2.2.8.2 Cleaning of Corrosion-Resisting Steel

Oil, paint and other foreign substances shall be removed from corrosion-resisting steel surfaces after fabrication. Cleaning shall be done by vapor degreasing or by the use of cleaners of the alkaline, emulsion or solvent type. After the surfaces have been cleaned they shall be given a final rinsing with clean water followed by a 24 hour period during which the surfaces are intermittently wet with clean water and then allowed to dry for the purpose of inspecting the clean surfaces. The surfaces shall be visually inspected for evidence of paint, oil, grease, welding slag, heat treatment scale, iron rust or other forms of contamination. If evidence of foreign substance exist the surface shall be cleaned in accordance with the applicable provisions of ASTM A 380. The proposed method of treatment shall be furnished for approval. After treatment the surfaces shall be visually reinspected. Brushes used to remove foreign substances shall have only stainless steel or nonmetallic bristles. Any contamination occurring subsequent to the initial cleaning shall be removed by one or more of the methods indicated above.

2.2.9 Shop Assembly

Each machinery and structural unit furnished shall be assembled in the shop to determine the correctness of the fabrication and matching of the component parts unless otherwise specified. Tolerances shall not exceed those shown. Each unit assembled shall be closely checked to ensure that all necessary clearances have been provided and that binding does not occur in any moving part. Assembly in the shop shall be in the same position as final installation in the field unless otherwise specified. Assembly and disassembly work shall be performed in the presence of the Contracting Officer unless waived in writing. Errors or defects disclosed shall be immediately remedied by the Contractor without cost to the Government.

Before disassembly for shipment each piece of a machinery or structural unit shall be match-marked to facilitate erection in the field. The location of match-marks shall be indicated by circling with a ring of white paint after the shop coat of paint has been applied or as otherwise directed.

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2.3 TESTS, INSPECTIONS, AND VERIFICATIONS

The Contractor shall have required material tests and analyses performed and certified by an approved laboratory to demonstrate that materials are in conformity with the specifications. These tests and analyses shall be performed and certified at the Contractor's expense. Tests, inspections, and verifications shall conform to the requirements of the particular sections of these specifications for the respective items of work unless otherwise specified or authorized. Tests shall be conducted in the presence of the Contracting Officer if so required. The Contractor shall furnish specimens and samples for additional independent tests and analyses upon request by the Contracting Officer. Specimens and samples shall be properly labeled and prepared for shipment.

2.3.1 Nondestructive Testing

When doubt exists as to the soundness of any material part such part may be subjected to any form of nondestructive testing determined by the Contracting Officer. This may include ultrasonic, magnaflux, dye penetrant, x-ray, gamma ray or any other test that will thoroughly investigate the part in question. The cost of such investigation will be borne by the Government. Any defects will be cause for rejection and rejected parts shall be replaced and retested at the Contractor's expense.

2.3.2 Tests of Machinery and Structural Units

The details for tests of machinery and structural units shall conform to the requirements of the particular sections of these specifications covering these items. Each complete machinery and structural unit shall be assembled and tested in the shop in the presence of the Contracting Officer unless otherwise directed. Waiving of tests will not relieve the Contractor of responsibility for any fault in operation, workmanship or material that occurs before the completion of the contract or guarantee.

After being installed at the site each complete machinery or structural unit shall be operated through a sufficient number of complete cycles to demonstrate to the satisfaction of the Contracting Officer that it meets the specified operational requirements in all respects.

2.3.3 Inspection of Structural Steel Welding

The Contractor shall maintain an approved inspection system and perform required inspections in accordance with Contract Clause CONTRACTOR INSPECTION SYSTEM. Welding shall be subject to inspection to determine conformance with the requirements of AWS D1.1/D1.1M, the approved welding procedures and provisions stated in other sections of these specifications. Nondestructive examination of designated welds will be required. Supplemental examination of any joint or coupon cut from any location in any joint may be required.

2.3.3.1 Visual Examination

All visual examination of completed welds shall be cleaned and carefully examined for insufficient throat or leg sizes, cracks, undercutting, overlap, excessive convexity or reinforcement and other surface defects to ensure compliance with the requirements of AWS D1.1/D1.1M, Section 3 and Section 9, Part D.

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2.3.3.2 Test Coupons

The Government reserves the right to require the Contractor to remove coupons from completed work when doubt as to soundness cannot be resolved by nondestructive examination. Should tests of any two coupons cut from the work of any welder show strengths less than that specified for the base metal it will be considered evidence of negligence or incompetence and such welder shall be removed from the work. When coupons are removed from any part of a structure the members cut shall be repaired in a neat manner with joints of the proper type to develop the full strength of the members.

Repaired joints shall be peened as approved or directed to relieve residual stress. The expense for removing and testing coupons, repairing cut members and the nondestructive examination of repairs shall be borne by the Government or the Contractor in accordance with the Section 00700 CONTRACT CLAUSES, paragraph INSPECTION AND ACCEPTANCE.

2.3.3.3 Supplemental Examination

When the soundness of any weld is suspected of being deficient due to faulty welding or stresses that might occur during shipment or erection the Government reserves the right to perform nondestructive supplemental examinations before final acceptance. The cost of such inspection will be borne by the Government or the Contractor in accordance with the Section 00700 CONTRACT CLAUSES, paragraph INSPECTION AND ACCEPTANCE.

2.3.4 Structural Steel Welding Repairs

Defective welds in the structural steel welding repairs shall be repaired in accordance with AWS D1.1/D1.1M, Subsection 3.7. Defective weld metal shall be removed to sound metal by use of air carbon-arc or oxygen gouging. Oxygen gouging shall not be used on ASTM A 514/A 514M steel. The surfaces shall be thoroughly cleaned before welding. Welds that have been repaired shall be retested by the same methods used in the original inspection. Except for the repair of members cut to remove test coupons and found to have acceptable welds costs of repairs and retesting shall be borne by the Contractor.

2.3.5 Inspection and Testing of Steel Stud Welding

Fabrication and verification inspection and testing of steel stud welding shall conform to the requirements of AWS D1.1/D1.1M, Subsection 7.8 except as otherwise specified. The Contracting Officer will serve as the verification inspector. One stud in every 100 and studs that do not show a full 360 degree weld flash, have been repaired by welding or whose reduction in length due to welding is less than normal shall be bent or torque tested as required by AWS D1.1/D1.1M, Subsection 7.8. If any of these studs fail two additional studs shall be bent or torque tested. If either of the two additional studs fail all of the studs represented by the tests shall be rejected. Studs that crack under testing in either the weld, base metal or shank shall be rejected and replaced by the Contractor at no additional cost.

2.3.6 Inspection of Steel Castings

The Contractor shall perform radiographic inspection of steel castings as designated and as described in the section of these specifications covering the particular item of work. The procedure for making, evaluating and reporting the radiographic inspection shall conform to the requirements of ASTM E 94. The castings shall be unacceptable if shown to have defects of

SECTION 05 50 14 Page 16 greater severity than the applicable reference standard specified in the following table:

SEVERITY LEVELS

DISCONTINUITY TYPE OR CLASSES

Category A - Gas and Blow Holes 2

Category B - Sand and Slag Inclusions 2

Category C - Shrinkage (all Types) 2

Category D - Cracks *

Category E - Hot Tears 1

Category F - Inserts, Unfused Chaplets and 1 Internal Chills

* The casting shall be scrapped with occurrence of any cracks, except for surface cracks. For repair of steel castings, see paragraph "Repair of Steel Castings".

The applicable referenced standards shall be as illustrated in ASTM E 446.

The evaluation of the radiographs shall be subject to approval and all records shall become the property of the Government.

2.3.6.1 Castings to be Inspected

The Contractor shall perform radiographic inspection of the pintle bearing castings. A sufficient number of radiographs shall be taken of the pintle bearing castings and bushings to thoroughly inspect one hundred percent (100%) of the entire bowl area which is to be occupied by the pintle bushing and one radiograph shall be taken for each group of bolt holes (in the bearing casting), both horizontal and vertical.

PART 3 EXECUTION

3.1 INSTALLATION

All parts to be installed shall be thoroughly cleaned. Packing compounds, rust, dirt, grit and other foreign matter shall be removed. Holes and grooves for lubrication shall be cleaned. Enclosed chambers or passages shall be examined to make sure that they are free from damaging materials.

Where units or items are shipped as assemblies they will be inspected prior to installation. Disassembly, cleaning and lubrication will not be required except where necessary to place the assembly in a clean and properly lubricated condition. Pipe wrenches, cold chisels or other tools likely to cause damage to the surfaces of rods, nuts or other parts shall not be used for assembling and tightening parts. Bolts and screws shall be tightened firmly and uniformly but care shall be taken not to overstress the threads. When a half nut is used for locking a full nut the half nut shall be placed first and followed by the full nut. Threads of all bolts except high strength bolts, nuts and screws shall be lubricated with an approved lubricant before assembly. Threads of corrosion-resisting steel bolts and nuts shall be coated with an approved antigalling compound.

Driving and drifting bolts or keys will not be permitted.

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3.1.1 Alignment and Setting

Each machinery or structural unit shall be accurately aligned by the use of steel shims or other approved methods so that no binding in any moving parts or distortion of any member occurs before it is fastened in place.

The alignment of all parts with respect to each other shall be true within the respective tolerances required. Machines shall be set true to the elevations shown.

3.1.2 Blocking and Wedges

All blocking and wedges used during installation for the support of parts to be grouted in foundations shall be removed before final grouting unless otherwise directed. Blocking and wedges left in the foundations with approval shall be of steel or iron.

3.1.3 Foundations and Grouting

Concreting of subbases and frames and the final grouting under parts of machines shall be in accordance with the procedures as specified in Section

03 30 00.70 CONCRETE: CAST-IN-PLACE.

3.2 PROTECTION OF FINISHED WORK

3.2.1 Machined Surfaces

Machined surfaces shall be thoroughly cleaned of foreign matter. All finished surfaces shall be protected by suitable means. Unassembled pins and bolts shall be oiled and wrapped with moisture resistant paper or protected by other approved means. Finished surfaces of ferrous metals to be in bolted contact shall be washed with an approved rust inhibitor and coated with an approved rust resisting compound for temporary protection during fabrication, shipping and storage periods. Finished surfaces of metals which shall be exposed after installation except corrosion resisting steel or nonferrous metals shall be painted as specified in Section 09 97 02

PAINTING: HYDRAULIC STRUCTURES.

3.2.2 Aluminum

Aluminum that shall be in contact with grout or concrete shall be protected from galvanic or corrosive action by being given a coat of zinc-chromate primer and a coat of aluminum paint. Aluminum in contact with structural steel shall be protected against galvanic or corrosive action by being given a coat of zinc-chromate primer and a coat of aluminum paint. The aluminum paint shall consist of a aluminum paste conforming to ASTM D 962, spar varnish and thinner compatible with the varnish. The aluminum paint shall be field mixed in proportion of 2 pounds of paste, not more than one gallon of spar varnish and not more than one pint of thinner.

3.3 TESTS

3.3.1 Workmanship

Workmanship shall be of the highest grade and in accordance with the best modern practices to conform with the specifications for the item of work being furnished.

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3.3.2 Production Welding

Production welding shall conform to the requirements of AWS D1.1/D1.1M or AWS D1.2/D1.2Mas applicable. Studs on which pre-production testing is to be performed shall be welded in the same general position as required on production items (flat, vertical, overhead or sloping). Test and production stud welding will be subjected to visual examination or inspection. If the reduction of the length of studs becomes less than normal as they are welded, welding shall be stopped immediately and not resumed until the cause has been corrected.

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2.2.9 Shop Assembly