05 01 50.pdf

Braddock and Charleroi L/D's, Painting Tainter Gates

SECTION TABLE OF CONTENTS

DIVISION 05 - METALS

SECTION 05 01 50

REPAIR OF DAMAGED CLOSURE PLATES AND DAM GATE

PART 1 GENERAL

1.1 SUMMARY

1.2 REFERENCES

1.3 SUBMITTALS

1.4 QUALIFICATION OF WELDERS AND WELDING OPERATORS

PART 2 PRODUCTS

PART 2 PRODUCTS

2.1 MISCELLANEOUS METALS AND STANDARD METAL ARTICLES

2.2 Structural Steel

2.3 FABRICATION

2.3.1 Structural Fabrication

2.3.2 Welding

2.3.2.1 Welding of Structural Steel

2.4 TESTS, INSPECTIONS, AND VERIFICATIONS

2.4.1 Inspection of Structural Steel Welding

2.4.1.1 Visual Examination

2.4.1.2 Nondestructive Examination

2.4.2 Structural Steel Welding Repairs

PART 3 EXECUTION

3.1 REPAIR OF DAMAGED CLOSURE PLATES

3.2 REPAIR OF BARGE DAMAGE, BRADDOCK GATE NO. 1

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SECTION 05 01 50 Page 1 W911WN-09-B-0006 Revised by Amendment No. 4

SECTION 05 01 50

REPAIR OF DAMAGED CLOSURE PLATES AND DAM GATE

PART 1 GENERAL

1.1 SUMMARY

The work under this section consists of furnishing all plant, labor and materials for repair of closure plates in the bottom units of the movable-crest tainter gates at Charleroi Locks and Dam as shown on the attached sketch and as specified herein. The work also consists of repair of recent barge damage at Gate No. 1 at Braddock Locks and Dam.

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.

ASTM INTERNATIONAL (ASTM)

ASTM A 36/A 36M (2008) Standard Specification for Carbon Structural Steel

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

AMERICAN WELDING SOCIETY (AWS)

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

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 Preconstruction Submittals

Welding Procedures for Structural Steel; G, ED

Schedules of welding procedures for steel structures shall be submitted and approved prior to commencing fabrication.

SD-06 Test Reports

Tests, Inspections, and Verifications

Certified test reports for materials shall be submitted with all

SECTION 05 01 50 Page 2 materials delivered to the site.

SD-07 Certificates

Qualification of Welders and Welding Operators

Certifications for welders and welding operators shall be submitted prior to commencing fabrication.

1.4 QUALIFICATION OF WELDERS AND WELDING OPERATORS

The Contractor shall certify that the welders, welding operators and tack welders who will perform structural steel welding have been qualified for the particular type of work to be done in accordance with the requirements of AWS D1.1 or ASME BPV 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 in the opinion of the Contracting Officer 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

PART 2 PRODUCTS

2.1 MISCELLANEOUS METALS AND STANDARD METAL ARTICLES

Miscellaneous metal materials shall conform to the respective specifications.

2.2 Structural Steel

ASTM A 36/A 36Mfor closure plates. ASTM A 572/A 572M, Grade 50 for Braddock Gate No. 1 repair, unless otherwise noted on the applicable reference drawings.

2.3 FABRICATION

2.3.1 Structural Fabrication

Shearing shall be accurate and all portions of the work shall be neatly finished. Corners shall be square and true unless otherwise shown on the drawings. Finished members shall be free of twists, bends and open joints. 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. A straight-edge or suitable template shall be used for hand-guided cuts. Surfaces and edges to be welded shall be prepared in accordance with AWS D1.1, Subsection 3.2.

Edges of cuts which are to be exposed or visible shall be ground or machined to provide a smooth edge.

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2.3.2 Welding

2.3.2.1 Welding of Structural Steel

a. Welding Procedures for Structural Steel. Welding procedures for structural steel shall be prequalified as described in AWS D1.1, Subsection 5.1 or shall be qualified by tests as prescribed in AWS D1.1, 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 a representative of 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, 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 on the drawings or in the specifications to receive nondestructive examination.

b. Welding Process. Welding of structural steel shall be by an 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, 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 on the drawings 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, 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, 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.

SECTION 05 01 50 Page 4

d. Workmanship. Workmanship for welding shall be in accordance with AWS D1.1, 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, Subsection 3.2.

(2) Temporary Welds. Temporary welds required for fabrication and erection shall be made under the controlled conditions prescribed herein 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 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.

(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.

2.4 TESTS, INSPECTIONS, AND VERIFICATIONS

2.4.1 Inspection of Structural Steel Welding

The Contractor shall maintain an approved inspection system and perform required inspections in accordance Section 00700 CONTRACT CLAUSES, paragraph CONTRACTOR INSPECTION SYSTEMINSPECTION OF CONSTRUCTION. Welding shall be subject to inspection by the Contracting Officer to determine conformance with the requirements of AWS D1.1, the approved welding procedures and provisions stated in other sections of these specifications. The Contracting Officer will require nondestructive examination of designated welds and may require supplemental examination of any joint or coupon cut from any location in any joint.

2.4.1.1 Visual Examination

All 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, Section 3 and Section 9, Part D.

2.4.1.2 Nondestructive Examination

Perform as designated or described in the sections of these specifications, the nondestructive examination of shop and field welds covering the particular items of work.

a. Testing Agency - The nondestructive examination of welds and the evaluation of examination tests as to the acceptability of the welds shall be performed by a testing agency adequately equipped and competent to perform such services or by the Contractor using suitable

SECTION 05 01 50 Page 5 equipment and qualified personnel. In either case, written approval of the examination procedures is required and the examination tests shall be made in the presence of the Contracting Officer. The evaluation of examination tests are subject to the approval and all records become the property of the Government.

b. Examination Procedures - Conform to the following requirements.

(1) Ultrasonic Testing - Making, evaluating and reporting ultrasonic testing of welds shall conform to the requirements of AWS D1.1/D1.1M, Section 6, Part C. Provide ultrasonic equipment capable of making a permanent record of the test indications.

Make a record of each weld tested.

c. Acceptability of Welds - Welds will be unacceptable if shown to have defects prohibited by AWS D1.1/D1.1M, or possess any degree of incomplete fusion, inadequate penetration or undercutting.

d. Welds to be Subject to Nondestructive Examination

Full penetration welds for Braddock Gate No. 1 repairs

2.4.2 Structural Steel Welding Repairs

Defective welds shall be repaired in accordance with AWS D1.1, Subsection

3.7. Defective weld metal shall be removed to sound metal by use of air carbon-arc or oxygen gouging. 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.

PART 3 EXECUTION

3.1 REPAIR OF DAMAGED CLOSURE PLATES

Some existing closure plates at the bottom of the bottom units of the movable-crest tainter gates (see DETAIL "B" on reference drawing 037-L4-48/10.1) have been damage by water entering the pocket, freezing, and causing the closure plates to buckle. Photographs of typical damage are included at the end of this section. The buckled plates shall be repaired prior to metallizing and painting the gates. The existing plate shall be removed as necessary to remove the buckled area and leave sufficient plate around the edges of the pocket to provide backing for the new plate. The new plate shall be cut to fit the pocket area and welded in place with a 5/16-inch fillet weld. The weld shall completely seal the joint between the gate and the new plate.

3.2 REPAIR OF BARGE DAMAGE, BRADDOCK GATE NO. 1

This work shall include repair to Braddock Tainter Gate No. 1 from approximately T2 to T4 as indicated on the attached marked up Drawing 037-LBR-48/17 and Braddock Gate Repair Sketch. The damaged skin plate and WT section shall be cut out to provide a smooth transition to the undamaged section. Splices between the existing and new skin plate and between the skin plate between the existing and new WT sections shall be full penetration welds and shall be ground smooth. Welds connecting the WT section to the skin plate shall be 3/16" fillet weld as shown on marked up Drawing 037-LBR-48/17 attached at the end of this section. Full

SECTION 05 01 50 Page 6 penetration welds shall be nondestructive tested. All new materials and areas where the existing coating is damaged on the interior of the gate shall be painted with System No. LRP35.1-M as specified in Section 09 97 02 PAINTING: HYDRAULIC STRUCTURES. The Contractor is alerted that the interior of the gate will be considered to be a confined space.

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SECTION 05 01 50 Page 7 thomas.e.andre Text Box

APPROXIMATE LOCATION OF DAMAGE

thomas.e.andre Line thomas.e.andre Oval

2.4.2 Structural Steel Welding Repairs

Marked Up Drawing

037-LBR-48/17

Braddock Gate Repair Sketch