W911WN17Q1805_Specifications.pdf

SPECIFICATION

NEW CUMBERLAND LOCK AND DAM

FABRICATE FLOATING MOORING BITTS

GENERAL REQUIREMENTS

1.0 Description of Work

The work shall consist of fabricating four (4) floating mooring bitts for New Cumberland Lock and Dam. Each floating mooring bitt shall consist of an upper steel structure and a high density polyethylene (HDPE) pontoon section. They shall be fabricated in accordance with these specifications and the attached drawings.

1.1 Unit Price Payment Items

1.1.1 General

The unit price and payment made for each item listed shall constitute full compensation for furnishing all plant, labor, materials, equipment, tests and reports, and for performing all work required for each of the unit price items and delivering the items as specified.

1.1.2 Unit Price Items

1.1.2.1 Floating Mooring Bitts for New Cumberland L/D

Unit price payment items include:

0001 Floating Mooring Bitts

a. Measurement for fabrication, painting, and delivery of the floating mooring bitts shall be based on the actual number of bitts tested and delivered by the Contractor, as approved by the Contracting Officer.

c. Unit of measure: Each (EA). A total of four (4) floating mooring bitts will be needed.

1.2 Submittals

The Contractor shall submit a fabrication and production schedule for Government review. The Contractor shall submit their Quality Control Plan for fabrication for Government review and approval.

1.3 Execution of Work

1.3.1 General

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

1.3.2 Delivery

The four (4) floating mooring bitts must be delivered no later than 180 calendar days after an issuance of a Notice of Award.

1.3.3 Delivery Location

The floating mooring bitts will be delivered to the following location:

Pittsburgh Engineer Warehouse and Repair Station (PEWARS) 3500 Grand Avenue Pittsburgh, PA 15225-1584 Tom Markish 412-337-9593

1.3.4 Delivery Coordination

The delivery of the floating mooring bitts shall be coordinated with Denise Polizzano of the Upper Ohio Area Office. The Contractor shall provide a minimum of 48 hours notice, excluding weekends and holidays, prior to delivery.

After award of contract, the designated point of contact is:

Denise M. Polizzano, Resident Engineer 3510 Grand Avenue Pittsburgh, PA 15225 (412)395-7680 Email – Denise.M.Polizzano@usace.army.mil

1.4 Access and General Protection/Security Policy and Procedures

The contractor and all associated subcontractors' employees shall comply with applicable installation, facility, and area commander installation and facility access and local security policies and procedures (provided by the Government Representative). The contractor shall also provide all information required for background checks to meet installation access requirements to be accomplished by the installation the USACE Security Office. The contractor workforce must comply with all personal identity verification requirements as directed by DoD, HQDA, and/or local policy. In addition to the changes otherwise authorized by the changes clause of this contract, should the Force Protection Condition (FPCON) at any individual facility or installation change, the Government may require changes in contractor security matters or processes. The contractor must submit the full name, Social Security Number, Date of Birth, and Place of Birth for all associated contractor or subcontractor employees to the USACE Security Specialist Paul M. Surace, 412-395-7162, paul.m.surace@usace.army.mil or Stephen Davidson, 412-395-7504, stephen.davidson@usace.army.mil. The District retains the right to deny any contractor and subcontractor employee from working on one of its contracts based on final background investigation results.

1.5 Equal Opportunity for Veterans

Veterans Employment Emphasis for U.S. Army Corps of Engineers Contracts

In addition to complying with the requirements outlined in FAR Part 22.13, FAR Provision 52.222-38, FAR Clause 52.222-35, FAR Clause 52.222-37, DFARS

222.13 and Department of Labor regulations, U.S. Army Corps of Engineers mailto:Denise.M.Polizzano@usace.army.mil mailto:paul.m.surace@usace.army.mil mailto:stephen.davidson@usace.army.mil

(USACE) contractors and subcontractors at all tiers are encouraged to promote the training and employment of U.S. veterans while performing under a USACE contract. While no set-aside, evaluation preference, or incentive applies to the solicitation or performance under the resultant contract, USACE contractors are encouraged to seek out highly qualified veterans to perform services under this contract. The following resources are available to assist USACE contractors in their outreach efforts:

U.S. Department of Labor Veterans employment: www.vets.gov/ Federal veteran employment information: www.fedshirevets.gov/index.aspx Veterans’ Employment and Training Service (VETS): http://www.dol.gov/vets/ Veterans Opportunity to Work (VOW) Program: http://benefits.va.gov/vow/ U.S. Army Warrior Transition Command Employment Index:

wtc.army.mil/modules/employers/index.html Hiring Our Heroes initiative: www.uschamberfoundation.org/hiring-our-heroes

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SECTION TABLE OF CONTENTS DIVISION

01 - GENERAL REQUIREMENTS SECTION

01 33 00

SUBMITTAL PROCEDURES

PART 1 GENERAL

1.1 Submittal Descriptions (SD)

1.2 SUBMITTAL CLASSIFICATION

1.2.1 Government Approved/Accepted (G)

1.2.2 Information Only

1.3 APPROVED/ACCEPTED SUBMITTALS

1.4 DISAPPROVED/NON-ACCEPTED/ SUBMITTALS

1.5 WITHHOLDING OF PAYMENT

PART 2 PRODUCTS (Not used)

PART 3 EXECUTION

3.1 CONSTRUCTION SUBMITTALS

3.1.1 GENERAL

3.2 SCHEDULING

3.3 TRANSMITTAL FORM (ENG FORM 4025)

3.4 SUBMITTAL PROCEDURE

3.4.1 Procedures

3.4.2 Deviations

3.5 CONTROL OF SUBMITTALS

3.6 GOVERNMENT APPROVED SUBMITTALS

3.7 INFORMATION ONLY SUBMITTALS

3.8 STAMPS

-- End of Section Table of Contents --

SECTION 01 33 00

SUBMITTAL PROCEDURES

1.1 Submittal Descriptions (SD)

Submittal requirements are specified in the technical sections. Submittals required are identified by SD numbers and titles as follows:

SD-01 Preconstruction Submittals

A document, required of the Contractor, or through the Contractor, from a supplier, installer, manufacturer, or other lower tier Contractor, the purpose of which is to confirm the quality or orderly progression of a portion of the work by documenting procedures, acceptability of methods or personnel, qualifications, or other verifications of quality.

SD-03 Product Data

Preprinted manufacturer material describing a product, system, or material, such as catalog cuts.

SD-05 Design Data

Submittals, which provide calculations, descriptions, or documentation regarding the work.

SD-06 Test Reports

Reports of inspections or tests, including analysis and interpretation of test results.

SD-07 Certificates

Statement signed by an official authorized to certify on behalf of the manufacturer of a product, system, or material, attesting that the product, system, or material meets specified requirements. The statement must be dated after the award of the contract, must state the Contractor's name and address, must name the project and location, and must list the specific requirements, which are being certified.

1.2 SUBMITTAL CLASSIFICATION

Submittals are classified as follows:

1.2.1 Government Approved/Accepted (G)

All submittals classified for Government Approval (G) are identified in submittal register Form 4288.

1.2.2 Information Only

All Contractor submittals not requiring Government approval/acceptance will be for information only.

1.3 APPROVED/ACCEPTED SUBMITTALS

The approval of submittals shall not be construed as a complete check, but will indicate only that the general method of construction, materials, detailing, and other information are satisfactory. Approval will not relieve the Contractor of the responsibility for any error which may exist on any dimensions and details. The Contractor shall be responsible for satisfactory construction of all work. After submittals have been approved by the Contracting Officer, no re-submittal for the purpose of substituting materials or equipment will be considered unless accompanied by an explanation of why a substitution is necessary.

1.4 DISAPPROVED/NON-ACCEPTED/ SUBMITTALS

The Contractor shall make all corrections required by the Contracting Officer and promptly furnish a corrected submittal in the form and number of copies specified for the initial submittal.

If the Contractor considers any correction indicated on the submittals to constitute a change to the contract, a notice in accordance with FAR 52.243-1 Changes – Fixed Price shall be given promptly to the Contracting Officer.

1.5 WITHHOLDING OF PAYMENT

Payment for materials incorporated in the work will not be made if required approvals/non-acceptance have not been obtained.

PART 2 PRODUCTS (Not used)

3.1 CONSTRUCTION SUBMITTALS

3.1.1 GENERAL

The Contractor shall make submittals as required by the specifications. The Contracting Officer may request submittals in addition to those specified when deemed necessary to adequately describe the work covered in the respective sections. Units of weights and measures used on all submittals shall be the same as those used on the contract drawings, or required per the contract documents. Each submittal shall be complete and in sufficient detail to allow ready determination of compliance with contract requirements. Proposed deviations from the contract requirements shall be clearly identified. Submittals shall include items such as Contractor's, manufacturer's, or fabricator's drawings; descriptive literature including but not limited to catalog cuts, diagrams, operating charts or curves; test reports; test cylinders; samples; O&M manuals (including parts list);

certifications; warranties; and other such required submittals. Submittals requiring Government approval shall be scheduled and made prior to the acquisition of the material or equipment covered thereby. Samples remaining upon completion of the work shall be picked up and disposed of in accordance with manufacturer's Material Safety Data Sheets (MSDS) and in compliance with existing laws and regulations.

3.2 SCHEDULING

Submittals covering component items forming a system or items that are interrelated shall be scheduled to be coordinated and submitted concurrently. Certifications to be submitted with the pertinent drawings shall be so scheduled. Adequate time (a minimum of 14 calendar days including weekends and holidays and exclusive of mailing time) shall be allowed and shown on the register for review and approval. No delay damages or time extensions will be allowed due to time lost in late submittals.

3.3 SUBMITTAL PROCEDURE

Submittals shall be made as follows:

3.3.1 Procedures

The Contractor shall submit to the Contracting Officer (1) one copy of all submittals.

3.3.2 Deviations

For submittals which include proposed deviations requested by the Contractor. Contractor shall set forth in writing the reason for any deviations and annotate such deviations on the submittal.

3.4 CONTROL OF SUBMITTALS

The Contractor shall carefully control his procurement operations to ensure that each individual submittal is made on or before the Contractor scheduled submittal date shown on the approved "Submittal Register."

3.5 GOVERNMENT APPROVED SUBMITTALS

Upon completion of review of submittals requiring Government approval/acceptance, the submittals will be identified as having received approval/acceptance by being so stamped and dated.

3.6 INFORMATION ONLY SUBMITTALS

The Contractor is responsible for preparing and retaining (1) one copy of all For Information Only (FIO) submittals. One copy of the FIO submittals will be used for historical record and transferred to the customer upon completion of the project. Approval of the Contracting Officer is not required on information only submittals. The Government reserves the right to require the Contractor to resubmit any of the FIO submittals found not to comply with the contract. This does not relieve the Contractor from the obligation to furnish material conforming to the plans and specifications;

will not prevent the Contracting Officer from requiring removal and replacement of nonconforming material incorporated in the work; and does not relieve the Contractor of the requirement to furnish samples for testing by the Government laboratory or for check testing by the Government in those instances where the technical specifications so prescribe.

-- End of Section --

SECTION TABLE OF CONTENTS DIVISION

01 - GENERAL REQUIREMENTS SECTION

01 42 00

SOURCES FOR REFERENCE PUBLICATIONS

1.1 REFERENCES

1.2 ORDERING INFORMATION

PART 2 PRODUCTS

SECTION 01 42 00

SOURCES FOR REFERENCE PUBLICATIONS

Various publications are referenced in other sections of the specifications to establish requirements for the work. These references are identified in each section by document number, date and title. The document number used in the citation is the number assigned by the standards producing organization, (e.g. ASTM B564 Nickel Alloy Forgings). However, when the standards producing organization has not assigned a number to a document, an identifying number has been assigned for reference purposes.

1.2 ORDERING INFORMATION

The addresses of the standards publishing organizations whose documents are referenced in other sections of these specifications are listed below, and if the source of the publications is different from the address of the sponsoring organization, that information is also provided. Documents listed in the specifications with numbers which were not assigned by the standards producing organization should be ordered from the source by title rather than by number.

AMERICAN WELDING SOCIETY (AWS)

550 N.W. LeJeune Road Miami, FL 33126 Ph: 800-443-9353 - 305-443-9353 Fax: 305-443-7559 E-mail: info@aws.org or customerservice@awspubs.com Internet: http://www.aws.org

ASME INTERNATIONAL (ASME)

Three Park Avenue, M/S 10E New York, NY 10016-5990 Ph: 800-854-7179 or 800-843-2763 Fax: 212-591-7674 E-mail: infocentral@asme.org Internet: http://www.asme.org

ASTM INTERNATIONAL (ASTM)

100 Barr Harbor Drive, P.O. Box C700 West Conshohocken, PA 19428-2959 Ph: 610-832-9585 Fax: 610-832-9555 E-mail: service@astm.org Internet: http://www.astm.org

PLASTICS PIPE INSTITUTE (PPI)

105 Decker Court, Suite 825 Irving, TX 75062 Ph: 469-499-1044 Fax: 469-499-1063 mailto:customerservice@awspubs.com http://www.aws.org/ mailto:infocentral@asme.org http://www.asme.org/ mailto:service@astm.org http://www.astm.org/

E-Mail: sboros@plasticpipe.org Internet: http://www.plasticpipe.org

SOCIETY OF AUTOMOTIVE ENGINEERS INTERNATIONAL (SAE)

400 Commonwealth Drive Warrendale, PA 15096-0001 Ph: 724-776-4970 Fax: 724-776-0790 E-mail: customerservice@sae.org Internet: http://www.sae.org

PART 2 PRODUCTS

Not Used

Not used mailto:sboros@plasticpipe.org http://www.plasticpipe.org/ mailto:customerservice@sae.org http://www.sae.org/

SECTION TABLE OF CONTENTS

DIVISION 05 - METALS

SECTION 05 50 14

STRUCTURAL METAL FABRICATIONS

1.2 SUBMITTALS

1.3 QUALITY ASSURANCE

1.3.1 Qualification of Welders and Welding Operators

2.1 FABRICATION

2.1.1 Structural Fabrication

2.1.1.1 Dimensional Tolerances for Structural Work

2.1.1.2 Structural Steel Fabrication

2.1.2 Welding

2.1.2.1 Welding of Structural Steel

2.1.2.2 Welding of Stainless Steel

2.1.2.3 Welding of Stainless Steel Studs

2.1.3 Machine Work

2.1.3.1 Finished Surfaces

2.1.3.2 Unfinished Surfaces

2.1.3.3 Pin Holes

2.1.3.4 Shafting

2.1.4 Miscellaneous Provisions

2.1.4.1 Metallic Coatings

2.1.4.2 Cleaning of Corrosion-Resisting Steel

2.1.5 Shop Assembly

2.2 TESTS, INSPECTIONS, AND VERIFICATIONS

2.2.1 Nondestructive Testing

2.2.2 Inspection of Structural and Stainless Steel Welding

2.2.2.1 Visual Examination

2.2.2.2 Nondestructive Examination

2.2.2.3 Test Coupons

2.2.2.4 Supplemental Examination

2.2.3 Structural and Stainless Steel Welding Repairs

2.2.4 Inspection and Testing of Stainless Steel Stud Welding

3.1 TESTS

3.1.1 Workmanship

3.2 PROTECTION OF FINISHED WORK

3.2.1 Machined Surfaces

SECTION 05 50 14

STRUCTURAL METAL FABRICATIONS

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 (2008) Structural Welding Code - Steel

AWS D1.6/D1.6M (2007) Structural Welding Code - Stainless

Steel

ASME INTERNATIONAL (ASME)

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

ASTM INTERNATIONAL (ASTM)

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

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

Engineering Chromium Electroplating

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

ASTM E 709 (2008) Standard Guide for Magnetic

Particle 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. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Work Plan – Welding Procedures; G

Schedules of welding procedures shall be submitted and approved prior to commencing any shop or field fabrication. The schedules shall be submitted concurrently with the weld testing plan. Welding procedures shall be submitted on forms similar to those contained in the AWS standards. The welding procedure number shall be identified in the tail of the arrow of the welding symbols on the shop drawings.

CQC Weld Inspection Plan; G

Proposed plan for quality control inspections as specified herein.

The plan shall be coordinated with the schedules of welding procedures.

Tests, Inspections, and Verifications; F

Certified test reports for required non destructive testing of welds.

Qualification of Welders and Welding Operators; G

Certifications for welders and welding operators prior to commencing fabrication.

Qualification of Weld Inspectors; G

Certifications for weld inspectors shall be submitted prior to commencing fabrication.

1.3 QUALITY ASSURANCE

1.3.1 Qualification of Welders and Welding Operators

Certify that the qualification of welders and 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/D1.1M and AWS D1.6/D1.6M , prior to commencing fabrication.

List the qualified welders by name and specify the code and procedures under which qualified and the date of qualification within the certification. Prior qualification will be accepted if welders have performed satisfactory work under the code for which qualified within the preceding three months. Welders are required 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. Contractor incurs all expenses in connection with qualification and requalification.

2.1 FABRICATION

2.1.1 Structural Fabrication

Material shall be straight before being laid off or worked. Perform straightening, if necessary, by methods that will not impair the metal.

Sharp kinks or bends will be cause for rejection of the material. Material with welds will not be accepted except where welding is definitely specified, indicated or otherwise approved. Make bends using approved dies, press brakes or bending rolls. Where heating is required, take precautions to avoid overheating the metal and allow it to cool in a manner that will not impair the original properties of the metal. Proposed flame cutting of material, other than structural steel, will be subject to approval and shall be indicated on detail drawings. Shearing shall be accurate and all portions of the work 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. Provide finished members free of twists, bends and open joints. Bolts, nuts and screws shall be tight.

2.1.1.1 Dimensional Tolerances for Structural Work

Measure dimensions using an approved calibrated steel tape of 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; component members without milled ends shall not deviate from the dimensions shown by 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.

2.1.1.2 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. Prepare surfaces and edges 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. Chip, grind or machine to sound metal hand-guided cuts which are to be exposed or visible.

2.1.2 Welding

2.1.2.1 Welding of Structural Steel

a. Welding Procedures for Structural Steel - Prequalify welding procedures for structural steel as described in AWS D1.1/D1.1M, Subsection 3.1 or qualify by tests as prescribed in AWS D1.1/D1.1M, Section 4. Properly documented evidence of compliance with all requirements of these specifications for previous qualification tests shall establish a welding procedure as prequalified. 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 or Contracting Officer Representative. 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, 6, 7 and applicable portions of Section 8. Provide within the schedule detailed procedure specifications and tables or diagrams showing the procedures to be used for each required joint. Include in the welding procedures 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 shall show types and locations of welds designated or in the specifications to receive nondestructive examination.

b. Welding Process - Perform welding of structural steel by an electric arc welding process using a method which excludes the atmosphere from the molten metal and conforms to the applicable provisions of AWS D1.1/D1.1M. Minimize residual stresses, distortion and shrinkage from welding.

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 be as shown where a specific choice of AWS specification allowable is required. Include the AWS designation of the electrodes to be used in the schedule of welding procedures. Use only low hydrogen electrodes for manual shielded metal-arc welding regardless of the thickness of the steel. Use a controlled temperature storage oven at the job site as prescribed by AWS D1.1/D1.1M, Subsection 3.5 to maintain low moisture of low hydrogen electrodes.

(2) Preheat and Interpass Temperature - Perform preheating as required by AWS D1.1/D1.1M, Subsection 3.5 or as otherwise specified except that the temperature of the base metal shall be at least 70 degrees F. Slowly and uniformly preheat the weldments 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 - Where stress relief heat treatment is specified or shown, perform in accordance with the requirements of AWS D1.1/D1.1M, Subsection 5.8 unless otherwise authorized or directed.

d. Workmanship - Perform welding workmanship 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 inspect surfaces to be welded to ensure compliance with AWS D1.1/D1.1M, Subsection 3.2.

(2) Temporary Welds - Make temporary welds, required for fabrication and erection, under the controlled conditions prescribed for permanent work. Make temporary welds using low-hydrogen welding electrodes and by welders qualified for permanent work as specified in these specifications. Conduct preheating for temporary welds 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. Remove each temporary weld and grind flush with adjacent surfaces after serving its purpose.

(3) Tack Welds - Subject tack welds that are to be incorporated into the permanent work to the same quality requirements as the permanent welds; clean and thoroughly fuse them with permanent welds. Perform preheating as specified above for temporary welds. Multiple-pass tack welds shall have cascaded ends. Remove defective tack welds before permanent welding.

2.1.2.2 Welding of Stainless Steel

a. Welding Procedures for Stainless Steel - Welding procedures for stainless steel shall be prequalified as described in AWS D1.6, Subsection 3 or shall be qualified by tests as prescribed in AWS D1.6, Section 4 and for stainless steel studs shall be as prescribed in AWS D1.6 section 7. Properly documented evidence of compliance with all requirements of these specifications for previous qualification tests shall establish a welding procedure as prequalified. 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 or Contracting Officer Representative. 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 D1.6, Sections 2, 3, 4, 5 and 7. 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 stainless 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 D1.6, Sections 1 thru 5. Welding for stainless steel studs shall be by an automatic welding machine or an electric arc welding process that excludes the atmosphere from the molten metal and shall conform the applicable provisions of AWS D1.6 Subsection 7.5 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 allowable is required. The AWS designation of the electrodes to be used shall be included in the schedule of welding procedures.

Handling, storage and certification of electrodes AWS D1.6, Subsection 5.1.4.

(2) Preheat and Interpass Temperature - Preheating shall be performed as required by AWS D1.6, 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 - Where stress relief heat treatment is specified or shown, it shall be in accordance with the requirements of AWS D1.6, Subsection 4.4 unless otherwise authorized or directed.

d. Workmanship - Workmanship for welding shall be in accordance with AWS D1.6, Section 3 and Subsection 7.4 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 D1.6, Subsection 3.2 and Subsection 7.4.2.

(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 D1.6 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.

2.1.2.3 Welding of Stainless Steel Studs

Conform to the requirements of AWS D1.6/D1.6M, Section 7, except as otherwise specified for 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.

2.1.3 Machine Work

Tolerances, allowances and gauges for metal fits between plain, non-threaded, cylindrical parts shall conform to tolerances shown unless otherwise modified by manufacturer requirements. Tolerances for machine-finished surfaces designated by non-decimal dimensions shall be within 1/64 inch. Sufficient machining stock will be allowed on placing pads to ensure true surfaces of solid material. All like parts be interchangeable.

2.1.3.1 Finished Surfaces

Provide surface finishes, indicated or specified, 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 use 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.

2.1.3.2 Unfinished Surfaces

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

2.1.3.3 Pin Holes

Pin holes are to 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.

2.1.3.4 Shafting

Turn or grind shafting to finish dimensions. Where metallic coatings are indicated allowances shall be made the coating thickness.

2.1.4 Miscellaneous Provisions

2.1.4.1 Metallic Coatings

a. Chromium Coatings - Apply chromium coatings for engineering in conformance with ASTM B 177.

2.1.4.2 Cleaning of Corrosion-Resisting Steel

Remove oil, paint and other foreign substances from corrosion-resisting steel surfaces after fabrication. Perform cleaning by vapor degreasing or by the use of cleaners of the alkaline, emulsion or solvent type. After the surfaces have been cleaned give 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. Visually inspect the surfaces for evidence of paint, oil, grease, welding slag, heat treatment scale, iron rust or other forms of contamination. If evidence of foreign substance is found, clean again in accordance with the applicable provisions of ASTM A 380. Furnish the proposed method of treatment for approval. Visually re-inspect after treatment. Use only stainless steel or nonmetallic bristle brushes to remove foreign substances. Any contamination occurring subsequent to the initial cleaning shall be removed by one or more of the methods indicated above.

2.1.5 Shop Assembly

Each floating mooring bitt shall be shop assembled to determine the correctness of the fabrication and matching of the component parts unless otherwise specified. Closely check each unit assembled to ensure that all necessary clearances have been provided and that binding does not occur in any moving part. Perform assembly and disassembly work in the presence of the Contracting Officer Representative unless waived in writing.

Immediately remedy errors or defects disclosed by the Contractor without cost to the Government.

2.2 TESTS, INSPECTIONS, AND VERIFICATIONS

2.2.1 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; replace and retest rejected parts at the Contractor's expense.

2.2.2 Inspection of Structural and Stainless Steel Welding

Welding will be subjected to inspection to determine conformance with the requirements of AWS D1.1/D1.1M and AWS D1.6/D1.6M. 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.

2.2.2.1 Visual Examination

All completed welds shall be subjected to visual examination. For all visual examination of completed welds clean and carefully examine 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 6, subsection 6.9, Part C.

or AWS D1.6/D1.6M Section 6.28.

2.2.2.2 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 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) Magnetic Particle Inspection - Magnetic particle inspection of welds shall conform to the applicable provisions of ASTM E 709.

(2) Dye Penetrant Inspection - Perform dye penetrant inspection of welds conforming to the applicable provisions of ASTM E 165.

c. Acceptability of Welds - Welds will be unacceptable if shown to have defects prohibited by AWS D1.1/D1.1M or AWS D1.6/D1.6M., or possess any degree of incomplete fusion, inadequate penetration or undercutting.

d. Welds to be Subject to Nondestructive Examination

As indicated on the drawings.

2.2.2.3 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 will be removed from the work. When coupons are removed from any part of a structure, repair the members cut 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 Contract Clauses FAR 52.246-2 Inspection of Supplies.

2.2.2.4 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.

2.2.3 Structural and Stainless Steel Welding Repairs

Repair defective welds in the structural steel welding repairs in accordance with AWS D1.1/D1.1M, Subsection 3.7. Stainless steel AWS D1.6/D1.6M, Subsection 5.12 or 5.13 as applicable.

2.2.4 Inspection and Testing of Stainless Steel Stud Welding

Perform visual inspection of stainless steel stud welding. Studs that do not show a full 360 degree weld flash shall be removed and the area from which it is removed shall be repaired by welding and made flush and smooth.

3.1 TESTS

3.1.1 Workmanship

Workmanship must 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.

3.2 PROTECTION OF FINISHED WORK

3.2.1 Machined Surfaces

Thoroughly clean foreign matter off machined surfaces. All finished surfaces shall be protected by suitable means. Oil and wrap unassembled pins and bolts with moisture resistant paper or protect them by other approved means. Wash finished surfaces of ferrous metals to be in bolted contact, with an approved rust inhibitor and coat them with an approved rust resisting compound for temporary protection during fabrication, shipping and storage periods. Paint finished surfaces of metals which will be exposed after installation, except corrosion resisting steel or nonferrous metals

SECTION TABLE OF CONTENTS

DIVISION 35 - WATERWAY AND MARINE CONSTRUCTION

SECTION 35 20 16.60

FLOATING MOORING BITTS

1.2 PAYMENT

1.2.1 Unit of Measure

1.3 SUBMITTALS

1.4 POLYETHYLENE PIPE MANUFACTURER'S REPRESENTATIVE

1.5 QUALIFICATION OF WELDERS AND WELDING OPERATORS

2.1 METALS

2.2 HDPE Plastic

2.3 Bushings and Spacers

2.4 PAINT SYSTEM

3.1 FABRICATION

3.1.1 Metal Fabrication

3.1.2 Pontoon Fabrication

3.1.3 Miscellaneous Provisions

3.1.4 Shop Assembly

3.1.4.1 Threaded Connections

3.2 TESTS, INSPECTIONS, AND VERIFICATIONS

3.2.1 Material Certifications

3.2.2 Metalwork Fabrication

3.2.3 Tests of Floating Mooring Bitts

3.2.3.1 Weight Test

3.2.3.2 Pontoon Pressure Test

3.3 PAINTING

3.4 SHIPPING

SECTION 35 20 16.60

FLOATING MOORING BITTS

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

AMERICAN SOCIETY FOR TESTING AND MATERIALS(ASTM)

ASTM D 3350 Standard Specification for Polyethylene

Plastics Pipe and Fittings Materials

PLASTICS PIPE INSTITUTE (PPI)

PPI TR3 Policies and Procedures for Developing Recommended Hydrostatic Design Stresses for Thermoplastic Pipe Materials

PPI TR4 Recommended Hydrostatic Strengths and

Design Stresses for Thermoplastic Pipe and Fittings Compounds

1.2 PAYMENT

Payment shall constitute full compensation for furnishing all plant, labor, materials and equipment for fabrication and delivery the floating mooring bitts.

1.2.1 Unit of Measure

Unit of measure is each.

1.3 SUBMITTALS

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

submittals without "G" designation are for information only. The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

Materials Orders

Copies of purchase orders, mill orders, shop orders, and work orders for materials shall be submitted prior to the use of the materials in the work. Where mill tests are required purchase orders include the test site address and the name of the testing agency.

Shipping Bill

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.

Promptly mail duplicate copies of shipping bills to Contracting

Officer’s Representative.

Material Certifications.

Certified test reports for materials shall be submitted with all materials delivered to the shop.

Weight Test; G, E

Contractor will report to the Contracting Officer the results of the specified analysis and measurements promptly upon completion.

Pontoon Pressure Test; G, E

Contractor will report to the Contracting Officer the results of the pressure test for each pontoon.

Polyethylene Pipe Manufacturer's Representative.

The name and qualifications of the manufacturer's representative and written certification from the manufacturer that the representative is technically qualified in all phases of PE jointing.

Calibration Certificate

Scales used to measure weight shall be verified to be accurate by either of the following:

A. Certification from a local "Standard Weights and Measurements" government agency that the scales have been tested and found to be accurate within the current calendar year.

B. Statement from a contractor regularly engaged in the calibration of scales of the type used by the contractor to measure the weight of floating mooring bitt components. Statement shall certify the scales were accurately calibrated within 90 days prior to the first measurement taken.

1.4 POLYETHYLENE PIPE MANUFACTURER'S REPRESENTATIVE

The Contractor shall have the polyethylene (PE) pipe manufacturer's representative present at their shop during the fabrication and testing of PE pontoons to provide technical assistance and to verify that the material joints are made in accordance with the manufacturer's prescribed procedures. When the representative feels that the Contractor is joining the PE pipe and fittings in a satisfactory manner, certification shall be written to note which individuals employed by the Contractor are capable of properly joining the PE pipe and fittings. The field representative shall advise the Contractor of unsatisfactory conditions immediately when they occur. Such conditions include improper diameter of pipe and fitting ends, poorly prepared joints, improper curing of joints, moving pipe before joints are cured, and any other condition which could have an adverse effect on the satisfactory completion and operation of the PE pontoons.

1.5 QUALIFICATION OF WELDERS AND WELDING OPERATORS

Qualification of welders and welding operators shall conform to the requirements of Section 05 50 14 STRUCTURAL METAL FABRICATIONS.

2.1 METALS

Metal materials, excluding bearing materials, shall be as specified on the drawings.

2.2 HDPE Plastic

Material used for the manufacturing of polyethylene pipe and plate shall be PE 3408 High Density Polyethylene (HDPE) meeting the ASTM D 3350 cell classification of 345434C. The Material shall have a minimum Hydrostatic Design Basic (HDB) of 1600 psi at 730 degree F when tested in accordance with PPI TR3 and shall be listed in the name of the pipe manufacturer in PPI TR4. The Manufacturer shall certify that the materials used to manufacture pipe meet these requirements. The pipe shall not degrade when exposed to sunlight.

2.3 Bushings and Spacers

Shall be self lubricating bearing material of an aluminum bronze substrate with an embedded lubricant of compounded graphite powders and epoxy resins similar to Lubron SL30. Equivalent products shall be capable of 5000 psi bearing pressure.

2.4 PAINT SYSTEM

Shall consist of two coats of two part high solids epoxy paint suitable for immersion service in freshwater. Paint shall be similar to Amerlock 2

3.1 FABRICATION

3.1.1 Metal Fabrication

Shall be as specified in section 05 50 14 STRUCTURAL METAL FABRICATION.

3.1.2 Pontoon Fabrication

Pontoon is fabricated from standard polyethylene pipe, custom polyethylene fittings consisting of end caps, guide shoes and bumper, and various metallic and non-metallic items as identified on the drawings.

The Pipe Manufacturer shall supply polyethylene pipe jointing procedures to the contractor that provide guidelines for handling and joining of polyethylene pipe. Joints between plain ends of polyethylene pipe shall be made by butt fusion. The Pipe Manufacturer's fusion procedures shall be followed at all times. The wall thicknesses of the adjoining pipes shall have the same dimension ratio (DR) at the point of fusion.

C.R.E.S. steel connecting plate shall be bonded to the upper end cap by an epoxy adhesive and mechanically attached by threaded stainless steel studs welded to the C.R.E.S. steel connecting plate. Epoxy adhesive shall be applied per manufacturer instructions.

Coat 1st

Product Amerlock

Color Silver/Aluminum

Dry Film Thickness 4 mils

2nd Amerlock 2 Silver/Aluminum 6 mils

3.1.3 Miscellaneous Provisions

Miscellaneous Provisions shall be as specified in section 05 50 14 STRUCTURAL

METAL FABRICATION.

3.1.4 Shop Assembly

Each floating mooring bitt shall be shop assembled to determine the correctness of the fabrication. Closely check each unit assembled to ensure that all necessary clearances have been provided and that binding does not occur in any moving part. Immediately remedy errors or defects disclosed by the Contractor without cost to the Government.

3.1.4.1 Threaded Connections

As indicated on contract plans.

3.2 TESTS, INSPECTIONS, AND VERIFICATIONS

3.2.1 Material Certifications

The Contractor shall have material tests certified by a testing laboratory or supplier to demonstrate that materials used in the fabrication of the floating mooring bitt components are in conformity with this specification and the contract drawings.

3.2.2 Metalwork Fabrication

Test, Inspections, and Verifications of the metalwork fabrication shall be as specified herein and in section 05 50 14 STRUCTURAL METAL FABRICATION.

3.2.3 Tests of Floating Mooring Bitts

3.2.3.1 Weight Test

Weight Analysis: Weight analysis of pontoons and upper carbon steel structure to be fabricated by the contractor shall be preformed before fabrication begins. Weight analysis shall be compared to the calculated design weights in indicated on the general arrangement sheets for the contracted style of floating mooring bitt.

Discrepancies in weight greater than 2.5 percent shall be reported to Contracting Officer's Representative for resolution before fabrication is allowed to begin.

Weight Measurements:

A. The first of the upper carbon steel structures and the first of each size pontoons shall be immediately weighed after fabrication.

If the measured weight of any of these first components differs more than plus or minus 2.5 percent from the calculated design weights, shown on drawing M-6. Fabrication of the particular component type shall stop and the Contracting Officer's Representative immediately notified. Fabrication of the specific failing component type shall not continue until the reason for the weight discrepancy is resolved or accounted for in design modifications.

B. The remaining components shall be weighed in a timely manner after fabrication. An individual pontoon fabricated for Lock Floating Mooring Bitt Repairs shall be rejected if its weight differs more than plus or minus 2.5 percent from the calculated design weight.