Revised_Spec_35_20_16.33_Amendment_0003.pdf

New Cumberland Auxillary Chamber Downstream Miter Gate

SECTION TABLE OF CONTENTS

DIVISION 35 - WATERWAY AND MARINE CONSTRUCTION

SECTION 35 20 16.33

MITER GATES

PART 1 GENERAL

1.1 REFERENCES

1.2 SUBMITTALS

1.3 QUALITY ASSURANCE

1.3.1 Qualification of Welders

1.3.2 Detail Drawings

1.3.2.1 Fabrication Drawings

1.3.2.2 Shop Assembly Drawings

1.3.2.3 Delivery Drawings

1.4 DELIVERY, STORAGE, AND HANDLING

1.4.1 Rubber Seals

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Metals

2.1.1.1 Structural Steel

2.1.1.2 Stainless Steel Bars and Shapes

2.1.1.3 Stainless Steel Plate, Sheet, and Strip

2.1.1.4 Aluminum Handrailing and Toe Plate

2.1.1.5 Aluminum Bar Grating

2.1.1.6 Bushings for Pins

2.1.2 Rubber Seals

2.1.2.1 Physical Characteristics

2.1.3 Bumpers and Fenders

2.2 MANUFACTURED UNITS

2.2.1 Bolts, Nuts and Washers

2.3 STANDARD COMMERCIAL PRODUCT

2.3.1 Hydraulic Bolt Tensioner and Diagonal Tensioning Equipment

2.4 FABRICATION

2.4.1 Structural Fabrication

2.4.2 Welding and Stress Relief

2.4.3 Bolted Connections

2.4.4 Machine Work

2.4.5 Miscellaneous Provisions

2.4.6 Fabrications

2.4.6.1 Gate Leaf

2.4.6.2 Quoin and Miter Contact Blocks

2.4.6.3 Pintle Assembly

2.4.6.3.1 Patterns

2.4.6.3.2 Fabrication of Patterns and Core Boxes

2.4.6.3.3 Disposition of Patterns, Core Boxes, and Templates

2.4.6.3.4 Castings

2.4.6.4 Gudgeon Anchorage

2.4.6.5 Seal Assemblies

SECTION 35 20 16.33 Page 1 Certified Final Document - RTA W911WN19B0002 - Amendment 3

2.4.6.6 Gate Leaf Diagonal Assemblies

2.4.6.7 Grease Lines

2.4.6.8 Handrailing and Toe Plate

2.4.6.9 Walkway Grating

2.4.6.10 Appurtenant Items

2.4.7 Shop Assembly

2.5 TESTS, INSPECTIONS, AND VERIFICATIONS

2.5.1 General

2.5.2 Dimension and Tolerance Verification

2.5.3 Testing of Rubber Seals

2.5.4 Testing and Inspection of Steel Castings

2.5.5 Testing and Inspection of Threaded Forgings

2.5.6 Weight Verification

PART 3 EXECUTION

3.1 INSTALLATION

3.1.1 Painting

3.1.2 Seal Assemblies

3.2 CATHODIC PROTECTION SYSTEM

3.3 PROTECTION OF FINISHED WORK

-- End of Section Table of Contents --

SECTION 35 20 16.33 Page 2

SECTION 35 20 16.33

MITER GATES

PART 1 GENERAL

1.1 REFERENCES

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

AMERICAN WELDING SOCIETY (AWS)

AWS D1.2/D1.2M (2014) Structural Welding Code - Aluminum

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

ASME INTERNATIONAL (ASME)

ASME B4.1 (1967; R 2009) Preferred Limits and Fits for Cylindrical Parts

ASME Y14.5 (2018) Dimensioning and Tolerancing

ASTM INTERNATIONAL (ASTM)

ASTM A148/A148M (2014) Standard Specification for Steel Castings, High Strength, for Structural Purposes

ASTM A193/A193M (2017) Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service and Other Special Purpose Applications

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

ASTM A240/A240M (2017) Standard Specification for Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications

ASTM A275/A275M (2018) Standard Practice for Magnetic Particle Examination of Steel Forgings

ASTM A276/A276M (2017) Standard Specification for Stainless Steel Bars and Shapes

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

SECTION 35 20 16.33 Page 3

ASTM A312/A312M (2017) Standard Specification for Seamless, Welded, and Heavily Cold Worked Austenitic Stainless Steel Pipes

ASTM A320/A320M (2017b) Standard Specification for Alloy-Steel and Stainless Steel Bolting for Low-Temperature Service

ASTM A370 (2017a) Standard Test Methods and Definitions for Mechanical Testing of Steel Products

ASTM A388/A388M (2016) Standard Practice for Ultrasonic Examination of Steel Forgings

ASTM A500/A500M (2018) Standard Specification for Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and Shapes

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

ASTM A564/A564M (2013; E 2017) Standard Specification for Hot-Rolled and Cold-Finished Age-Hardening Stainless Steel Bars and Shapes

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

ASTM A668/A668M (2017) Standard Specification for Steel Forgings, Carbon and Alloy, for General Industrial Use

ASTM A709/A709M (2018) Standard Specification for Structural Steel for Bridges

ASTM B148 (2014) Standard Specification for Aluminum-Bronze Sand Castings

ASTM B209 (2014) Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate

ASTM B429/B429M (2010; E 2012) Standard Specification for Aluminum-Alloy Extruded Structural Pipe and Tube

ASTM B505/B505M (2018) Standard Specification for Copper Alloy Continuous Castings

ASTM C412 (2011) Concrete Drain Tile

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

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

SECTION 35 20 16.33 Page 4

ASTM D395 (2016; E 2017) Standard Test Methods for Rubber Property - Compression Set

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

ASTM D412 (2016) Standard Test Methods for Vulcanized Rubber and Thermoplastic Elastomers - Tension

ASTM D413 (1998; R 2017) Standard Test Methods for Rubber Property - Adhesion to Flexible Substrate

ASTM D471 (2016a) Standard Test Method for Rubber Property - Effect of Liquids

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

ASTM D572 (2004; R 2010) Rubber Deterioration by Heat and Oxygen

ASTM D638 (2014) Standard Test Method for Tensile Properties of Plastics

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

ASTM E94/E94M (2017) Standard Guide for Radiographic Examination Using Industrial Radiographic Film

ASTM E112 (201) Standard Test Method for Determining Average Grain Size

ASTM E186 (2015) Standard Reference Radiographs for Heavy-Walled (2 to 41/2 in. (50.8 to 114 mm)) Steel Castings

ASTM E350 (2018) Standard Test Methods for Chemical Analysis of Carbon Steel, Low-Alloy Steel, Silicon Electrical Steel, Ingot Iron, and Wrought Iron

ASTM E446 (2014) Radiographs for Steel Castings Up to 2 In. (51mm) in Thickness

ASTM F788 (2013) Standard Specification for Surface Discontinuities of Bolts, Screws, and Studs, Inch and Metric Series

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

SECTION 35 20 16.33 Page 5

Strength, Inch and Metric Dimensions

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

NATIONAL ASSOCIATION OF ARCHITECTURAL METAL MANUFACTURERS (NAAMM)

NAAMM MBG 531 (2017) Metal Bar Grating Manual

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-02 Shop Drawings

Detail Drawings; G,DO

Grease Line Drawings; G, DO

SD-03 Product Data

Materials

Hydraulic Bolt Tensioner And Diagonal Tensioning Equipment; G,DO

SD-04 Samples

Materials

SD-06 Test Reports

Tests, Inspections, and Verifications

Weight Verification

1.3 QUALITY ASSURANCE

1.3.1 Qualification of Welders

Provide qualification of welders and welding operators conforming to the requirements of Section 05 59 13 FABRICATION OF HYDRAULIC STEEL STRUCTURES.

1.3.2 Detail Drawings

Submit detail drawings, including fabrication drawings, shop assembly drawings, delivery drawings, and field installation drawings, conforming to the requirements specified herein and in Section 05 59 13 FABRICATION

OF HYDRAULIC STEEL STRUCTURES.

1.3.2.1 Fabrication Drawings

Show on the fabrication drawings complete details of materials, tolerances, connections, and proposed welding sequences which clearly differentiate shop welds and field welds.

SECTION 35 20 16.33 Page 6

1.3.2.2 Shop Assembly Drawings

Show on the shop assembly drawings details for connecting the adjoining fabricated components in the shop to assure satisfactory field installation.

1.3.2.3 Delivery Drawings

Show on the delivery drawings descriptions of methods of delivering components to the delivery location, including details for supporting fabricated components during shipping to prevent distortion or other damages.

1.4 DELIVERY, STORAGE, AND HANDLING

Perform delivery, storage, and handling of materials and fabricated items in accordance with the requirements specified herein, in Section 01 35 00.00 08 SPECIAL PROCEDURES, paragraph STORAGE AND DELIVERY OF MITER GATE LEAFS, and in Section 05 59 13 FABRICATION OF HYDRAULIC STEEL STRUCTURES. All necessary precautions shall be taken to avoid distortion of the gate leaf or any component parts during handling, shipping, and delivery.

1.4.1 Rubber Seals

Store rubber seals in a place which permits free circulation of air, maintains a temperature of 70 degrees F or less, and prevents the rubber from being exposed to the direct rays of the sun. Keep rubber seals free of oils, grease, and other materials which would deteriorate the rubber.

Do not distort rubber seals during handling.

PART 2 PRODUCTS

2.1 MATERIALS

Submit system of identification which shows the disposition of specific lots of approved materials and fabricated items in the work, before completion of the contract. Materials orders, materials lists and materials shipping bills shall conform with the requirements of Section 05 59 13 FABRICATION OF HYDRAULIC STEEL STRUCTURES, unless noted otherwise on the contract drawings.

2.1.1 Metals

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

05 59 13 FABRICATION OF HYDRAULIC STEEL STRUCTURES.

2.1.1.1 Structural Steel

Structural steel shapes and plates shall conform to ASTM A709/A709M , unless noted otherwise on the contract drawings. Members or components designated as fracture critical members (FCM) shall conform to ASTM A709/A709M Grade 50F Zone 2 using fine-grain mill practice as specified in ASTM A6/A6M. Nonfracture critical members shall conform to ASTM A6/A6M Grade 50T Zone 2, unless noted otherwise. Weathering steel is not permitted.

SECTION 35 20 16.33 Page 7

Hollow structural sections shall conform to ASTM A500/A500M .

2.1.1.2 Stainless Steel Bars and Shapes

Stainless steel bars and shapes shall conform to ASTM A276/A276M , UNS S30400 Condition A, hot-finished or cold-finished, Class C or ASTM A564/A564M , UNS S 17400 Condition A, age-hardened heat treatment, hot-finished or cold-finished, Class C as specified on the drawings.

2.1.1.3 Stainless Steel Plate, Sheet, and Strip

Stainless steel plate, sheet, and strip shall conform to ASTM A240/A240M , UNS S30400 as specified on the drawings. Plate finish shall be hot-rolled, annealed or heat-treated, and blast-cleaned or pickled. Sheet and strip finish shall be No. 1.

2.1.1.4 Aluminum Handrailing and Toe Plate

Aluminum handrails shall consist of 2 inch nominal Schedule 80 pipe ASTM B429/B429M . Railings and pipe collars shall be anodized and aluminum color. All fasteners shall be Series 300 stainless steel.

Aluminum toe plate shall be as specified on the drawings and conform to ASTM B209 Alloy 6063.

2.1.1.5 Aluminum Bar Grating

Aluminum bar grating shall be P-19-4 (1-3/4" x 3/16") aluminum as specified on the drawings and in accordance with NAAMM MBG 531.

2.1.1.6 Bushings for Pins

Bushings for pins shall be as specified on the contract drawings in accordance with ASTM B148 or ASTM B505/B505M , unless noted otherwise.

2.1.2 Rubber Seals

Rubber seals shall be of the mold type only, shall be compounded of natural rubber, synthetic polyisoprene, or a blend of both, and shall contain reinforcing carbon black, zinc oxide, accelerators, antioxidants, vulcanizing agents, and plasticizers.

2.1.2.1 Physical Characteristics

Physical characteristics of the seals shall meet the following requirements:

PHYSICAL TEST TEST VALUE TEST METHOD

SPECIFICATION

Tensile Strength 2,500 psi (min.) ASTM D412

Elongation at Break 450 percent (min.) ASTM D412

300 percent Modulus 900 psi (min.) ASTM D412

SECTION 35 20 16.33 Page 8

PHYSICAL TEST TEST VALUE TEST METHOD

SPECIFICATION

Durometer Hardness (Shore Type A)

60 to 70 ASTM D2240

*Water Absorption 5 percent by weight (max.) ASTM D471

Compression Set 30 percent (max.) ASTM D395

Tensile Strength (after aging 48 hrs)

80 percent tensile strength (min.)

ASTM A709/A709M

The "Water Absorption" test shall be performed with distilled water. The washed specimen shall be blotted dry with filter paper or other absorbent material and suspended by means of small glass rods in the oven at a temperature of 70 degrees C plus or minus 2 degrees for 22 plus or minus 1/4 hour. The specimen shall be removed, allowed to cool to room temperature in air, and weighed. The weight shall be recorded to the nearest 1 mg as M subscript 1 (M subscript 1 is defined in ASTM D471).

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

2.1.3 Bumpers and Fenders

Composite section fender pads shall consist of ultra high molecular weight polyethylene (UHMW-PE) plastic on top of a rubber or synthetic rubber backing. The final cross section shall meet the dimensional requirements shown on the drawings. Lengths of fenders and bolting patterns shall also be as shown on the contract drawings. The ultra-high molecular weight polyethylene material shall be cut and beveled to the cross-sectional dimensions shown on the drawings and shall be yellow in color. The UHMW-PE shall be manufactured with a maximum of 50 percent regenerated material;

and with a molecular weight of 3,000,000 to 5,000,000, in accordance with ASTM D4020, compression molded, stress relieved, and including an ultraviolet manufactured by Solidur Plastics Company, 200 Industrial Drive, Rte. 66 North, Delmont, PA 15626, or "ULTRA FEND" as manufactured by Ultra-Pply, Inc., 2926 South Steel Street, Tacoma, WA 98409 Physical characteristics of the UHMW-PE shall meet the following:

a. Static Coefficient of Friction to Steel (Dry) - less than 0.25

b. Specific Gravity - greater than 0.92 ( ASTM D792)

c. Water Absorption - no water absorption shall be shown under long term immersion ( ASTM D570)

d. Izod Impact - fender shall exhibit a non-breaking condition under Izod type impact test ( ASTM D256)

e. Tensile Strength - minimum break tensile strength of 4,000 psi (

ASTM D638)

f. Hardness - 65-70 Durometer ( ASTM D2240)

The rubber backing materials shall be molded or extruded and shall be compounded of natural or synthetic polyisoprene or a blend of both and shall contain reinforcing carbon black, zinc oxide, accelerators, SECTION 35 20 16.33 Page 9 antioxidants, vulcanizing agents, and plasticizers.

PHYSICAL TEST TEST VALUE SPECIFICATION

Tensile Strength 3,000 psi (min.) ASTM C412

Elongation at Break 450% (min.) ASTM C412

300% Modulus 900 psi (min.) ASTM C412

Durometer Hardness (Shore Type A)

60-70 ASTM D2240

Water Absorption 5% by Weight (Max.) ASTM D471

Compression Set 30% (Max.) ASTM D395

Tensile Strength (after aging 48 hr.)

80% (Min.) ASTM D572

* The "Water Absorption" test shall be performed with distilled water. The washed specimen shall be blotted dry with filter paper or other absorbent material and suspended by means of small glass rods in the oven at a temperature of 70 degrees C plus or minus 2 degrees for 22 plus or minus 1/4 hour. The specimen shall be removed, allowed to cool to room temperature in air, and weighed. The weight shall be recorded to the nearest 1 mg as M subscript 1 (M subscript 1 is defined in ASTM D471).

The immersion temperature shall be 70 degrees C plus or minus 1 degree and the duration of immersion shall be 166 hours. Method of attaching the rubber backing to the structure is indicated on the contract drawings.

2.2 MANUFACTURED UNITS

Bolts, nuts, washers, screws and other manufactured units shall conform with the requirements shown and specified herein and in Section 05 59 13

FABRICATION OF HYDRAULIC STEEL STRUCTURES.

2.2.1 Bolts, Nuts and Washers

Unless noted otherwise in the contract plans; high-strength bolts, nuts, and washers shall conform to ASTM F3125/F3125M Grade A325 Type I, ASTM A563, and ASTM F436/F436M respectively. Bolts, nuts, studs, stud bolts and bolting materials other than high-strength shall conform to ASTM A307 Grade A, ASTM A320/A320M , or ASTM A193/A193M with ASTM A194/A194M nuts, as specified on the contract drawings. Bolts 1/2 inch and larger shall have hexagon heads. The finished shank of bolts shall be long enough to provide full bearing. Washers for use with bolts shall conform to the requirements specified in the applicable specification for bolts.

Coat threads of corrosion-resisting steel bolts and nuts with an approved antigalling compound.

2.3 STANDARD COMMERCIAL PRODUCT

All items shall be in accordance with the requirements of this specification and shall be the manufacturer's standard commercial product. Additional or better features which are not specifically

SECTION 35 20 16.33 Page 10 prohibited by this specification, but which are a part of manufacturer's standard commercial product, shall be included. A standard commercial product is one that has been sold or is being currently offered for sale on the commercial market through advertisements or manufacturer's catalogs or brochures, and represents the latest production model.

2.3.1 Hydraulic Bolt Tensioner and Diagonal Tensioning Equipment

The Hydraulic Bolt Tensioner (load cell) shall be equal to or better than Enerpac Model GT4-LCB as specified on the drawings. Provide tensioning equipment as specified on the drawings to be used for tensioning the miter gate leaf diagonals. Tensioning of the diagonals will be performed by others and is not a part of this contract. Diagonal tensioning equipment components shall be able to reach an operating pressure of 21,750 psi and verified to fit the configuration necessary for stressing the diagonals.

Additional information is provided on the drawings. All operating manuals, maintenance manuals, and warrantee information shall also be provided.

2.4 FABRICATION

2.4.1 Structural Fabrication

Structural fabrication shall conform with the requirements shown and specified herein and in Section 05 59 13 FABRICATION OF HYDRAULIC STEEL STRUCTURES. Components shall be shop-fabricated of the materials specified and shown. Dimensional tolerances shall be as specified and shown on the drawings. Splices shall occur only where shown on the contract drawings or approved by the Government. Pin holes shall be bored in components after welding, straightening, stress-relieving, and threading operations are completed. Brackets, eye bar sections, and other components requiring straightening shall be straightened by methods which will not damage the material. Bronze bushings shall be press-fitted with supporting components. Bolt connections, lugs, clips, or other pick-up assembly devices shall be provided for components as shown and required for proper assembly and installation.

2.4.2 Welding and Stress Relief

Welding shall conform with the requirements specified in Section 05 59 13 FABRICATION OF HYDRAULIC STEEL STRUCTURES and AWS D1.5M/D1.5 . Components shall be stress-relief heat treated after welding where shown.

Stress-relieving of components shall be performed prior to the attachment of miscellaneous appurtenances. Components identified for thermal stress relief will be thermally stress relieved prior to the attachment of sub assemblies and other appurtenant items. Stress relief heat treatment shall be in accordance with the requirements of AWS D1.5M/D1.5 . Vibratory Stress Relief will not be allowed.

Welding of aluminum shall be in accordance with AWS D1.2/D1.2M .

2.4.3 Bolted Connections

Bolted connections shall conform with the requirements specified in Section 05 59 13 FABRICATION OF HYDRAULIC STEEL STRUCTURES.

2.4.4 Machine Work

Tolerances and clearances for machine work shall be as shown on the

SECTION 35 20 16.33 Page 11 contract plans and if not shown on the plans, shall be as defined within these specifications. All geometric and coordinate dimensioning methods on the contract plans shall be interpreted in accordance with ASME Y14.5 .

All dimensions shown on drawings are finished dimensions. 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.

2.4.5 Miscellaneous Provisions

Miscellaneous provisions for fabrication shall conform with the requirements specified herein and in Section 05 59 13 FABRICATION OF

HYDRAULIC STEEL STRUCTURES.

2.4.6 Fabrications

2.4.6.1 Gate Leaf

Gate leaf shall be of welded structural steel fabrication consisting of horizontal girders, intercostals, diaphragms, quoin post, gudgeon pin hood, operating strut connections, skin plate, and adjustable diagonals.

Gate leaf shall be shop-fabricated. The overall height of the gate leaf shall not vary from the nominal dimension or differ from the mating gate leaf by more than 1/4 inch. The surfaces of framing elements to which skin plates are to be welded shall not vary from a true plane by more than 3/16 inch. The outside surfaces of skin plates welded to framing members shall not vary from a true plane by more than 3/16 inch. Splices in skin plates shall be located only where shown on the contract drawings or approved. Gate leaf shall be provided complete with quoin and miter contact blocks, miter guide assembly, pintle assembly, gudgeon anchorage, seal assembly, and other appurtenant components as required for complete installation, specified herein and shown.

2.4.6.2 Quoin and Miter Contact Blocks

Quoin and miter contact blocks shall be of stainless steel bars conforming to ASTM A276/A276M as shown on the contract drawings. Splices in gate leaf contact block shall occur only at the centerlines of horizontal girders. Contact faces of contact blocks shall be milled at splices to assure watertight joints. Contact blocks shall be provided with adjusting bolts as shown.

2.4.6.3 Pintle Assembly

Pintle assembly shall consist of pintle socket, pintle ball, and pintle base as shown. Pintle socket shall be of cast steel conforming to ASTM A148/A148M Grade 90-60. Pintle socket shall be press-fitted with an

SECTION 35 20 16.33 Page 12 aluminum bronze bushing, conforming to ASTM B148, with bearing surfaces finished truly hemispherical. Pintle ball shall be of forged alloy steel conforming to ASTM A668/A668M Class D, with bearing surfaces of corrosion-resisting steel. Pintle ball shall receive a 16 microinch finish and shall be fitted into the bushing by scraping until uniform contact is attained over the entire bearing surface as determined by testing with carbon paper or other approved coloring. Pintle base shall be of cast steel conforming to ASTM A148/A148M Grade 90-60. Bolt holes for attaching pintle socket to gate leaf shall be drilled and reamed after the pintle socket is assembled with gate leaf. Pintle socket shall be connected to the bottom of the lower girder web of the gate leaf with stainless steel bolts.

2.4.6.3.1 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 Testing and Inspection of Steel Castings. Patterns Casting patterns for those parts listed below shall be furnished by the Fabricator , and supplied to the Government at the end of the contract. These patterns will become the property of the Government and shall not be used for work under any other contract unless specifically authorized. All other patterns shall remain the property of the Fabricator.

1. Pintle socket

2. Pintle base

All other patterns shall remain the property of the Fabricator.

2.4.6.3.2 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.

2.4.6.3.3 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

SECTION 35 20 16.33 Page 13 including those loaned to the Fabricator by the Government used shall be thoroughly cleaned, crated and delivered in first-class condition with a list of same in duplicate to U.S. Army Corps of Engineers, Pittsburgh Engineer Warehouse & Repair Station 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 Fabricator shall be replaced by the Fabricator without charge to the Government.

2.4.6.3.4 Castings

Castings weighing more than 500 required pounds shall 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. Should these finished dimensions or wall thickness of casting differ from the contract plans the Fabricator is responsible for adjusting dimensions of interfacing parts, such as, mounting bolts, connecting pins, and bushings, for example. These changing dimensions shall be indicated on detail drawings and submitted for approval. Holes bored in castings shall be spot faced to provide the flatness requirements of paragraph Machine Work.

Additional machining of castings shall be in accordance with paragraph Machine Work. 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 welded and stress relieved.

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

2.4.6.4 Gudgeon Anchorage

Gudgeon anchorage shall consist of gudgeon pin barrel, gudgeon anchorage bars and links, gudgeon pin, adjusting wedges, and associated components as shown on the contract drawings. Gudgeon anchorage bars and links shall be of forged alloy steel conforming to ASTM A668/A668M Class D. Gudgeon pin shall be of forged alloy steel conforming to ASTM A668/A668M Class K.

2.4.6.5 Seal Assemblies

Seal assemblies shall consist of rubber seals, stainless steel retainer and spacer bars, and fasteners. Rubber seals shall be continuous over the full length. Seals shall be accurately fitted and drilled for proper

SECTION 35 20 16.33 Page 14 installation. Bolt holes shall be drilled in the rubber seals by using prepared templates or the retainer bars as templates. Splices in seals shall be fully molded, develop a minimum tensile strength of 50 percent of the unspliced seal, and occur only at locations shown. All vulcanizing of splices shall be done in the shop. The vulcanized splices between molded corners and straight lengths shall be located as close to the corners as practicable. Splices shall be on a 45 degree bevel related to the "thickness" of the seal. The surfaces of finished splices shall be smooth and free of irregularities. Stainless steel retainer bars shall be field-spliced only where shown and machine-finished after splicing.

2.4.6.6 Gate Leaf Diagonal Assemblies

Diagonal assemblies consist of diagonal bars fabricated from ASTM A709/A709M Grade 50T Zone 2 material and threaded diagonal rod forgings of ASTM A668/A668M Class L material.

Paint entire diagonal bar and rod forging assemblies, excluding threads, prior to install the diagonals on the gate leaf. The diagonal rod threads shall be shop coated with Cosmoline in liew of painting. Coat unpainted threads with marine grade anti-seize lubricant produced by Loctite Corporation or similar product prior to installing heavy hex nuts.

Fill opening between diagonal rod forging and diagonal bar with Copps K-009 or equal after welding and painting, as shown on the drawings.

2.4.6.7 Grease Lines

Grease supply and return lines shall be ASTM A312/A312M Type 316 Schedule 80 stainless steel pipe as specified on the drawings. Grease lines shall be attached as shown on the contract drawings at the intersection of each horizontal member that the line crosses. Submit Grease Line Drawings for approval.

The grease line shall be checked for obstructions and purged of all foreign matter prior to delivery of the gate leafs. The top end of the grease line shall have a grease fitting installed.

2.4.6.8 Handrailing and Toe Plate

Provide railings with toe plate as type specified and show, furnish, and install complete with all fittings, brackets, fasteners, sleeves, and other appurtenances as shown on the draiwngs and as required for proper installation.

2.4.6.9 Walkway Grating

Provide grating of the material and size shown, and fabricated in sectional panels of the width and length shown, or as appropriate, to accurately fit within the supporting recess frames. Provide openings through panels as shown or as required. Band edges of gratings and openings through gratings which require the cutting of more than one bearing bar. Grating shall be removable.

2.4.6.10 Appurtenant Items

Sill assemblies, latches, bumpers fenders, seal plates and shapes, and other appurtenant items shall conform to details specified and shown.

SECTION 35 20 16.33 Page 15

2.4.7 Shop Assembly

Shop assembly requirements for miter gate leafs and appurtenant items shall be as shown and specified herein and in Section 05 59 13 FABRICATION OF HYDRAULIC STEEL STRUCTURES. Miter gate leafs and appurtenant items, as listed herein, shall be assembled completely in the shop, unless otherwise approved by the Contracting Officer's Representative, to assure satisfactory quality control and field installation. Adjoining components shall be fitted and bolted together to facilitate field connections. The matchmarking of unassembled items shall be carefully preserved until the items are assembled. Mating surfaces and machined surfaces shall be covered with a rust preventive until assembly. Assembled components shall be shop-welded in their final positions as much as delivery and field installation conditions will permit. Rubber seals shall be fitted and drilled to match the seal retainers, match-marked, and removed for shipment. Shop assembly and disassembly work shall be performed in the presence of the Contracting Officer's Representative unless otherwise approved by the Contracting Officer's Representative. The presence of the Contracting Officer's Representative will not relieve the Fabricator of any responsibility under this contract.

Each miter gate leaf will be delivered completely shop assembled with the following components attached to the gate leaf:

a. Diagonals

b. Strut pin housing

c. Mitering device assemblies

d. Miter contact block assemblies

e. Quoin contact block assemblies

f. Cathodic protection anodes

g. Grease lines

h. Pintle socket and bushing

i. Fender assemblies

j. Recess latch strikes

k. Gate stops

l. Lifting lugs

m. Turning feet

Additional fabricated items and components shall be delivered loose, with the gate leafs, to the specified delivery location. These items include:

a. Pintles and pintle bases

b. Diagonal tensioning equipment

c. Walkways and grating

d. Handrail

e. Strut pins and connection components

f. Gudgeon pins

g. Gudgeon anchor bars and link plates

h. Gudgeon anchorage hardware

i. Bottom rubber J-seal with clamp bars and bolts

j. Additional pintle sockets with bushings

k. All remaining required appurtenant items

2.5 TESTS, INSPECTIONS, AND VERIFICATIONS

Submit certified test reports for material tests with all materials delivered to the delivery location.

2.5.1 General

Tests, Inspections, and Verifications for materials shall conform to the

SECTION 35 20 16.33 Page 16 requirements specified herein and in Section 05 59 13 FABRICATION OF

HYDRAULIC STEEL STRUCTURES.

2.5.2 Dimension and Tolerance Verification

The miter gate leafs will be surveyed at the fabrication facility by the Government using LiDAR to verify dimensions and tolerances during the fabrication. The Government will minimize impacts but accommodations will need to be made to survey the gate, not limited to rotating, moving, or lifting the gate leaf and sub-assemblies.

The Fabricator shall notify the Government not less than 30 calendar days prior to the date the gate is sufficiently assembled prior to painting and will be available for surveying.

2.5.3 Testing of Rubber Seals

The fluorocarbon film of rubber seals shall be tested for adhesion bond in accordance with ASTM D413 using either the machine method or the deadweight method. A 1 inch long piece of seal shall be cut from the end of the seal which has been masked and subjected to tension at an angle approximately 90 degrees to the rubber surface. There shall be no separation between the fluorocarbon film and the rubber when subjected to the following loads:

THICKNESS OF FLUOROCARBON

FILM

MACHINE METHOD AT 2 INCHES

PER MINUTE

DEADWEIGHT METHOD

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

2.5.4 Testing and Inspection of Steel Castings

Perform radiographic inspection of steel castings at the casting plant 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 must conform to the requirements of ASTM E94/E94M. The castings will be unacceptable if shown to have defects of greater severity than the applicable reference standard specified in the following table:

CASTINGS UP TO 2 INCHES IN THICKNESS

SEVERITY LEVELS

DISCONTINUITY TYPE OR CLASSES

Category A - Gas and blow holes Category B - Sand and slag inclusions Category C - Shrinkage, all types Category D - Cracks .......................... 1* Category E - Hot tears ....................... 1* Category F - Inserts, unfused chaplets Internal chills

*Acceptable only when the angle between the defect and the direction of the principal stress is not greater than 20 degrees.

CASTINGS OVER 2 INCHES IN THICKNESS

SECTION 35 20 16.33 Page 17

DISCONTINUITY TYPE SEVERITY LEVELS

Gas porosity Sand and slag inclusions Shrinkage Inserts Cracks Hot Tears

Use the applicable referenced standards as illustrated in ASTM E446 and ASTM E186. The evaluation of the radiographs will be subject to approval and all records will become the property of the Government.

2.5.5 Testing and Inspection of Threaded Forgings

Tests, Inspections, and Verifications for the materials used in threaded forgings shall be provided. Testing lab and personnel certifications required by the standards listed in this paragraph shall be submitted to the Contracting Officer's Representative for approval prior to testing.

Each finished forging shall be visually examined by the Government.

Visible surface discontinuities, (i.e. quench cracks, forging cracks, seams, voids, tool marks, gouges and thread laps) as defined by ASTM F788 shall be reason for product rejection. The following required test shall be performed on a randomly selected 25 percent of the forgings produced.

Chemical analysis shall conform to ASTM E350. Tension and impact test shall be in accordance with ASTM A370. Average grain size of the forgings shall be ASTM No. 5 or finer after final heat treatment as defined by ASTM E112. Specimens for all test, except ultrasonic and magnetic particle examination, shall be taken from prolongations.

Ultrasonic examination of forgings shall be in accordance with ASTM A388/A388M . Ultrasonic examination shall be conducted prior to thread rolling operation. Internal defects reported by ultrasonic examination with a major axis dimension of 0.2 inch shall be reason for rejection. Magnetic particle examination shall be in accordance with ASTM A275/A275M . Magnetic particle examination shall be by the wet method and performed on forgings after thread rolling operations. Indication reported by magnetic particle examination with a length of 0.09 inch measured along its major axis shall be reason for rejection. Each forging produced shall receive ultrasonic and/or magnetic particle examination if indication in excess of the above allowable dimensions are found in 40 percent of the examined pieces.

2.5.6 Weight Verification

Once completely assembled (fully welded, painted, and with all required components attached for shipping), each gate leaf shall be hung from the lifting points, weighed, and the weight recorded and submitted to the Government. All components that are designated to be shipped loose shall be also be weighed, and weight recorded and submitted to the Government.

The Fabricator shall notify the Government not less than 30 calendar days prior to the date weight testing will be performed.

SECTION 35 20 16.33 Page 18

PART 3 EXECUTION

3.1 INSTALLATION

Installation is not a part of this contract, however assembly requirements specified herein and in Section 05 59 13 FABRICATION OF HYDRAULIC STEEL STRUCTURES are a part of this contract. Miter gate leafs and appurtenant items shall be assembled for installation in strict accordance with the contract drawings, approved installation drawings, and shop match-markings. Bearing surfaces requiring lubrication shall be thoroughly cleaned and lubricated with an approved lubricant before assembly and installation. Components to be field-welded shall be in correct alignment before welding is commenced.

3.1.1 Painting

Exposed parts of gates and appurtenances except machined surfaces, corrosion-resistant surfaces, cathodic protection system anodes, and other specified surfaces shall be painted as specified in Section 09 97 02

PAINTING: HYDRAULIC STRUCTURES.

3.1.2 Seal Assemblies

Rubber seal assemblies shall be shipped loose.

3.2 CATHODIC PROTECTION SYSTEM

The cathodic protection system shall conform to Section 26 42 14.00 10

CATHODIC PROTECTION SYSTEMS FOR LOCK MITER GATES.

3.3 PROTECTION OF FINISHED WORK

Protection of finished work shall conform to the requirements of Section

05 59 13 FABRICATION OF HYDRAULIC STEEL STRUCTURES.

-- End of Section --

SECTION 35 20 16.33 Page 19