Drawings_-_Spec.pdf

FY15 Mac Lock Bulk Head Replacement, Sault Ste. Marie, MI MACARTLKBULKHRPL

PROJECT TABLE OF CONTENTS

DIVISION 01 - GENERAL REQUIREMENTS

01 22 00 MEASUREMENT AND PAYMENT

01 33 00 SUBMITTAL PROCEDURES

01 78 00 CLOSEOUT SUBMITTALS

DIVISION 05 - METALS

05 59 13 FABRICATION OF HYDRAULIC STEEL STRUCTURES

DIVISION 09 - FINISHES

09 97 02 PAINTING: HYDRAULIC STRUCTURES

-- End of Project Table of Contents --

PROJECT TABLE OF CONTENTS Page 1

SECTION TABLE OF CONTENTS

DIVISION 01 - GENERAL REQUIREMENTS

SECTION 01 22 00

MEASUREMENT AND PAYMENT

PART 1 GENERAL

1.1 COMPENSATION

1.2 APPROVAL OF MATERIALS OR ALTERNATES

1.3 MEASUREMENT UNITS

1.4 UNIT PRICES

1.4.1 Culvert Bulkheads

1.4.1.1 Unit of Measure

PART 2 PRODUCTS (Not Applicable)

PART 3 EXECUTION (Not Applicable)

-- End of Section Table of Contents --

SECTION 01 22 00 Page 1

SECTION 01 22 00

MEASUREMENT AND PAYMENT

PART 1 GENERAL

1.1 COMPENSATION

The payment provided for in the contract shall constitute full compensation for furnishing all materials and for performing all work under the contract in a complete and acceptable manner. The contract work shall include providing plant, equipment, tools, supplies, labor, supervision, incidental materials, quality control, environmental protection, and meeting safety requirements, and for performing all work required for which separate payment is not otherwise provided. Compensation for all work shown, specified, or essential to completion of the project (whether or not the specific material or operation is indicated) shall be included on the bidding schedule. The payment provided for in the contract includes compensation for all risk, loss, damage, and expense arising out of the nature of the work or its prosecution, subject to conditions of the contract. Payment for each contract line item will constitute full compensation for furnishing materials, fabricating and delivering the deliverables as specified.

1.2 APPROVAL OF MATERIALS OR ALTERNATES

Requests for approval of materials and products, or substitutes thereof, will not be considered prior to award of the contract.

1.3 MEASUREMENT UNITS

When materials are measured in units other than the measurement units specified as the basis of payment, the measured quantities shall be converted to the specified unit of measure. Factors for conversions from one basis or unit of measurement to another shall be approved by the Contracting Officer.

1.4 UNIT PRICES

Payment items for the work of this contract are listed in the BIDDING SCHEDULE and described below. The payment items provided for on the bidding schedule embody the majority of the work; but the work descriptions provided below do not specifically discuss all incidental work required to complete the contract work.

1.4.1 Culvert Bulkheads

Payment will be made for furnishing all materials, equipment and labor and performing all operations necessary for fabrication and delivery of the bulkheads as shown and specified. All incidental costs shall be included in the line item to which it pertains. Payment shall be made upon

SECTION 01 22 00 Page 2 successful fabrication and delivery as defined in the specifications. The Contractor is responsible for storing and protection of all until final delivery. The Contractor is responsible for repair of any damages (paint or structural) to the bulkheads at no cost to the Government until final delivery and acceptance at the Soo Area Office, (SAO) Sault Ste. Marie, Michigan.

1.4.1.1 Unit of Measure

Unit of measure: Each.

PART 2 PRODUCTS (Not Applicable)

PART 3 EXECUTION (Not Applicable)

-- End of Section --

SECTION 01 22 00 Page 3

DIVISION 01 - GENERAL REQUIREMENTS

SECTION 01 33 00

SUBMITTAL PROCEDURES

PART 1 GENERAL

1.1 DEFINITIONS

1.1.1 Submittal

1.1.2 Submittal Descriptions (SD)

1.1.3 Approving Authority

1.1.4 Work

1.2 SUBMITTALS

1.3 SUBMITTAL REGISTER

1.4 SCHEDULING

1.5 TRANSMITTAL FORM (ENG FORM 4025)

1.6 SUBMITTAL PROCEDURES

1.6.1 Deviations

1.7 CONTROL OF SUBMITTALS

1.8 GOVERNMENT APPROVED SUBMITTALS

1.9 INFORMATION ONLY SUBMITTALS

PART 2 PRODUCTS

PART 3 EXECUTION

SECTION 01 33 00 Page 1

SECTION 01 33 00

SUBMITTAL PROCEDURES

PART 1 GENERAL

1.1 DEFINITIONS

1.1.1 Submittal

Contract Clauses "FAR 52.236-5, Material and Workmanship," paragraph (b) and "FAR 52.236-21, Specifications and Drawings for Construction," paragraphs (d), (e), and (f) apply to all "submittals."

1.1.2 Submittal Descriptions (SD)

Submittals requirements are specified in the technical sections.

Submittals are identified by SD numbers and titles as follows.

SD-01 Preconstruction Submittals

Certificates of insurance.

Surety bonds.

List of proposed subcontractors.

List of proposed products.

Construction Progress Schedule.

Submittal register.

Schedule of prices.

Work plan.

Quality control plan.

SD-02 Shop Drawings

Drawings, diagrams and schedules specifically prepared to illustrate some portion of the work.

Diagrams and instructions from a manufacturer or fabricator for use in producing the product and as aids to the Contractor for integrating the product or system into the project.

Drawings prepared by or for the Contractor to show how multiple systems and interdisciplinary work will be coordinated.

SD-03 Product Data

Catalog cuts, illustrations, schedules, diagrams, performance charts, instructions and brochures illustrating size, physical appearance and other characteristics of materials, systems or equipment for some portion of the work.

Samples of warranty language when the contract requires extended product warranties.

SD-06 Test Reports

SECTION 01 33 00 Page 2

Report signed by authorized official of testing laboratory that a material, product or system identical to the material, product or system to be provided has been tested in accord with specified requirements. (Testing must have been within three years of date of contract award for the project.)

Report which includes findings of a test required to be performed by the Contractor on an actual portion of the work or prototype prepared for the project before shipment to job site.

Report which includes finding of a test made at the job site or on sample taken from the job site, on portion of work during or after installation.

Investigation reports.

Daily logs and checklists.

Final acceptance test and operational test procedure.

SD-07 Certificates

Document required of Contractor, or of a manufacturer, supplier, installer or subcontractor through Contractor, the purpose of which is to further quality of orderly progression of a portion of the work by documenting procedures, acceptability of methods or personnel qualifications.

1.1.3 Approving Authority

Office authorized to approve submittal; such as

Area Office Field (AOF) Engineering and Construction Office (EC) Engineering and Construction Geotech and Structures Branch (EC-G)

1.1.4 Work

As used in this section, on- and off-site construction required by contract documents, including labor necessary to produce submittals, construction, materials, products, equipment, and systems incorporated or to be incorporated in such construction.

1.2 SUBMITTALS

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

submittals not having a "G" designation are for information only or as otherwise designated. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. The following shall be submitted in accordance with Section

01330 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Submittal register; G

1.3 SUBMITTAL REGISTER

At the end of this section is a submittal register showing items of

SECTION 01 33 00 Page 3 equipment and materials for which submittals are required by the specifications; this list may not be all inclusive and additional submittals may be required. The Contractor shall maintain a submittal register for the project in accordance with Section 01312A QUALITY CONTROL SYSTEM (QCS). The Government will provide the initial submittal register in electronic format. Thereafter, the Contractor shall maintain a complete list of all submittals, including completion of all data columns. Dates on which submittals are received and returned by the Government will be included in its export file to the Contractor. The Contractor shall track all submittals.

1.4 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 15 calendar days, and 30 calendar days for structural 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 for time lost in late submittals.

1.5 TRANSMITTAL FORM (ENG FORM 4025)

ENG Form 4025 shall be used for submitting both Government approved and information only submittals in accordance with the instructions on the reverse side of the form. These forms will be furnished to the Contractor. This form shall be properly completed by filling out all the heading blank spaces and identifying each item submitted. Special care shall be exercised to ensure proper listing of the specification paragraph and/or sheet number of the contract drawings pertinent to the data submitted for each item.

1.6 SUBMITTAL PROCEDURES

1.6.1 Deviations

For submittals which include proposed deviations requested by the Contractor, the column "variation" of ENG Form 4025 shall be checked. The Contractor shall set forth in writing the reason for any deviations and annotate such deviations on the submittal. The Government reserves the right to rescind inadvertent approval of submittals containing unnoted deviations.

1.7 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."

1.8 GOVERNMENT APPROVED SUBMITTALS

Upon completion of review of submittals requiring Government approval, the submittals will be identified as having received approval by being so stamped and dated. 3 copies or one (1) Adobe format of the submittal will be retained by the Contracting Officer and 3 copies or one (1) Adobe format of the submittal will be returned to the Contractor.

1.9 INFORMATION ONLY SUBMITTALS

Normally submittals for information only will not be returned. Approval of

SECTION 01 33 00 Page 4 the Contracting Officer is not required on information only submittals.

The Government reserves the right to require the Contractor to resubmit any item 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.

PART 2 PRODUCTS

Not Used

PART 3 EXECUTION

Not Used

SECTION 01 33 00 Page 5

SUBMITTAL FORM,Jan 96 PREVIOUS EDITION IS OBSOLETE PAGE 1 OF 2 PAGES

FY15 Mac Lock Bulk Head Replacement, Sault Ste. Marie, MI

01 33 00 SD-01 Preconstruction Submittals

GSubmittal register

01 78 00 SD-01 Preconstruction Submittals

1.3Reproducible Drawings

1.3CAD System Drawings

SD-02 Shop Drawings

1.3Record Drawings

SD-03 Product Data

1.3Spare Parts Data

SD-07 Certificates

1.3Work Plan

SD-10 Operation and Maintenance

Data

Operation and Maintenance

Manuals

05 59 13 SD-01 Preconstruction Submittals

1.2.3 G EC-GWelding Procedure Specifications

(WPS)

1.2.4 G EC-GFracture Control Plan (FCP)

1.2.1 G EC-GWeld Tracking Log Template

SD-02 Shop Drawings

1.4.5 G EC-GShop Drawings

2.2.2 G EC-GAssembly

2.3.7 G EC-GWelding Repairs - Non-Fracture

Critical Members

SUBMITTAL REGISTER

CONTRACT NO.

TITLE AND LOCATION CONTRACTOR

CONTRACTOR:

SCHEDULE DATES

CONTRACTOR

ACTION

APPROVING AUTHORITY

A C T I V I T Y

N O

T R A N S M I T T A L

N O

S P E C

S E C T

DESCRIPTION

ITEM SUBMITTED

P A R A G R A P H

C L A S S I F I C A T I O N

G O V T

O R

A E

R E V W

R SUBMIT

APPROVAL

NEEDED

BY

MATERIAL

NEEDED

BY

A C T I O N

C O D E

DATE

OF

ACTION

DATE FWD

TO APPR

AUTH/

DATE RCD

FROM

CONTR

DATE FWD

TO OTHER

REVIEWER

DATE RCD

FROM OTH

REVIEWER

A C T I O N

C O D E

DATE

OF

ACTION

MAILED

TO

CONTR/

DATE RCD

FRM APPR

AUTH REMARKS

(a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) (m) (n) (o) (p) (q) (r)

SUBMITTAL FORM,Jan 96 PREVIOUS EDITION IS OBSOLETE PAGE 2 OF 2 PAGES

FY15 Mac Lock Bulk Head Replacement, Sault Ste. Marie, MI

05 59 13 2.3.7 G EC-GWelding Repairs - Fracture

Critical Members

1.5.1 G EC-GDelivery/Shipping Plan

SD-03 Product Data

2.2.3Materials Disposition Record

SD-06 Test Reports

2.3 G EC-GCertified Test Reports

1.2.2 G EC-GWeld Tracking Log

1.4 G EC-GWitness Points

SD-07 Certificates

1.2 G EC-GWork Plan

1.4.1 G EC-GQualification of Welders and

Welding Operators

1.4.2 G EC-GInspector Qualifications

1.4.3 G EC-GQualification of Structural Steel

Fabricator

SD-09 Manufacturer’s Field

Reports

2.3.8 G EC-GControl Dimensions

09 97 02 SD-04 Samples

2.1 G AOFSpecial Paint Formulas

SUBMITTAL REGISTER

CONTRACT NO.

TITLE AND LOCATION CONTRACTOR

CONTRACTOR:

SCHEDULE DATES

CONTRACTOR

ACTION

APPROVING AUTHORITY

A C T I V I T Y

N O

T R A N S M I T T A L

N O

S P E C

S E C T

DESCRIPTION

ITEM SUBMITTED

P A R A G R A P H

C L A S S I F I C A T I O N

G O V T

O R

A E

R E V W

R SUBMIT

APPROVAL

NEEDED

BY

MATERIAL

NEEDED

BY

A C T I O N

C O D E

DATE

OF

ACTION

DATE FWD

TO APPR

AUTH/

DATE RCD

FROM

CONTR

DATE FWD

TO OTHER

REVIEWER

DATE RCD

FROM OTH

REVIEWER

A C T I O N

C O D E

DATE

OF

ACTION

MAILED

TO

CONTR/

DATE RCD

FRM APPR

AUTH REMARKS

(a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) (m) (n) (o) (p) (q) (r)

DIVISION 01 - GENERAL REQUIREMENTS

SECTION 01 78 00

CLOSEOUT SUBMITTALS

PART 1 GENERAL

1.1 SUMMARY

1.2 SUBMITTALS

1.3 GENERAL

PART 2 PRODUCTS

PART 3 EXECUTION

SECTION 01 78 00 Page 1

SECTION 01 78 00

CLOSEOUT SUBMITTALS

PART 1 GENERAL

1.1 SUMMARY

The requirements of this Section apply to, and are a component part of each section of the specifications.

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 01330 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

The following shall be submitted in accordance with paragraph entitled, "General," of this section.

Reproducible Drawings CAD System Drawings

SD-02 Shop Drawings

Record Drawings shall be submitted in accordance with paragraph entitled, "General," of this section.

SD-03 Product Data

Spare Parts Data shall indicate manufacturer's name, part number, nomenclature, and stock level recommended for maintenance and repair. List those items that may be standard to the normal maintenance of the system.

SD-07 Certificates

A Work Plan shall be submitted in accordance with paragraph entitled, "General," of this section.

SD-10 Operation and Maintenance Data

Operation and Maintenance Manuals shall be submitted in accordance with paragraph entitled, "Operation and Maintenance," of this section.

1.3 GENERAL

Reproducible Drawings and CAD System Drawings shall be submitted as follows:

SECTION 01 78 00 Page 2

Computer Aided Design and Drafting (CADD) Drawings

Only personnel proficient in the preparation of CADD drawings shall be employed to modify the contract drawings or prepare additional new drawings. Additions and corrections to the contract drawings shall be equal in quality and detail to that of the originals. Line colors, line weights, lettering, layering conventions, and symbols shall be the same as the original line colors, line weights, lettering, layering conventions, and symbols. If additional drawings are required, they shall be prepared using the specified electronic file format applying the same graphic standards specified for original drawings. The title block and drawing border to be used for any new final as-built drawings shall be identical to that used on the contract drawings. Additions and corrections to the contract drawings shall be accomplished using CADD files. The Contractor will be furnished "as-designed" drawings in Microstation 8V format compatible with a Windows NT operating system. The electronic files will be supplied on compact disc, read-only memory (CD-ROM)]. The Contractor shall be responsible for providing all program files and hardware necessary to prepare final as-built drawings. The Contracting Officer will review final as-built drawings for accuracy and the Contractor shall make required corrections, changes, additions, and deletions.

a. CADD colors shall be the "base" colors of red, green, and blue.

Color code for changes shall be as follows:

(1) Deletions (red) - Deleted graphic items (lines) shall be colored red with red lettering in notes and leaders.

(2) Additions (Green) - Added items shall be drawn in green with green lettering in notes and leaders.

(3) Special (Blue) - Items requiring special information, coordination, or special detailing or detailing notes shall be in blue.

b. The Contract Drawing files shall be renamed in a manner related to the contract number (i.e., 98-C-10.DGN) as instructed in the Pre-Construction conference. Marked-up changes shall be made only to those renamed files. All changes shall be made on the layer/level as the original item. There shall be no deletions of existing lines; existing lines shall be over struck in red. Additions shall be in green with line weights the same as the drawing. Special notes shall be in blue on layer #63.

c. When final revisions have been completed, the cover sheet drawing shall show the wording "RECORD DRAWING AS-BUILT" followed by the name of the Contractor in letters at least 3/16 inch high. All other contract drawings shall be marked either "AS-Built" drawing denoting no revisions on the sheet or "Revised As-Built" denoting one or more revisions. Original contract drawings shall be dated in the revision block.

d. Within 20 days after Government approval of all of the working as-built drawings for a phase of work, the Contractor shall prepare the final CADD as-built drawings for that phase of work and submit two sets of blue-lined prints of these drawings for Government review and approval.

The Government will promptly return one set of prints annotated with any necessary corrections. Within 10 days the Contractor shall revise the CADD files accordingly at no additional cost and submit one set of final prints for the completed phase of work to the Government. Within 20 days of

SECTION 01 78 00 Page 3 substantial completion of all phases of work, the Contractor shall submit the final as-built drawing package for the entire project. The submittal shall consist of one set of electronic files on compact disc, read-only memory (CD-ROM)], one set of mylars, two sets of blue-line prints and one set of the approved working as-built drawings. They shall be complete in all details and identical in form and function to the contract drawing files supplied by the Government. Any transactions or adjustments necessary to accomplish this is the responsibility of the Contractor. The Government reserves the right to reject any drawing files it deems incompatible with the customer's CADD system. Paper prints, drawing files and storage media submitted will become the property of the Government upon final approval. Failure to submit final as-built drawing files and marked prints as specified shall be cause for withholding any payment due the Contractor under this contract. Approval and acceptance of final as-built drawings shall be accomplished before final payment is made to the Contractor.

Record Drawings shall be submitted under the following criteria:

In order to minimize the time for final payment at the completion of the project, the Contractor shall update the Record Drawings every month with the Contracting Officer's authorized representative. This update will be a part of "the monthly request for payment meeting," and payment--or a portion of the payment, including final payment--may be withheld until the Record Drawings have been updated, and accepted by the Contracting Officer.

After completion of all construction and before final payment is made under this contract, the Contractor shall provide the Contracting Officer with one complete set of CAD system drawings with all changes clearly identifiable on the computer screen along with one hard copy of the same (with advance permission given by the Contracting Officer).

Preventative Maintenance and Condition Monitoring (Predictive Testing) and Inspection schedules shall be submitted by the Contractor with instructions that state when systems should be retested.

Schedule shall define the anticipated length of each test, test apparatus, number of personnel identified by responsibility, and a testing validation procedure permitting the record operation capability requirements. Each test feature; e.g., gpm, rpm, psi, shall have a signoff blank for the Contractor and Contracting Officer. A remarks column of the testing validation procedure shall include references to operating limits of time, pressure, temperature, volume, voltage, current, acceleration, velocity, alignment, calibration, adjustments, cleaning, or special system notes.

Procedures for preventative maintenance, inspection, adjustment, lubrication and cleaning necessary to minimize corrective maintenance and repair shall be delineated.

Repair requirements shall inform operators how to check out, troubleshoot, repair, and replace components of the system. Instructions shall include electrical and mechanical schematics and diagrams and diagnostic techniques necessary to enable operation and troubleshooting of the system after acceptance.

A Work Plan shall be submitted to the Contracting Officer for project closeout. Plan shall include all scheduled inspections, instruction classes, items, closeout dates for all functions, and shall list the required Government and Contractor personnel that will be taking part in

SECTION 01 78 00 Page 4 these functions.

Posted Instructions shall be submitted by the Contractor with labels, signs, and templates of operating instructions that are required to be mounted or installed on or near the product for normal, safe operation.

Contractor shall submit 6 copies of the project operation and maintenance manuals 30 calendar days prior to testing the system involved. Data shall be updated and resubmitted for final approval no later than 30 calendar days prior to contract completion.

Spare Parts Data shall indicate manufacturer's name, part number, nomenclature, and stock level required for maintenance and repair. List those items that may be standard to the normal maintenance of the system.

PART 2 PRODUCTS

Not Used

PART 3 EXECUTION

Not Used

SECTION 01 78 00 Page 5

DIVISION 05 - METALS

SECTION 05 59 13

FABRICATION OF HYDRAULIC STEEL STRUCTURES

PART 1 GENERAL

1.1 REFERENCES

1.2 SYSTEM DESCRIPTION

1.2.1 Weld Tracking Log Template

1.2.2 Weld Tracking Log

1.2.3 Welding Procedure Specifications (WPS)

1.2.4 Fracture Critical Members (FCM)

1.3 SUBMITTALS

1.4 QUALITY ASSURANCE

1.4.1 Qualification of Welders and Welding Operators

1.4.2 Inspector Qualifications

1.4.3 Qualification of Structural Steel Fabricator

1.4.4 Testing by the Government

1.4.5 Shop Drawings

1.5 DELIVERY, STORAGE, AND HANDLING

1.5.1 Culvert Bulkheads

1.5.2 Rubber Seals

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Structural Steel

2.1.2 Fracture Critical Structural Steel

2.1.3 Rubber Seals

2.1.3.1 Physical Characteristics

2.1.4 Seal Clamp Bar

2.1.5 Bolts, Nuts, and Washers

2.1.6 Seal Clamp Bar Fasteners

2.1.7 Lifting Cables and Hardware

2.1.8 UHMW Blocks

2.2 FABRICATION

2.2.1 Structural Fabrication

2.2.2 Assembly

2.2.3 Materials Disposition Record

2.2.4 Welded Connections

2.2.5 Flat Head Hex Socket Cap Screw and Bolted Connections

2.2.6 Miscellaneous Provisions

2.2.7 Shop Assembly

2.3 CERTIFIED TEST REPORTS

2.3.1 General

2.3.2 Nondestructive Testing

2.3.3 Inspection of Structural Steel Welding

2.3.4 Welds to be Subject to Nondestructive Examination

2.3.5 Test Coupons

2.3.6 Supplemental Examination

SECTION 05 59 13 Page 1

2.3.7 Structural Steel Welding Repairs

2.3.8 Control Dimensions

2.3.9 Testing of Rubber Seals

PART 3 EXECUTION

3.1 SEAL INSTALLATION

3.2 PROTECTION OF FINISHED WORK

3.3 PAINTING

ATTACHMENTS:

PQR

SECTION 05 59 13 Page 2

SECTION 05 59 13

FABRICATION OF HYDRAULIC STEEL STRUCTURES

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 SOCIETY FOR NONDESTRUCTIVE TESTING (ASNT)

ASNT SNT-TC-1A (2011; Text Correction 2012) Recommended Practice for Personnel Qualification and Certification in Nondestructive Testing

AMERICAN WELDING SOCIETY (AWS)

AWS D1.5M/D1.5 (2010) Bridge Welding Code

AWS QC1 (2007) Standard for AWS Certification of Welding Inspectors

ASTM INTERNATIONAL (ASTM)

ASTM A307 (2012) Standard Specification for Carbon Steel Bolts and Studs, 60 000 PSI Tensile Strength

ASTM A563 (2007a) Standard Specification for Carbon and Alloy Steel Nuts

ASTM A572/A572M (2012) Standard Specification for High-Strength Low-Alloy Columbium-Vanadium Structural Steel

ASTM A574 (2013) Standard Specification for Alloy Steel Socket-Head Cap Screws

ASTM D6712-01 (2009) Standard Specification for Ultra High Molecular Weight Polyethylene Solid Plastic Shapes

ASTM E165/E165M (2012) Standard Practice for Liquid Penetrant Examinationfor General Industry

ASTM E709 (2008) Standard Guide for Magnetic Particle Examination

ASTM F844 (2007a) Washers, Steel, Plain (Flat), Unhardened for General Use

SECTION 05 59 13 Page 3

U.S. ARMY CORPS OF ENGINEERS (USACE)

EM 385-1-1 (2008; Errata 1-2010; Changes 1-3 2010;

Changes 4-6 2011; Change 7 2012) Safety and Health Requirements Manual

1.2 SYSTEM DESCRIPTION

Provide a detailed Work Plan for fabrication, including descriptions of shop facilities, equipment, number of personnel, and related information prior to the Pre-fabrication Conference, and procedures for safe conduct of the work, careful removal and disposition of materials, protection of property that is to remain undisturbed, and coordination with other work in progress. Include in the procedures a detailed description of the methods and equipment to be used for each operation, and the sequence of operations in accordance with EM 385-1-1. The Work Plan shall include the recommended measuring system for ensuring dimensional tolerances. The fabrication of the following listed structures under this contract shall be performed according to this section of the specifications:

1. Culvert Bulkheads

a. Material with welds will not be accepted unless the welding is specified or indicated on the drawings or otherwise approved. Welding shall not be started until welding procedures, inspectors, nondestructive testing personnel, welders, welding operators, and tackers have been qualified and approved. Each Contractor performing welding shall maintain records of the test results obtained in welding procedure, and welder, welding operator, and tacker performance qualifications.

b. As it is used in these specifications, "The Engineer" refers to the District or engineer of record. The AWS D1.5M/D1.5 definition of "The Engineer" as specified in AWS D1.5M/D1.5 section 1.1.3 shall refer to the District or engineer of record in lieu of the state bridge engineer as specified in section 1.1.3 of AWS D1.5M/D1.5.

c. Schedule a Prefabrication Conference as soon as possible after Notice to Proceed and prior to any fabrication. The Prefabrication Conference shall include, at a minimum, the Prime Contractor, Fabricator, the Fabricator's primary QC representative, the COR, the GQAR, and the Engineer of record for the structure or structures being fabricated.

The Prefabrication Conference shall occur either at the Fabrication Facilities or a similar location as deemed appropriate.

1.2.1 Weld Tracking Log Template

Submit for approval a weld tracking log template, a minimum of 30 days prior to commencement of fabrication, to identify all necessary components to be addressed in the tracking of all welds for the structures in question. A weld-tracking log will be developed and maintained as described in the following paragraphs.

1.2.2 Weld Tracking Log

Submit a log capable of individually identifying and tracking every weld on the project. Member identification shall follow the numbering scheme shown on the shop drawings. The log shall include the member to be welded, member type (FCM and Non-FCM), type of weld including temporary and tack

SECTION 05 59 13 Page 4 welds, welding position, applicable WPS reference, AWS joint preparation designation, name or stamping designation of welder, welding operator or tacker, date and time of completion of welding and/or tacking, name and date of CWI visual inspection, NDT testing performed, including the type of inspection, date(s) of inspection, inspector name, and the acceptance criteria used, description of defects found and reason for non-compliance, corrective action taken, or whether the weld is acceptable. Weld identification on the shop drawing shall match weld tracking log identification. A completed log shall be bound together for each structure and two copies shall be submitted to the Contracting Officer immediately upon completion of the fabrication of each structure. Draft copies of NDT testing shall be furnished to the Contracting Officer upon request and shall be available on the shop floor during any inspection.

1.2.3 Welding Procedure Specifications (WPS)

Submit a Welding Procedure Specification (WPS), with attached PQR and supporting test documentation on forms similar or equivalent to the sample forms in AWS D1.5M/D1.5, Annex III, for each weld, including prequalified welds, in accordance with paragraph Welded Connections approved before fabrication is commenced. Welding Procedure Specifications shall be individually identified and shall be referenced on the shop drawings. In case of conflict between this specification and AWS D1.5M/D1.5 as applicable, this specification governs.

1.2.4 Fracture Critical Members (FCM)

FCM are shown on the Contract Drawings and include all attachments and connections to these members as defined in AWS D1.5M/D1.5. All materials to be welded shall be as specified in part 2 of this specification section, using killed fine-grain mill practice, unless otherwise shown or specified. Mill repairs of base metal are prohibited. Welding for fracture critical members shall meet all requirements of AWS D1.5M/D1.5 Section 12, including:

a. 12.5 Welding Processes. All procedures shall be qualified as required.

b. 12.6 Consumable Requirements. All welding consumables shall be heat or lot-tested by the manufacturer to determine conformance with the requirements of the Fracture Control Plan (FCP). Exceptions are not allowed. Toughness test results shall meet the values specified in Table 12.1 of AWS D1.5M/D1.5. Submit a Fracture Control Plan (FCP) for welding on all Fracture Critical Members (FCM) in accordance with AWS D1.5M/D1.5, Section 12. Welding Procedures, qualifications, and certifications shall be submitted showing compliance with FCP requirements

c. 12.7 Welding Procedure Specifications (WPS). All procedures, including repair welds, shall be prequalified or qualified by test as required and documented in the WPS and Procedure guidelines of AWS D1.5M/D1.5.

d. 12.8 Certification and Qualification. Welders and welding operators shall meet the applicable requirements of AWS D1.5M/D1.5.

e. Material handling and preparation, including thermal cutting, preparation of base metal, and straightening, curving, cambering shall meet the applicable requirements.

f. 12.13 Tack Welds and Temporary Welds. All welds shall be located

SECTION 05 59 13 Page 5 within the joint and shall meet the requirements of AWS D1.5M/D1.5, Table 12.2. Temporary welds on FCM are not permitted.

g. Welding processes, including preheat, interpass temperatures, and postweld thermal treatment shall meet the applicable requirements.

h. 12.16 Weld Inspection. The Quality Control inspection program shall be documented in the FCP. All inspectors and NDT technicians shall be qualified as required. All butt joints shall be tested with UT and RT. Inspection procedures and documentation are as specified in the applicable sections of AWS D1.5M/D1.5. Cooling times must be strictly adhered to.

i. 12.17 Repair Welding. Repair welds must be classified as "critical repairs" or "non-critical repairs" for all repair welding. Repair procedures shall follow the minimum provisions unless specified otherwise. Repair procedures must be qualified and approved and subject to the same QA/QC inspection requirements as other welds.

Minimum preheat for repair welding shall be as defined in AWS D1.5M/D1.5 section 12.17.6. All weld repairs to fracture critical members shall be considered critical welds in accordance with AWS D1.5M/D1.5 Section

12.17.3 and shall be approved by the engineer of record.

1.3 SUBMITTALS

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

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Welding Procedure Specifications (WPS); G, EC-G Fracture Control Plan (FCP); G, EC-G Weld Tracking Log Template; G, EC-G

SD-02 Shop Drawings

Shop Drawings; G, EC-G Assembly; G, EC-G Welding Repairs - Non-Fracture Critical Members; G, EC-G Welding Repairs - Fracture Critical Members; G, EC-G Delivery/Shipping Plan; G, EC-G

SD-03 Product Data

Materials Disposition Record

SD-06 Test Reports

Certified Test Reports; G, EC-G Weld Tracking Log; G, EC-G Witness Points; G, EC-G

SD-07 Certificates

Work Plan; G, EC-G Qualification of Welders and Welding Operators; G, EC-G

SECTION 05 59 13 Page 6

Inspector Qualifications; G, EC-G Qualification of Structural Steel Fabricator; G, EC-G

SD-09 Manufacturer's Field Reports

Control Dimensions; G, EC-G

1.4 QUALITY ASSURANCE

Establish Witness Points for the Initial QA Inspection, Intermediate QA Inspections, and Final Inspection as follows. Start the Initial QA Inspection after the Government has determined that there is substantial completion of components that comprise a reasonable sampling of each significant FCM and non-FCM details. The extent of completion and details and the date of the Initial QA Inspection shall be determined at the Prefabrication Conference by the Government after discussion with the Contractor. At that time, produce a detailed schedule showing the progression of work and completion of components. This schedule will be updated weekly and provided by e-mail to the Contracting Officer. Give the Contracting Officer two weeks notice prior to the predetermined date for the Initial QA Inspection, including adjustments for changes in schedule.

Intermediate QA Inspections will be conducted on an as needed basis and at the discretion of the Government. All QA inspections will follow AWS D1.5M/D1.5 and AASHTO/NSBA Steel Bridge Collaboration S 4.1 - 2002 Steel Bridge Fabrication QC/QA Guide Specification. Provide unpainted components for each QA NDT and Visual Inspection. At these stages of construction, give the Contracting Officer three working days to inspect the structure. The QA Inspection period shall not commence until after a minimum period of 72 hours after any welding. After the Contracting Officer and the Engineer of Record has inspected the structure, make any changes required to the structure as directed by the Contracting Officer before proceeding with any additional welding. Proceed with the construction until the next witness point is reached, unless it is waived in writing by the Contracting Officer. Each structure fabricated is subject to a Final Fabrication Inspection prior to painting. A Final Fabrication Inspection shall be conducted after the first structure is completed. Final Fabrication Inspections of additional structures shall be scheduled and coordinated with the Contracting Officer and the Engineer of Record. Give the Contracting Officer a minimum notice of two weeks prior to the Final Fabrication Inspection.

1.4.1 Qualification of Welders and Welding Operators

Submit welder, welding operator and tacker qualification certification for each welder, welding operator or tack welder to the Government Representative/Contracting Officer/ Engineer. Qualifications shall be approved before fabrication is commenced in accordance with Section 2.2.4 Welded Connections. A CWI meeting the specified qualifications shall approve all welder qualifications. Welders, welding operators, and tack welders shall be limited to welding procedures for which they are certified. Test welds shall be prepared, welded, and tested in accordance with the requirements of AWS D1.5M/D1.5. Before assigning any welder, welding operator, or tacker to work under this contract, submit the names of the welders, welding operators, and tackers to be employed, and certification that each individual is qualified as specified. The certification shall state the type of welding and positions for which the welder, welding operator, or tacker is qualified, the code and procedure under which the individual is qualified, the date qualified, and the name of the firm and person certifying the qualification tests. The

SECTION 05 59 13 Page 7 certification shall be kept current for the duration of the contract.

Welder and welding operator qualification test records shall be submitted on forms similar or equivalent to the sample forms in AWS D1.5M/D1.5, Annex III. All welders performing fracture critical welds under this specification shall be qualified according to Section 12 of AWS D1.5M/D1.5.

All welders performing non fracture critical welds shall be qualified according to Section 6 of AWS D1.5M/D1.5. All qualifications shall be current prior to commencing any work. Submit a log for each welder showing that he/she is current in the process and procedures being proposed for this work.

1.4.2 Inspector Qualifications

All inspectors, performing structural steel inspection in accordance with these specifications, shall be qualified and certified in conformance with AWS QC1. Provide an AWS Certified Welding Inspector (CWI) as the primary point of contact for quality control of welding. When several CWI and NDT technicians are working, one primary individual shall be designated as having primary responsibility for all quality control in accordance with AWS D1.5M/D1.5 Section 6.1.2.2. Non-certified inspectors and certified associate weld inspectors (CAWI) shall not be used for inspection under these specifications. All personnel who perform NDT shall be qualified in accordance with: ASNT SNT-TC-1A NDT Level II or III. All personnel performing NDT shall be supervised by personnel possessing a Level III ASNT NDT certification in accordance with AWS D1.5M/D1.5 section 6.1.3.4 and section 12.16.1.2. Submit copies of certificates showing evidence of qualifications or certifications for welding inspectors and NDT personnel.

1.4.3 Qualification of Structural Steel Fabricator

The fabricating plant and fabricator shall be certified under the AISC (American Institute of Steel Construction) Quality Certification Program, and shall be designated an AISC Certified Plant, Category CBR (Major Steel Bridge) with a Fracture Critical Endorsement (F) at time of bid. The fabricator or fabrication plant shall possess five 5 years documented experience on projects of similar scope. Similar scope means projects of similar size and similar amounts of welding and detail types. Submit copies of the AISC certificate indicating that the fabrication plant meets the specified structural steelwork category and documented experience. The wire rope slings and rubber seals are excluded from the AISC fabricator certification requirements.

1.4.4 Testing by the Government

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

1.4.5 Shop Drawings

Prepare all shop drawings using a Registered Professional Engineer or under the direct supervision of a Registered Professional Engineer. Elements of fabricated items inadvertently omitted on contract drawings shall be returned to the Engineer of Record for detailing or shall be detailed by the fabricator and so indicated on the shop drawings. Any and all details

SECTION 05 59 13 Page 8 developed by the fabricator shall be clouded on the shop drawings for separate approval by the Engineer of Record. Any items designed by the Contractor shall be prepared and sealed by a Registered Professional Engineer. No splices shall be included in the structure without approval of the Engineer of Record. All field welds required shall be identified on the shop drawings. Each weld, both shop and field welds, required shall be provided a unique identifier to permit tracking on the weld tracking log.

Prior to performing any fabrication of the HSS structures listed in paragraph System Description above, submit complete, detailed shop drawings to the Contracting Officer and Engineer of Record for approval. Shop drawings shall show complete details of materials, tolerances, connections, and proposed welding sequences. Shop drawings shall include catalog cuts, templates, fabrication and assembly details, and type, grade, and class of materials, as appropriate. All FCM, including attachments that meet the FCM definition, shall be identified on the shop drawings as well as all temporary and tack welds. Each member shall be identified following the numbering scheme shown on the drawings. A table shall be provided containing a list of all members and a reference to each material certificate and test report that applies to that member. Shop drawings shall identify weld procedures and NDT required for each weld. Any and all splices shall be included in the shop drawings and clouded for engineer approval.

1.5 DELIVERY, STORAGE, AND HANDLING

1.5.1 Culvert Bulkheads

Notify the Contracting Officer at least 28 days in advance of delivery of the structures. Shipping of the structures shall be at the Contractor's expense. All structures shall be delivered to the Soo Locks Complex at 119 East Water Street, Sault Sainte Marie, MI 49783. Contractor coordination for delivery shall be through the Detroit District Contracting Officer.

The structures shall be arranged on the delivery vehicles such that no damage occurs during shipping. All sling lifting lugs shall be directed

up. Submit a Delivery/Shipping Plan showing orientation and locations of structures on the delivery vehicles prior to shipment for Government approval. Submit drawings providing descriptions of methods of delivering the completed structural units, including details for support during shipment to prevent distortion or other damages, and orientation and location of the structure on transport equipment. The USACE Soo Area Office staff will unload the completed bulkheads from the Contractor's delivery equipment.

1.5.2 Rubber Seals

Seals shall be removed from crates upon delivery and laid out into their natural position until attached to gates. Avoid prolonged storage in direlct sunlight. Do not store other items on top of rubber seals. Avoid bending or rolling of seals. Keep rubber seals free of oils, grease, and other materials which would deteriorate the rubber. Rubber seals shall not be distorted during handling.

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Structural Steel

All structual steel materials not identified as FCM shall be ASTM A572/A572M, SECTION 05 59 13 Page 9

Grade 50.

2.1.2 Fracture Critical Structural Steel

All structural steel identified on the project drawings as fracture critical members (FCM) shall be ASTM A572/A572M, Grade 50, with supplementary requirement S5 Charpy V-Notch (CVN) impact test. Material shall have a minimum average CVN fracture toughness value of 25 ft-lb when tested at 10 degrees Fahrenheit. No individual CVN value shall be less than 20 ft-lbs. Fracture Critical Members (FCM) include the following:

Horizontal and Vertical Girders, Lifting Lugs, Plate Intercostals, Skin Plate, Relief Valve Plate and Stiffeners. Mill repairs of base metal are prohibited.

2.1.3 Rubber Seals

Rubber seals shall be molded only and material shall be compounded of natural rubber and shall contain reinforcing carbon black, zinc oxide, accelerators, antioxidants, vulcanizing agents, and plasticizers. Top seals shall be fluorocarbon clad rubber seals. Each gate shall be provided with bulb seals and wedge seals as shown on the drawings. Side seals shall be spliced to top and bottom seals by the manufacturer where possible. No field splicing of seals shall take place without approval of COR. The surfaces of finished splices shall be smooth and free of irregularities.

Bolt holes in the rubber seals shall be match-drilled with the seal support and clamping bars, as applicable; to insure proper fit and spacing between holes of the completed seal assembly. Seal support and clamping bars shall conform to the configurations shown on the drawings and shall be machine finished. The seals shall be installed after painting has been completed.

2.1.3.1 Physical Characteristics

Physical characteristics of the seals shall meet the following requirements:

PHYSICAL TEST TEST VALUE TEST METHOD

SPECIFICATION

Tensile Strength 2500 psi (min.) ASTM D412

Elongation at Break 450 percent (min.) ASTM D412

300 percent 900 psi (min.) ASTM D412

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 of tensile strength (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 hours 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

SECTION 05 59 13 Page 10 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.

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

Tensile strength 2,000 psi (min.)

Elongation 250 percent (min.)

The outside surface of the bonded film shall be flush with the surface of the rubber seal and shall be free of adhering or bonded rubber. Strips and corner seals shall be molded in lengths suitable for obtaining the finish lengths shown and with sufficient excess length to provide test specimens for testing the adequacy of the adhesion bond between the film and bulb of the seal. At one end of each strip or corner seal to be tested, the fluorocarbon film shall be masked during bonding to prevent a bond for a length sufficient to hold the film securely during testing.

2.1.4 Seal Clamp Bar

Seal clamp bars shall conform to ASTM A572/A572M, Grade 50.

2.1.5 Bolts, Nuts, and Washers

All bolts shall have a standard head and be hot-dipped galvanized.

a. Bolts - All bolts shall meet ASTM A307 Grade A Hot-Dipped Galvanized.

b. Nuts - All nuts shall meet ASTM A563 and be Hot-Dipped Galvanized.

c. Washers - All washers shall meet ASTM F844 and be Hot-Dipped Galvanized.

2.1.6 Seal Clamp Bar Fasteners

Seal clamp bar fasteners shall be 5/8" diameter flat head hex socket cap screws and shall conform to ASTM A574. Cap screws shall be countersunk as shown on the project drawings. Lock nuts and washers shall be of compatable alloy steel materials.

2.1.7 Lifting Cables and Hardware

Lifting cables shall be sized and located as shown on the project drawings.

All cables shall be IWRC type wire rope. All primary lifting cables, shackels and miscellanious hardware shall have a capacity of 25 tons or greater.

2.1.8 UHMW Blocks

Ultra-High-Molecular-Weight (UHMW) blocks shall be cut to the size and shape as shown on the project drawings. Material shall comply with ASTM D6712-01 and be of Grade 1 or Grade 2 material for General Purpose use. The color of the materials shall be a standard color and shall be indicated on project shop drawings.

SECTION 05 59 13 Page 11

2.2 FABRICATION

2.2.1 Structural Fabrication

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