Specification_Section_35_20_16.33_-_Miter_Gates_-_Amdt_0001.pdf

MITER AND QUOIN CONTACT BLOCK REPLACEMENT P2_153619

POE

SECTION TABLE OF CONTENTS

DIVISION 35 - WATERWAY AND MARINE CONSTRUCTION

SECTION 35 20 16.33

MITER GATES

01/08

PART 1 GENERAL

1.1 UNIT PRICES

1.1.1 Miter and Quoin Contact Block Replacement

1.1.1.1 Payment

1.1.1.1.1 Unit of Measure

1.2 REFERENCES

1.3 SUBMITTALS

1.4 QUALITY ASSURANCE

1.4.1 Qualification of Welders

1.4.2 Safety Provisions for Zinc Filler

1.4.3 Detail Drawings

1.4.3.1 Fabrication Drawings

1.4.3.2 Delivery Drawings

1.4.3.3 Field Installation Drawings

1.5 DELIVERY, STORAGE, AND HANDLING

1.5.1 Rubber Seals

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Metals

2.1.1.1 Structural Steel

2.1.1.2 Stainless Steel Plate, Sheet, and Strip

2.1.1.3 Alloy Steel

2.1.2 Rubber Seals

2.1.2.1 Physical Characteristics

2.1.3 Zinc Filler

2.1.4 Liquidfied Petroleum (LP) Gas

2.2 MANUFACTURED UNITS

2.2.1 Bolts, Nuts and Washers

2.3 FABRICATION

2.3.1 Structural Fabrication

2.3.2 Bolted Connections

2.3.3 Machine Work

2.3.4 Miscellaneous Provisions

2.3.5 Fabrications

2.3.5.1 Quoin and Miter Contact Blocks

2.3.5.2 Rubber Corner Seal Seal Assemblies

2.4 TESTS, INSPECTIONS, AND VERIFICATIONS

2.4.1 General

PART 3 EXECUTION

3.1 INSTALLATION

3.1.1 Gate Leaf

SECTION 35 20 16.33 Page 1

05/09/17 - CERTIFIED FINAL READY TO ADVERTISE - AMDT 0001

3.1.2 Gate Leaf Quoin and Miter Contact Blocks

3.1.2.1 Placing Zinc Filler (SHALL BE COMPLETED BY THE GOVERNMENT)

3.1.2.2 Adjusting Contact Blocks

3.1.3 Mock-Up and Test Placing of Zinc Filler

3.1.4 Painting

3.2 FIELD TESTS AND INSPECTIONS

3.2.1 Acceptance Trial Operation

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

01/08

PART 1 GENERAL

1.1 UNIT PRICES

1.1.1 Miter and Quoin Contact Block Replacement

1.1.1.1 Payment

1.1.1.1.1 Unit of Measure

Unit of measure: Job.

1.2 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.

ASTM INTERNATIONAL (ASTM)

ASTM A240/A240M (2016) Standard Specification for Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications

ASTM A307 (2014) Standard Specification for Carbon Steel Bolts and Studs, 60 000 PSI Tensile Strength

ASTM A322 (2013) Standard Specification Steel Bars, Alloy, Standard Grades

ASTM A36/A36M (2014) Standard Specification for Carbon Structural Steel

ASTM B6 (2013) Standard Specification for Zinc

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

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

ASTM D412 (2015a) Standard Test Methods for Vulcanized Rubber and Thermoplastic Elastomers - Tension

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

SECTION 35 20 16.33 Page 3

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

ASTM F593 (2013a; E 2016) Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs

ASTM F594 (2009; E 2015) Standard Specification for Stainless Steel Nuts

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-02 Shop Drawings

Detail Drawings; G, LRL

Mock-Up; G, LRL

SD-03 Product Data

Materials

SD-04 Samples

Materials; G, LRL

SD-06 Test Reports

Tests, Inspections, and Verifications

1.4 QUALITY ASSURANCE

1.4.1 Qualification of Welders

Provide qualification of welders and welding operators conforming to the requirements of Section 05 50 14 STRUCTURAL METAL FABRICATIONS.

1.4.2 Safety Provisions for Zinc Filler

The following special safety provisions are required for heating and placing zinc filler (to be performed by the Government):

a. Workers shall wear protective clothing including hard hats with fine wire mesh screen, goggles, leather sleeves, chaps, apron, and leather gloves.

b. Workers shall wear air-line respirators certified by National Institute for Occupational Safety and Health (NIOSH) or Mine Safety and Health Administration (MSHA). In enclosed spaces, both local exhaust ventilation and air-line respirators are required. Local exhaust ventilation shall consist of movable hoods placed close to the work to remove fumes at the source.

SECTION 35 20 16.33 Page 4

c. Ladles, equipment, and material shall be pre-heated before being used so that they will be moisture-free.

d. Heating devices and ladles shall be placed on a level, firm foundation, and protected against traffic, accidental tipping, or similar hazard.

e. Hot zinc shall not be carried up or down ladders.

f. Buckets or vessels used for handling and transporting hot zinc shall be substantially constructed and shall not be filled higher than 4 inches from the top.

1.4.3 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 50 14 STRUCTURAL METAL FABRICATIONS. Contractor shall also submit for approval a detailed layout of the Mock-Up.

1.4.3.1 Fabrication Drawings

Show on the fabrication drawings complete details of materials, tolerances, connections.

1.4.3.2 Delivery Drawings

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

1.4.3.3 Field Installation Drawings

Show on the field installation drawings a detailed description of the field installation procedures. Include in the description the location and method of support of installation and handling equipment; provisions to be taken to protect concrete and other work during installation; method of maintaining components in correct alignment; plan for heated enclosures;

methods for installing quoin and miter blocks, including checking and maintaining alignments of the blocks during placement of zinc filler; and methods for installing other appurtenant items.

****AMDT #0001****

1.5 DELIVERY, STORAGE, AND HANDLING

Perform delivery, handling, and storage of materials and fabricated items in accordance with the requirements specified herein and in Section 05 50 14

STRUCTURAL METAL FABRICATIONS.

****AMDT #0001****

1.5.1 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.

SECTION 35 20 16.33 Page 5

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 50 14 STRUCTURAL METAL FABRICATIONS. Submit approved samples prior to use of the represented materials or items in the work. Samples of standard and shop fabricated items shall be full size and complete as required for installation in the work. Approved samples may be installed in the work provided each sample is clearly identified and its location recorded.

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 .

2.1.1.1 Structural Steel

Structural steel shall conform to ASTM A36/A36M.

2.1.1.2 Stainless Steel Plate, Sheet, and Strip

Stainless steel plate, sheet, and strip shall conform to ASTM A240/A240M, UNS S 30403 Condition A. Plate finish shall be hot-rolled, annealed or heat-treated, and blast-cleaned or pickled.

2.1.1.3 Alloy Steel

Alloy steel bars shall be ASTM A322, UNS G41400, annealed.

2.1.2 Rubber Seals

Rubber seals 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

Durometer Hardness (Shore Type A)

60 to 70 ASTM D2240

*Water Absorption 5 percent by weight (max.)

ASTM D471

SECTION 35 20 16.33 Page 6

PHYSICAL TEST TEST VALUE TEST METHOD

SPECIFICATION

Compression Set 30 percent (max.) ASTM D395

Tensile Strength (after aging 48 hrs)

80 percent 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 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 Zinc Filler

The Government shall provide ASTM B6, Prime Western Grade zinc to be used by the Government during placement of zinc filler.

2.1.4 Liquidfied Petroleum (LP) Gas

The Contractor shall provide LP gas to fuel the Governmnt's industrial furnances used to melt zinc filler. The Contractor shall lease two (2) LP tanks having the capacity to hold 150 gallons of useable LP gas each. The LP tanks size shall be kept to a minimum to facilitate movement as need during the repositioning of the furnances. Ideally the tanks shall be 190 gallon to 220 gallon capacity. In addition to the initial tank fills the Contractor shall arrange for up to an additional 600 gallons of LP gas to be delivered as needed.

2.2 MANUFACTURED UNITS

Bolts, nuts, washers, screws and other manufactured units shall conform with the requirements shown and specified herein.

2.2.1 Bolts, Nuts and Washers

Bolts shall be ASTM A307, Grade A. Where use of stainless steel threaded fasteners are shown in the drawings bolts and studs shall be ASTM F593, Group 1 or 2. Stainless steel nuts shall be with ASTM F594, Group 1 or 2, with 316 flat washer. 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 if not indicated on the drawings.

2.3 FABRICATION

2.3.1 Structural Fabrication

Structural fabrication shall conform with the requirements shown and specified herein and in Section 05 50 14 STRUCTURAL METAL FABRICATIONS.

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 or approved. Pin holes shall be bored in components after welding, straightening, stress-relieving, and threading operations are completed. Brackets, eye bar sections, and other

SECTION 35 20 16.33 Page 7 components requiring straightening shall be straightened by methods which will not damage the material. Bolt connections, lugs, clips, or other pick-up assembly devices shall be provided for components as shown and required for proper assembly and installation.

2.3.2 Bolted Connections

Bolted connections shall conform with the requirements specified in Section

05 50 14 STRUCTURAL METAL FABRICATIONS.

2.3.3 Machine Work

Machine work shall conform with the requirements specified in Section

05 50 14 STRUCTURAL METAL FABRICATIONS.

2.3.4 Miscellaneous Provisions

Miscellaneous provisions for fabrication shall conform with the requirements specified herein and in Section 05 50 14 STRUCTURAL METAL

FABRICATIONS.

2.3.5 Fabrications

2.3.5.1 Quoin and Miter Contact Blocks

Quoin and miter contact blocks shall be of alloy steel bars conforming to ASTM A322 UNS G41400. Splices in contact blocks shall be made as detailed in the drawings so that there will not be a continuous joint across the block. Waterstops shall be ASTM A322 UNS G41400. Contact blocks shall be provided with adjusting bolts as shown.

2.3.5.2 Rubber Corner Seal Seal Assemblies

Rubber Corner Seal assemblies shall consist of rubber seals with properties as specified in paragraph titled "Rubber Seals", and embedded metal retainer made of stainless steel plate as specified in paragraph titled "Stainless Steel Plate, Sheet, and Strip" and threaded stainless fasteners as specified in paragraph titled "MANUFACTURED UNITS". Provide stainless shims, stainless steel plate as specified in paragraph titled "Stainless Steel Plate, Sheet, and Strip" . Splices in seals shall be fully molded, develop a minimum tensile strength of 50 percent of the unspliced seal.

All vulcanizing of splices shall be done in the shop. The surfaces of finished splices shall be smooth and free of irregularities.

2.4 TESTS, INSPECTIONS, AND VERIFICATIONS

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

2.4.1 General

Tests, Inspections, and Verifications for materials shall conform to the requirements specified herein and in Section 05 50 14 STRUCTURAL METAL

FABRICATIONS.

SECTION 35 20 16.33 Page 8

PART 3 EXECUTION

3.1 INSTALLATION

Installation shall conform with the requirements specified herein and in Section 05 50 14 STRUCTURAL METAL FABRICATIONS. Miter gates and appurtenant items shall be assembled for installation in strict accordance with the contract drawings, approved installation drawings, and shop match-markings. Surfaces requiring lubrication shall be lubricated with an approved lubricant before assembly and installation..

3.1.1 Gate Leaf

Gate leaf components not assembled in the shop shall be assembled in the field as required for installation. All necessary precautions shall be taken to avoid distortion of the gate leaf or any component parts. Special care shall be exercised to prevent any sag of the miter ends.

3.1.2 Gate Leaf Quoin and Miter Contact Blocks

After the gate leaf diagonals are prestressed (completed by the Government, prior to the Contractor beginning construction on the miter gates) all contact block measurements and clearances shall be measured before existing contact blocks are removed. All existing contact blocks shall be removed, zinc filler removed, areas cleaned/blasted, side rails repaired, and threaded pull bolt threads cleaned/retapped.

Beginning the adjustment of the miter blocks requires first setting the mitering device to align the miter blocks and channels. The channels shall be set to be aligned, and it should be verified that the rubber J-seal is adequately on the sill. The gate leaf miter contact blocks shall be adjusted to provide contact at the top and 3/4" (+/- 1/8") gap, measured using a flexible shim feeler gauges, at the bottom for Gate 3 and 1/2" (+/- 1/8") gap at the bottom for Gate 1. The gap at the bottom of the miter contact blocks shall be evenly distributed between each leaf. With the top and bottom miter contact blocks adjusted and the mitering device set for a mitered position, the quoin contact blocks shall be adjusted such that 1/ 32" clearance between the quoin contact blocks and the wall quoin contact blocks is achieved as measured using a flexible shim feeler gauge.

Steamboat ratchets or equivalent may be attached to the downstream bottom girder of the miter contact blocks to pull the miter contact blocks together. The remaining/intermediate miter contact blocks shall then be adjusted to be fully in contact. Miter contact blocks must be totally in contact while the gates are in the loaded miter position similar to hydraulically loaded gates. The quoin contact blocks should also be in full contact at this time. With all contact blocks adjusted accordingly, the gates should be opened and a ten foot straight edge used to test the straightness of the blocks. All contacting surfaces shall be within 1/32" from the top and bottom block segment.

After final adjustments of gate leaf quoin and miter contact blocks have been made with the gate leaf in the mitered position, the gate leaf shall be swung out of miter and zinc filler poured behind the quoin and miter contact blocks (placing of zinc filler shall be completed by the Government). Prior to pouring of the filler, the surfaces to receive the filler shall be cleaned free of dirt, rust, and other foreign materials.

The adjusting and holding bolts shall be lubricated with grease or other bond breaker to prevent adherence of the zinc filler.

SECTION 35 20 16.33 Page 9

3.1.2.1 Placing Zinc Filler (SHALL BE COMPLETED BY THE GOVERNMENT)

Immediately preceding the pouring of the zinc filler, the adjacent metal components shall be enclosed in a contractor designed temperature control shelter. Metal preheating and zinc placement to be performed by the Government. The adjacent metal components shall be pre-heated to a temperature of 212 to 300 degrees F so as not to buckle the metal components. The zinc filler shall then be poured at a temperature which will insure that it will completely fill all interstices. Pouring temperature of zinc filler shall be maintained between 810 and 900 degrees F to minimize volatilization and oxidation of the zinc.

3.1.2.2 Adjusting Contact Blocks

After the contact blocks are adjusted, the gate leaves shall swing into the mitered position without interference of the quoin contact blocks and the gate leaf quoin contact post shall make tight contact with the wall quoin contact block. The zinc filler shall be poured after the contact blocks are adjusted (zinc placement to be performed by the Government). After the zinc has cooled, quoin and miter contact blocks shall be drawn up against the filler by tightening of the adjusting bolts.

****ADMT #0001****

3.1.3 Mock-Up and Test Placing of Zinc Filler

The contractor is required to provide a 10' mock-up structure as laid out in the drawings (S-209) to represent Poe Miter Gate and wall conditions.

The contractor is responsible for structurally stabilizing the mock-up.

The contractor is to provide an enclosure to shield the mock-up from wind and temperature extremes. Zinc pouring will be performed by the Government on the mock-up. The mock-up shall be located in one of the laydown areas shown on G-003 (specific location within the laydown areas shall be approved by the COR and Soo personnel) and must be completed 60 days prior to the construction start date in order for the Government to be able to coordinate test zinc pouring prior to the construction start date. The site layout should mimic actual site conditions and should include the temperature control shelter layout as intended to keep the steel at required temperature and for worker warmth. Any deviation from this configuration shall be thoroughly designed to meet the requirements of the specifications and be approved 120 days before construction start date. The test pour shall be conducted as specified in Paragraph Titled "Gate Leaf Quoin and Miter Contact Blocks" contained within this specification section.

After the test placement the Contractor shall dismantle and dispose of the mock-up stucrure.

****ADMT #0001****

3.1.4 Painting

Areas of miter and quoin post in which the existing paint has been damage due to heat from placing zinc filler shall be painted as specified in Section 09 97 02 PAINTING: HYDRAULIC STRUCTURES.

3.2 FIELD TESTS AND INSPECTIONS

3.2.1 Acceptance Trial Operation

After completion of the contact block installation, the Contracting Officer will examine the gates for final acceptance. The gates will be examined first to determine whether or not the workmanship conforms to the specification requirements. The gates will then beoperated from the

SECTION 35 20 16.33 Page 10 fully-opened to the fully-closed position a sufficient number of times to demonstrate to the Contracting Officer's satisfaction that all parts are functioning properly. The workmanship in the fabrication and installation of contact blocks shall be such that the gates in the closed position Shall be within the dimensional tolerances given the paragraph titled "Gate Leaf Quoin and Miter Contact Blocks". Required repairs or replacements to correct defects, as determined by the Contracting Officer, shall be made at no cost to the Government. The trial operation shall be repeated after defects are corrected. Prior to final acceptance of the gates, provide temporary restraints to prevent unauthorized operation of the gates.

3.3 PROTECTION OF FINISHED WORK

Protection of finished work shall conform to the requirements of Section

05 50 14 STRUCTURAL METAL FABRICATIONS.

-- End of Section --

SECTION 35 20 16.33 Page 11