Specifications_-_35_50_56.pdf

SECTION TABLE OF CONTENTS

DIVISION 35 - WATERWAY AND MARINE CONSTRUCTION

SECTION 35 50 56

MITER GATE ANCHORAGES REMOVAL AND INSTALLATION

PART 1 GENERAL

1.1 REFERENCES

1.2 SUBMITTALS

1.3 SUBMITTAL DESCRIPTIONS

1.3.1 Work Plan

PART 2 PRODUCTS

2.1 MATERIALS AND STANDARD ARTICLES

2.2 GOVERNMENT-FURNISHED MATERIAL AND EQUIPMENT

PART 3 EXECUTION

3.1 SEQUENCE OF WORK

3.1.1 Work Accomplished Prior to Lock Closure

3.1.2 Work Accomplished during Winter Lock Closure

3.2 SURVEY CONTROL SYSTEM

3.2.1 Survey Control Work Plan

3.2.2 Survey Control Records

3.3 Existing Anchorage Location Records

3.4 INITIAL CONCRETE DEMOLITION

3.5 REPLACEMENT ANCHORAGE AND PIN PLATE INSTALLATION

3.6 CONCRETE PLACEMENT

3.7 POSITIONING OF MITER GATES DURING ANCHORAGE DEMOLITION

3.8 REMOVAL PROCEDURE FOR MITER GATE ANCHORAGE LINKS AND RELATED

COMPONENTS

3.9 FINAL CONCRETE AND GATE ANCHORAGE DEMOLITION

3.10 INSTALLATION PROCEDURE FOR MITER GATE ANCHORAGE LINKS AND RELATED

COMPONENTS

3.10.1 Installation Of Replacement Bushings and Pins

3.10.2 Primary Link Pin Plate and Saddle for Gate 2

3.11 MITER GATE ADJUSTING

3.12 MISCELLANEOUS ITEMS

3.12.1 Existing Light Standards

3.12.2 Air Vent Recesses

3.12.3 By-pass Valve Stem Extensions

3.12.4 Existing Gate Anchorage

3.12.5 Existing Electrical Conduits

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SECTION 35 50 56 Page 1

SECTION 35 50 56

MITER GATE ANCHORAGES REMOVAL AND INSTALLATION

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.

RESEARCH COUNCIL ON STRUCTURAL CONNECTIONS (RCSC)

c/o AMERICAN INSTITUTE of STEEL CONSTRUCTION (AISC)

AISC 348-14 (2014) RCSC Specification for Structural Joints Using High Strength Bolts

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. The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Work Plan; G, MVS Survey Control Work Plan; G, MVS

Survey Control Records; G, MVS Bushing Hole Measurements Existing Anchorage Location Records; G, MVS

1.3 SUBMITTAL DESCRIPTIONS

1.3.1 Work Plan

The work plan shall include, at a minimum, the following information:

a. Proposed sequence of work.

b. Delivery plan for materials and assemblies to the lock.

c. Tools and machinery planned for use in demolition and installation of new anchorages, removal and installation of gate anchorage components.

d. Plan for locating anchorage in proper position; templates or patterns planned for use.

e. Plan for assembly of slip-critical anchorage pin plate and shear key connections, including tensioning method and description of required verification testing.

f. Plan to prevent the miter gates from being frozen in.

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h. Plan for setting and leveling anchorage frames.

i. Plan for sequencing the assembly of anchorage components, slip-critical components.

j. Plan for conducting off-site work as part of this Contract.

k. Plan for locating existing anchorage frames prior to initial demolition and saw cutting.

PART 2 PRODUCTS

2.1 MATERIALS AND STANDARD ARTICLES

Materials and standard articles shall conform to the respective specifications and other designated requirements. Sizes shall be as specified or shown on the drawings. Where material requirements are not specified, materials furnished shall be suitable for the intended use and shall be subject to the approval of the Contracting Officer.

2.2 GOVERNMENT-FURNISHED MATERIAL AND EQUIPMENT

Pursuant to Contract Clause "FAR 52.245-2, Government Property (Fixed Price Contracts)", the Government will furnish the following materials and equipment for installation by the Contractor:

3 1/8" thick steel plate ASTM A709, Grade HPS 70W (quantity 1)

2 1/2" thick steel plate ASTM A709, Grade HPS 70W (quantity 1)

Steel plate dimensions are shown at the end of this section. Material Test Report (MTR) are available for this material. This material is suitable for use in fabricating pin plates detailed on Sheet SG505.

PART 3 EXECUTION

3.1 SEQUENCE OF WORK

3.1.1 Work Accomplished Prior to Lock Closure

This work shall be conducted with the navigation lock open. The Contractor shall not interfere with operation of the lock. Work prior to lock closure shall be accomplished in the following sequence:

a. Shop fabrication of anchorage frames, as specified in SECTION 05 59 13. Shop fabrication of miscellaneous steel, including pins, bushings, and recess seat angles, as speified in SECTION 05 50 15.

b. Mobilize equipment and materials to the Soo Lock Complex.

c. Establish Survey Control System, as specified herein.

d. Relocation of electrical circuits as necessary.

e. Anchor rod demonstration testing.

f. Initial concrete demolition, including removal of existing light

SECTION 35 50 56 Page 3 standards, as specified herein.

g. Concrete drilling and installation of anchor rods as specified in SECTION 03 01 33 and herein.

h. Installation of replacement anchorage frames, as specified herein.

i. Installation of dowels and concrete, as specified in SECTION 03 31 01.00 10 and herein. Relocation of air vent recesses and light standards.

3.1.2 Work Accomplished during Winter Lock Closure

Winter lock closure work shall be accomplished in the following sequence:

a. Placement of gate(s) at miter position; load relief to anchorages, as specified herein.

b. Disassembly of anchorage components, as specified herein.

c. Final demolition of concrete and existing anchorage frame, as specified herein.

d. Installation of pin plates into replacement anchorage frames, as specified herein.

e. Installation of remaining dowels and concrete, as specified herein and in SECTION 03 31 01.00 10.

f. Reassembly of anchorage components with new bushings and pins, as applicable, as specified herein.

g. Release of mitered gate and adjustment of anchorages, as specified herein.

3.2 SURVEY CONTROL SYSTEM

The Contractor shall create a Survey Control System to re-establish the location of the new gate anchorages in the same location as the existing anchorages. The replacement anchorages shall be installed on the same horizontal alignment as the existing anchorages and the pin plate(s) shall be at the same elevation as the existing pin plates. On drawing SG601, Control Pts. A and B shall be used to define the horizontal alignment of the replacement anchorages. The centerline of the pin plates is also shown on Drawing SG601. The Contractor may add additional control points as necessary to ensure the Survey Control System is adequate to acheive the below specified accuracy. The system shall provide a positional uncertainty based on a 95-percent confidence level. The positional tolerance of all points located, established, or identified as part of this survey shall have a maximum positional uncertainty of 0.01 feet relative to all other points located, established, or identified as part of this survey. The control system may be independent and local at each anchorage replacement location.

All coordinates shall be reported in the local coordinate system of the facility, which is known as the Canal system. The government will provide four horizontal control points in the vicinity of the project with published coordinates. The government will provide the elevation of the canal datum benchmark, which is located on the Davis building.

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3.2.1 Survey Control Work Plan

The Contractor shall prepare a Survey Control Work Plan describing the methods that will be used for the Survey Control System and shall contain, at a minimum, the following information.

a. Description of the vertical measurement system used to locate and measure all survey points. Identification of the vertical measurement system shall, at a minimum, shall contain the reference datum and units of measure. Local vertical systems, if used, shall have a minimum of three recoverable reference points.

b. Use of appropriate error propogation and other measurement design theory to select the proper instruments, field procedures, geometric layouts and computational procedures to control and adjust random and systematic errors in order to achieve the allowable positional tolerance of all survey points.

c. Calibration information for each distance measuring instrument, stating the calibration requirements of the instrument manufacturer and the calibration history of the instrument.

3.2.2 Survey Control Records

The Contractor shall maintain records of all field measurements, notes, sketches, and computations relating to all survey points recovered, established, or computed. Survey Control Records shall also include a Contractor provided Survey Point Report identifying, at a minimum, point descriptions and recovery information, point establishment methods, and point coordinate values along with positional error estimates.

3.3 Existing Anchorage Location Records

The contractor shall expose, as shown on the drawings, and locate the existing anchorages prior to initial demolition and saw cutting. The existing anchorages shall be located at the intersection of the existing anchorage and concrete elevation 119.12 and at the interface between the initial and final demolition. During concrete demolition, the existing anchorage shall not be distributed. The contractor shall locate each existing anchorage relative to control point A and B per drawing SG601. The vertical and horizontal locations shall be located to an accuracy of 1/8".

Records shall be maintained in accordance with Section 3.2.2 of this specification. Existing anchorage location records shall be submitted to the Government concurrently with the shop drawings being submitted in accordance with specification Section 05 59 13.

3.4 INITIAL CONCRETE DEMOLITION

Initial concrete demolition shall be conducted during the navigation season with the lock in operation. During Initial concrete demolition, the existing anchorages shall not be disturbed. Concrete shall be demolished to the extent that anchor rods and the anchorage frames may be fully installed without the pin plates as shown on the drawings. Existing light standards that interfere with concrete demolition shall be removed and stored for later reinstallation. Anchorage recess cover plates shall be removed and retained for later reinstallation. Concrete demolition shall be in accordance with SECTION 02 41 00.

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3.5 REPLACEMENT ANCHORAGE AND PIN PLATE INSTALLATION

After initial concrete demolition and anchor rod demonstration tests are complete, anchor rod holes shall be drilled and anchor rods installed. The Contractor shall be aware of embedded conduits and shall have taken previous measures to de-energize any conduits and re-route wiring. The Contractor shall use a template, pattern, or other means to ensure anchor rods are precisely located in order for the anchorage and connecting pin holes to be in the correct locations. After the anchor rods are installed and grouted, the Contractor shall install the anchorage, and, using a template, pattern, or other means, properly position the anchorage. The contractor shall level and vertically adjust the anchorage using the leveling anchors as shown on the drawings or other methods proposed by the Contractor and included in the approved work plan. After the anchorage is properly positioned, both horizontally and vertically, grout shall be installed under the anchorage as shown on the drawings. The Contractor shall ensure that grout completely fills the void between the anchorage frame and the concrete below; the Contractor shall also block grout material out of the anchor rod holes by applying titanium putty between the bottom anchorage flange hole and anchor rod. The Contractor shall ensure that a debonding agent is applied to the anchor rods for the portions shown on the drawings. After the grout has cured, high strength epoxy compound shall be installed in the anchorage anchor rod holes as shown on the drawings. After grout and compounds have cured, the anchor rod nuts and washers shall be installed as specified in Section 03 01 33. After final concrete demolition and demolition of the top portion of the existing anchorage frame, the pin plates may be installed; install the pin plates and shims as shown on the drawings. Please note that as specified on the drawings, all pin plates and shims shall be matched to a particular anchorage frame to provide a clearance fit of 0.01 inches or less at any point within the faying surfaces, after taking into account the required coating thickness on the faying surfaces. Some small adjustments in pin hole location may be accomplished by using the small clearance available in the bolt holes. Pin plates shall be aligned using the actual or dummy pin to ensure that top and bottom pin plates are on the same vertical axis.

The Contractor shall ensure that all pin plates and shims are aligned and flush with one another. After proper alignment of the pin plates and shims is acheived, install the connecting bolts and washers as shown on the drawings. For the primary anchorage, pretensioning of the connecting bolts shall not be accomplished until all components of the anchorage are assembled, installed and properly aligned, including the lever arm, primary pin Mk 21/18-20, and spring box pin Mk 21/19A-4. The bolts shall be pretensioned in accordance with Research Council on Structural Connections "Specification for Structural Joints Using High Strength Bolts", AISC 348-14.

The Contractor shall ensure that faying surfaces for this connection are coated with system no. 1 as specified in SECTION 09 97 13.00 40 STEEL COATINGS. The Contractor shall complete preinstallation verification tests in accordance with AISC 348-14 Section 7.2. After the placement of the anchorage frame has been approved by the Contracting Officer, a portion of the anchorage frame shall be coated with a debonding agent as shown on the drawings and in the specifications.

3.6 CONCRETE PLACEMENT

The Contractor shall install reinforcing steel and place new concrete into demolished areas as shown on the drawings. The contractor may place concrete into initial demolition areas prior to final demolition. After the pin plates are installed and the pin hole locations have been verified as correct, the Contractor shall install dowels and backfill demolished

SECTION 35 50 56 Page 6 concrete areas with new concrete as shown on the drawings. Reinforcing dowels shall be installed with epoxy grout as shown on the drawings and as specified. Recess seat angles shall be fabricated and installed as shown on the drawings. Hydraulic head shall not be released until all components of the anchorage frame and anchorage link assembly are installed, all new conrete has acheived the specified strength as specified in SECTION 03 31 01.00 10, and the Contractor has received written approval from the Contracting Officer.

3.7 POSITIONING OF MITER GATES DURING ANCHORAGE DEMOLITION

After lock closure, but before final demolition of the existing miter gate anchorages, the Government will place the miter gate being worked on in the miter position and apply full hydraulic head to the miter gate; see Section 01 35 13 - Special Project Procedures for specific sequence information.

"Full hydraulic head" is defined as the gate supporting the natural upper river level on the upstream face and the natural lower river level on the downstream face of that gate. If the optional work is awarded, final demolition for gates 2 and 5 cannot be performed concurrently; only one of gates 2 or 5 may have hydraulic head applied at one time. The chamber will be maintained at either the upper or lower level using valve settings adjusted by the Government. Hydraulic head shall not be released until all components of the anchorage frame and anchorage link assembly are installed, all new conrete has achieved the specified strength as specified in SECTION 03 31 01.00 10, and the Contractor has received written approval from the Contracting Officer. The Contractor shall install and maintain a system, such as bubblers, to prevent the gates from being frozen in. A description of this system shall be included in the work plan

3.8 REMOVAL PROCEDURE FOR MITER GATE ANCHORAGE LINKS AND RELATED COMPONENTS

The miter gate leaves shall be placed in the mitered position with hydraulic head applied as described above, so that load to the anchorage links is relieved. The Contractor shall record the distances between the centerline of connecting pins on the anchorage links shown on reference drawing D1-36-4 in order to reinstall the links in the same orientation.

During the removal procedure, the anchorage links shall be supported by blocking or other means to prevent damage. The Contractor shall disassemble lubrication lines and set them aside for later reinstallation.

At this point connecting pins MK 21/18-20 (2 locations),and 21/18-8 (2 locations), as shown on D1-36-4, shall be removed using a crane. Any alternate method of removing the connecting pins must first be approved by the Contracting Officer. After the connecting pins are removed, the gudgeon pin MK 21/18-3 shall be removed by use of an auxiliary crane. Any alternate method of removing the gudgeon pin MK 21/18-3 must first be approved by the Contracting Officer. All associated hardware removed shall be retained for use during the installation, as applicable. After gudgeon pin MK 21/18-3 is removed, the anchorage link assembly shall be rotated until clear of the gate and removed from the recess area. The gate anchorage assembly shall be disassembled. The Contractor shall disassemble the anchorage links by removing the sleeve nuts. The Contractor shall clean and degrease the threads of the link bars and sleeve nuts and deliver same to the Soo Area Shops within 7 working days of removal. The Government will inspect the threads, reassemble the link bars within 4 working days per assembly. The Contractor shall pickup the assemblies at the Soo Area Shops. The lever arm, MK 21/19A-1, reference drawing D1-36-6, shall be retained by the Contractor; the Contractor shall remove and replace bushings in the lever arm as shown on the drawings and specified herein. The Contractor shall also remove and replace Gudgeon Pin steel

SECTION 35 50 56 Page 7 bushings, as shown on the drawings and specified herein. The Contractor shall clean and degrease the gudgeon pin plate area for inspection. The Contractor shall verify the gudgeon yoke pin plates match as-built conditions. Any alternative method for disassembly of anchorage linkages and components shall be detailed in the work plan and approved by the Contracting Officer and Soo Yards and Maintenance Shops (SYM).

3.9 FINAL CONCRETE AND GATE ANCHORAGE DEMOLITION

Prior to final demolition, the Contractor shall survey the location of all connecting pins in accordance with paragraph 3.2, Survey Control System, and plan Sheet SG601, Survey Control Points, to ensure that replacement anchorages are properly located. After the Survey Point Report has been submitted, in accordance with paragraph 3.2.2, to the Government and the Contractor has received written approval from the Government, the Contractor may proceed with final demolition. After the miter gate is mitered with hydraulic head applied and load to the anchorages is relieved, with anchorage links and pins removed, the Contractor shall proceed with final concrete demolition and demolition of the top portion of the existing anchorage as shown on the drawings.

3.10 INSTALLATION PROCEDURE FOR MITER GATE ANCHORAGE LINKS AND RELATED

COMPONENTS

The Contractor shall ensure that all anchorage links are set to the original distance between connecting pins measured before the links were disassembled. The existing lever arm, MK 21/19A-1 shall be reinstalled into the primary anchorage and connected to the spring box with new connecting pins. The anchorage bar assembly shall be moved into position and new gudgeon pin MK 21/18-1 shall be installed. At this point the connecting pins to the lever arm and secondary anchorage shall be installed. Connecting pin keeper plates shall be reinstalled. Lubrication lines shall be reconnected to the original locations. All grease lines shall be pumped with clean grease until lines are purged prior to re-assembly; grease provided by Contractor shall be compatible with existing grease in use.

3.10.1 Installation Of Replacement Bushings and Pins

Bushings and pins called out with mark numbers on sheets M2701 and M5701 shall be fabricated and installed. Certain locations where bushings are called out do not currently have bushings installed. At these locations the Contractor shall bore the holes as shown on the drawings to accommodate new bushings. The locations include the spring box lugs and Gudgeon pin holes as detailed on sheet M2702 and M5702. For all locations where existing bushings are to be removed and replaced, the Contractor shall measure the existing holes after bushing removal and submit the bushing hole measurements to the Government.

3.10.2 Primary Link Pin Plate and Saddle for Gate 2

The primary anchorage pin plate connects to the primary link pin plate as shown on the drawings. At this pin connection, the bearing plate must be affixed in the proper position to prevent lateral translation of the joint under operation. At assembly of the primary anchorages for gate 2, the pin plates, primary link pin plates, and saddle shall be assembled first. When the proper position of these components has been acheived, the bearing plate shall be positioned using the anchor bolt leveling nuts and washers until the bearing plate is in firm contact with the primary pin plate

SECTION 35 50 56 Page 8 bearing surface. After the position of the bearing plates has been approved by the Contracting Officer, high strength non-shrink grout shall be placed behing the bearing plate as shown on the drawings.

3.11 MITER GATE ADJUSTING

After the anchorage links have been installed, each gate shall be rotated throughout its full travel range, then the gate shall be moved to the miter position. Adjustment of the anchor bars shall consist of turning the sleeve nuts on the anchorage links so that the quoin blocks and miter blocks are in firm contact when the gate is in the mitered position and the difference in elevation between the quoin end and miter end is not greater than 1/2-inch in the miter position or the open position. Adjustment of the sleeve nuts for the anchorage links is accomplished with the gate leaf in the mitered position. The Government may conduct strain gage testing of the anchorage links to determine the suitable adjustment of the anchorage links. The Contractor shall make further adjustments based on this testing and as directed by the Contracting Officer.

3.12 MISCELLANEOUS ITEMS

3.12.1 Existing Light Standards

An existing light standard in the vicinity of Gate 5 primary anchorages interfere with installation of the new anchorage frames. Existing light standards shall be preserved for re-use. Contractor shall ensure embedded portion of light standard is encompassed within the major block removal of the shear key demolition area. After major block removal, contractor shall prepare the light standard for later installation by sawcutting concrete from the embedded portion of the light standard as much as practicable.

Light standards shall be re-installed at the new location as shown on the drawings; at the correct elevation and perfectly plumb. Electrical lines shall be re-routed as shown on the plan sheets. During demolition, handling and re-installation, the contractor shall take all necessary measures, including temporary supports, as necessary to prevent damage to the existing light standards.

3.12.2 Air Vent Recesses

An 8" diameter air vent with associated vent recess and runoff drain pipes interfere with the installation of the new secondary anchorage frames at Gate 5. These items shall be demolished and re-establised as shown on the drawings using new vent and drain pipes and flap valve.

3.12.3 By-pass Valve Stem Extensions

The by-pass valve stem extensions located within the demolition area of Gate 5 secondary anchorages shall remain in-place and be preserved. The Contractor shall take measures to protect the stem extension during concrete demolition by limiting methods to hand tools or smaller power tools in the vicinity of the stem. Concrete demolition shall completely expose the steel pipe sleeve of the stem within the demolition area.

3.12.4 Existing Gate Anchorage

The existing mastic material located around the existing gate anchorages contains asbestos. Contractor shall follow applicable sections of EM 385-1-1 during demolition in this area. Mastic locations are defined on the reference drawings.

SECTION 35 50 56 Page 9

3.12.5 Existing Electrical Conduits

The existing electrical conduits are asbestor-cement. Contractor shall follow applicable setion of EM 385-1-1 during demolition, drilling, and cable pulling.

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SECTION 35 50 56 Page 10