Technical_Specifications_Amendment_0001.pdf

TDA Navlock Projects - US Gate, Controls, Gudgeon

SECTION TABLE OF CONTENTS

DIVISION 01 - GENERAL REQUIREMENTS

SECTION 01 11 00.00 25

SUMMARY OF WORK

PART 1 GENERAL

1.1 SUMMARY

1.2 WORK COVERED BY CONTRACT DOCUMENTS

1.2.1 Project Description

1.2.2 Location

1.3 INTERIM CONSTRUCTION COMPLETION DATE

1.4 CONTRACT DRAWINGS

1.5 OCCUPANCY OF PREMISES

1.6 EXISTING WORK

1.7 GOVERNMENT-FURNISHED MATERIAL AND EQUIPMENT

PART 2 PRODUCTS - NOT USED

PART 3 EXECUTION - NOT USED

-- End of Section Table of Contents --

SECTION 01 11 00.00 25 Page 1

SECTION 01 11 00.00 25

SUMMARY OF WORK

PART 1 GENERAL

1.1 SUMMARY

This Section provides a summary of the various Contract work elements and their relationship to each other. This Section does not provide the technical detail for particular work activities, but describes the work as a whole, providing overall perspective to the separate tasks and their interrelationships. Use this Section in conjunction with all the Specification Sections and the Drawings to establish the total work requirements.

1.2 WORK COVERED BY CONTRACT DOCUMENTS

1.2.1 Project Description

a. The work planned for this contract includes the removal and replacement of the following components

Mandatory:

(1) Upstream gate structure and anchors

(2) Upstream gate mechanical equipment

(3) Upstream gate controls

(4) Downstream gate gudgeon

Optional:

(5) Main switch gear (LCQ) with GFE

(6) Controls upgrade

(7) Downstream gate cathodic protection

(8) Downstream gate quoin blocks

(9) Downstream gate lower gate seal

(10) Downstream gate mechanical operating system

(11) Tainter valve HPU

b. The planned work will include providing all temporary utilities, power load requirements, and other ancillary work to support the work called out in this contract.

1.2.2 Location

The work will be located at The Dalles Lock and Dam. Contractor access to

SECTION 01 11 00.00 25 Page 2 the work site will be from The Dalles Lock and Dam North gate.

1.3 INTERIM CONSTRUCTION COMPLETION DATE

In accordance with Section 00800 Contract Clause 52.211-10 and 52.211-12, work must be completely finished as specified for each of the dates.

a. Interim completion date for trunnion hub assembly: 1 July 2016

b. Interim completion date for Government commissioning: Construction must be complete and ready for Government commissioning at 8:00 A.M. on 06 March 2017. Prior to Government commissioning, all features must be complete, all systems must be functional, and all Contractor required testing must be complete.

c. FINAL CONSTRUCTION PHYSICAL COMPLETION: All construction, features in the Plans and Specifications, temporary construction supports, construction aids and construction debris must be removed from the site. The date stated for completion must include all work and final cleanup of the premises.

d. CONTRACT END DATE: All submittals, As-Built Drawings, O&M Manuals and all other requirements submitted and approved.

1.4 CONTRACT DRAWINGS

a. The Drawings that accompany these Specifications are a part thereof.

b. One set of full size Contract drawings, maps, and Specifications will be furnished to the Contractor without charge per Section 00700 Contract Clause 252.236-7001, CONTRACT DRAWINGS AND SPECIFICATIONS.

Reference publications will not be furnished.

c. Contractor must immediately check furnished Drawings and notify the Government of any discrepancies.

1.5 OCCUPANCY OF PREMISES

a. Building(s) will be occupied during performance of work under this Contract.

b. Before work is started, the Contractor must arrange with the Contracting Officer a sequence of procedure, means of access, space for storage of materials and equipment, and use of approaches, corridors, and stairways.

1.6 EXISTING WORK

In addition to Section 00700 Contract Clause 52.236-9, PROTECTION OF

EXISTING VEGETATION, STRUCTURES, EQUIPMENT, UTILITIES, AND IMPROVEMENTS:

a. Remove or alter existing work in such a manner as to prevent injury or damage to any portion of the existing work to remain.

b. Upon completion of the work, repair or replace portions of existing work, which have been damaged by Contractor's operations, to preconstruction conditions at the expense of the Contractor.

SECTION 01 11 00.00 25 Page 3

1.7 GOVERNMENT-FURNISHED MATERIAL AND EQUIPMENT

a. Pursuant to Contract Clause 52.245-1, GOVERNMENT PROPERTY, the Government will furnish the following materials and equipment for installation by the Contractor:

ITEM NO. DESCRIPTION QUANTITY

1 4160V Load Break 2 Switches - ZP1 and ZP2

2 4160:480V Dry-Type 2 Transformers - T1 and T2

3 480V Switchgear - LSQ 1

4 High Resistance Grounding 2 Units - HRG1 and HRG2

5 Remote Breaker Control 1 Panel - LSQR

6 480V Motor Control 1 Center - LCQ

7 480V Distribution 2 Panels - SQ5 and SQ6

8 480:240/120V Dry-Type 1 Transformer - T7

9 240/120V Panel - SR7 1

10 #12 Multi-Conductor Cable 2500 FT 2-Conductors + Ground

11 #12 Multi-Conductor Cable 1000 FT 12-Conductors

12 #12 Multi-Conductor Cable 200 FT 6-Conductors

13 #10 Multi-Conductor Cable 300 FT 2-Conductors + Ground

14 #10 Multi-Conductor Cable 650 FT 3-Conductors + Ground

15 #10 Multi-Conductor Cable 650 FT 3-Conductors + Ground

16 #8 Multi-Conductor Cable 8700 FT 3-Conductors + Ground

17 #6 Single-Conductor Cable 20 FT Ground Wire

18 #4 Multi-Conductor Cable 1200 FT 3-Conductors + Ground

SECTION 01 11 00.00 25 Page 4

ITEM NO. DESCRIPTION QUANTITY

19 #4 Single-Conductor Cable 20 FT

20 #2 Multi-Conductor Cable 5050 FT 3-Conductors + Ground

21 #1 Single-Conductor Cable 30 FT

22 1/0 Single-Conductor Cable 300 FT 5KV Medium Voltage

23 1/0 Multi-Conductor Cable 1300 FT 3-Conductors + Ground

24 2/0 Multi-Conductor Cable 2950 FT 3-Conductors + Ground

25 3/0 Multi-Conductor Cable 1400 FT 3-Conductors + Ground

26 4/0 Multi-Conductor Cable 500 FT 3-Conductors + Ground

27 350 Multi-Conductor Cable 3900 FT 3-Conductors + Ground

b. Quantities stated for the above items are all that will be furnished by the Government. Contractor must furnish any additional quantities required.

PART 2 PRODUCTS - NOT USED

PART 3 EXECUTION - NOT USED

-- End of Section --

SECTION 01 11 00.00 25 Page 5

DIVISION 05 - METALS

SECTION 05 59 13.00 25

STRUCTURAL STEEL FABRICATION OF UPSTREAM GATE

PART 1 GENERAL

1.1 SUMMARY

1.2 REFERENCES

1.3 SYSTEM DESCRIPTION

1.3.1 Weld Tracking Log Template

1.3.2 Weld Tracking Log

1.3.3 Welding Procedure Specifications (WPS)

1.3.4 Fracture Critical Members (FCM)

1.3.5 NDT Written Practice

1.4 SUBMITTALS

1.5 QUALITY ASSURANCE

1.5.1 Qualification of Welders and Welding Operators

1.5.2 Inspector Qualifications

1.5.3 Qualification of Structural Steel Fabricator

1.5.4 Quality Assurance Testing by the Government

1.5.5 Shop Drawings

1.6 DELIVERY, STORAGE, AND HANDLING

PART 2 PRODUCTS

2.1 FABRICATION

2.1.1 Structural Fabrication

2.1.2 Assembly and Fabrication Sequencing Plan

2.1.3 Splicing Restriction

2.1.4 Materials Disposition Record

2.1.5 Welded Connections

2.1.5.1 Additional Welded Connections Requirements for Trunnion Hub

Assembly and Mock-up

2.1.5.2 Stress-Relief Heat Treatment

2.1.6 Miscellaneous Provisions

2.1.7 Shop Assembly

2.2 Testing and Inspection

2.2.1 General

2.2.2 Nondestructive Testing

2.2.3 Inspection of Structural Steel Welding

2.2.4 Welds to be Subject to Nondestructive Examination

2.2.5 Test Coupons

2.2.6 Supplemental Examination

2.2.7 Structural Steel Welding Repairs

2.2.8 Control Dimensions

2.3 MISCELLANEOUS METALS AND STANDARD METAL ARTICLES

2.3.1 General

2.3.2 Structural Carbon Steel

2.4 RUBBER SEALS AND RETAINING HARDWARE

2.4.1 General

SECTION 05 59 13.00 25 Page 1

2.4.2 Rubber Bulb and Flapper Seals

2.4.3 Neoprene Rubber Gaskets

2.4.4 Seal Retaining Hardware and Side Roller Bolts

PART 3 EXECUTION

3.1 INSTALLATION

3.1.1 Cleaning

3.1.2 Alignment and Setting

3.2 PROTECTION OF FINISHED WORK

3.3 PAINTING

3.4 SEALS

SECTION 05 59 13.00 25 Page 2

SECTION 05 59 13.00 25

STRUCTURAL STEEL FABRICATION OF UPSTREAM GATE

PART 1 GENERAL

1.1 SUMMARY

This section covers the fabrication of the upstream gate.

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.

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

AISC 303 (2010) Code of Standard Practice for Steel Buildings and Bridges

AISC 325 (2011) Steel Construction Manual

AISC 326 (2009) Detailing for Steel Construction

AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING (ASNT)

ANSI/ASNT CP-189 (2011) ASNT Standard for Qualification and Certification of Nondestructive Testing Personnel (ANSI/ASNT CP-105-2006)

ASTM INTERNATIONAL (ASTM)

ASTM A325 (2014) Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength

ASTM A563 (2007a; R2014) Standard Specification for Carbon and Alloy Steel Nuts

ASTM A668/A668M (2014) Standard Specification for Steel Forgings, Carbon and Alloy, for General Industrial Use

ASTM A709/A709M (2013a) Standard Specification for Structural Steel for Bridges

ASTM D395 (2014) Standard Test Methods for Rubber Property - Compression Set

ASTM D412 (2006a; R 2013) Standard Test Methods for Vulcanized Rubber and Thermoplastic Elastomers - Tension

ASTM D471 (2012a) Standard Test Method for Rubber

SECTION 05 59 13.00 25 Page 3

Property - Effect of Liquids

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

ASTM D2240 (2005; R 2010) Standard Test Method for Rubber Property - Durometer Hardness

ASTM E165 (2009) Standard Test Method for Liquid Penetrant Examination

ASTM E709 (2014) Standard Guide for Magnetic Particle Examination

ASTM F436 (2011) Hardened Steel Washers

AMERICAN WELDING SOCIETY (AWS)

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

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

AWS A2.4 (2012) Standard Symbols for Welding, Brazing and Nondestructive Examination

AWS A3.0M/A3.0 (2010) Standard Welding Terms and Definitions

U.S. ARMY CORPS OF ENGINEERS (USACE)

EM 385-1-1 (2014) Safety and Health Requirements Manual

1.3 SYSTEM DESCRIPTION

a. Provide structural material fabricated and assembled meeting the requirements of AASHTO/NSBA Steel Bridge Collaboration "Steel Bridge Fabrication Guide Specification" and AWS welding codes, except as modified in this document.

b. Before the start of work, the fabricator is to supply a Quality Control Plan (QCP) to the Engineer for approval. Ensure the QCP describes the methods, equipment, and procedures which will be utilized to ensure quality control. The Engineer will use the AASHTO/NSBA, "Steel Bridge Fabrication QC/QA Guide Specification," as the basis for approving the QCP.

c. Submit a Material Tracking Log Template. The material tracking log template must identify how all material will be tracked in the fabrication shop from receiving through complete assembly. Use low stress die stamps for the identification coding of material. Stamp each component with low-stress stamping to include the project number, part number, and additional required information to permit tracking of material. Use material travelers to conform with the material tracking log and quality control plan.

d. The contractor/fabricator has the responsibility to ensure that all work performed complies with the QCP and generate Non Conformance

SECTION 05 59 13.00 25 Page 4

Reports (NCR's)for all work deemed to not meet quality control standards. If the Government determines that fabrication work does not comply with the QCP or that fabrication does not follow approved fabrication procedures, the Government will deem the materials as non-conforming. If the Government finds non-conforming work, the prime contractor must direct the fabricator/subcontractor to immediately correct the procedure, conduct additional tests, and submit a written non-conformance report containing data required by the Government to ensure compliance with the QCP. Perform additional testing as required by the Government at no additional cost to the Government.

e. During each stage of fabrication of major structural components, ensure the fabricator provides and maintains material identification to establish the heat of the material from which the component is fabricated. Provide the Engineer with a list showing heat numbers referenced to the material incorporated into each component. The Engineer will reject material that loses its material identification unless the identity can be re-established to the satisfaction of the Engineer. Material Test Reports or Certified Test Reports must be submitted for all material used in fabrication prior to incorporation into the structure.

f. Provide fracture critical members with identification numbers placed on each individual piece of material that is referenced to the corresponding heat number.

g. Properly document all nonconformances using a Nonconformance Report form. Submit a Non Conformance Report Form Template prior to fabrication. The Non Conformance Report Template will be used during fabrication to record and submit all Nonconformances. Submit a Non Conformance Report on the approved form to the Engineer documenting any deviation from the QCP, approved shop drawings, code, Work Plan and/or specifications.

h. Include the following in the Non-conformance Report form:

(1) Company name and address,

(2) Report title,

(3) Non-conformance Report number,

(4) Date,

(5) Company job number,

(6) Piece mark,

(7) Owner of structure,

(8) Contractor,

(9) Owner's project number,

(10) Location,

(11) Detailed description of the non-conformance,

(12) Photo, sketch, or drawing, SECTION 05 59 13.00 25 Page 5

(13) Proposed repair/disposition of the non-conformance, and

(14) Quality Control Manager's signature and date.

i. 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. Update the Work Plan as conditions warrant. The procedures must provide 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 fabrication of the following listed structures under this contract must be performed according to this section of the specifications:

(1) Upstream navigational lock tainter gate

(a) Material with welds will not be accepted unless the welding is specified or indicated on the drawings or otherwise approved.

Welding must not be started until welding procedures, inspectors, nondestructive testing personnel, welders, welding operators, and tackers have been qualified and approved. Each Contractor performing welding must 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 theDistrict engineer of record.

(c) Schedule a Prefabrication Conference as soon as possible after Notice to Proceed and prior to any fabrication. The Prefabrication Conference must 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 must occur either at the Fabrication Facilities or a similar location as deemed appropriate. The format of the prefabrication conference must include a review of these specifications, discussion of the fabricator's QCP, identification of roles and responsibilities including roles and responsibilities of fabrication subcontractors. The contractor must prepare for this meeting by reviewing plans and specifications and code concerns prior to this meeting and be prepared to discuss any issues regarding the fabrication including WPS qualification requirements and required witnessing of testing. Complicated connections that may require prototyping for both welding and inspection must be identified and discussed. In addition, hold points/witness points must be established during the prefabrication conference.

1.3.1 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 by the Contractor as described in the following paragraphs.

SECTION 05 59 13.00 25 Page 6

1.3.2 Weld Tracking Log

Provide a log capable of individually identifying and tracking every weld on the project. Member identification must follow the numbering scheme shown on the shop drawings. The log must include the member to be welded, member type (FCM and Non-FCM), type of weld including temporary and tack welds which are not fully consumed, 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 (weld time required to designate required hold time prior to NDT), 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 must match weld tracking log identification. Continually maintain the weld tracking log. The weld tracking log, including draft copies of NDT testing, must be available on the shop floor during any inspection. A completed log must be bound together for each structure included in the Fabrication Record upon completion of the fabrication of each structure.

1.3.3 Welding Procedure Specifications (WPS)

Submit a Welding Procedure Specification (WPS) for each weld, including prequalified welds, in accordance with paragraph Welded Connections approved before fabrication is commenced. Welding Procedure Specifications must be individually identified and must be referenced on the shop drawings. In case of conflict between this specification and AWS D1.5M/D1.5 as applicable, this specification governs. The following items must not be considered ancillary items as defined in AWS D1.5 Section 1.3.6 and must be subjected to the same level of inspection required for primary welds under

AWS D1.5:

Seal hardware

1.3.4 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 must be ASTM A709/A709M, grade as specified or shown on the drawings, using killed fine-grain mill practice, unless otherwise shown or specified. Mill repairs of base metal are prohibited. Toughness must meet the requirements of ASTM A709/A709M, Table 9, for Zone 2, unless otherwise indicated or specified. All materials used for the construction of fracture critical components must meet the requirements of Section 10 of ASTM A709/A709M and must include mill certification showing that the material meets the necessary toughness requirements. Welding for fracture critical members must meet all requirements of AWS D1.5M/D1.5 Section 12, including:

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

b. 12.6 Consumable Requirements. All welding consumables must be heat or lot-tested by the manufacturer to determine conformance with the requirements of the Fracture Control Plan (FCP) in accordance with AWS D1.5M/D1.5 Section 12.6. Toughness test results must meet the values specified in Table 12.1 of AWS D1.5M/D1.5.

SECTION 05 59 13.00 25 Page 7

c. 12.7 Welding Procedure Specifications (WPS). All procedures, including repair welds, must 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 must 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 must meet the applicable requirements.

f. 12.13 Tack Welds and Temporary Welds. All welds must be located within the joint and must meet the requirements of AWS D1.5M/D1.5, Table 12.2. Temporary welds on FCM are not permitted. Any and all temporary welding required for the fabrication or assembly of welded components (i.e. lifting aides, assembly jigs etc.) must be submitted for Engineer approval prior to use.

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

h. 12.16 Weld Inspection. The Quality Control inspection program must be documented in the FCP. All inspectors and NDT technicians must be qualified as required. All butt joints must 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 must 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 must be as defined in AWS D1.5M/D1.5 section 12.17.6. All weld repairs to fracture critical members must be considered critical welds in accordance with AWS D1.5 Section 12.17.3 and must be approved by the engineer of record.

1.3.5 NDT Written Practice

The written practice must establish the minimum requirements for education, training, experience, examination and certification of personnel responsible for conducting nondestructive tests while in the employment of the contracted company. It applies to all persons conducting nondestructive tests that are required to be certified to the provisions of ANSI/ASNT CP-189. Additionally the methods of nondestructive testing are to be outlined and described in the written practice and explanation as to how they will be used in accordance with the applicable codes, standards and specifications. In addition to the written practice, submit NDT Equipment Calibration Records for all NDT equipment used by both the fabricator and any subcontractors performing NDE.

1.4 SUBMITTALS

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

submittals not having a "G" designation are for Contractor Quality Control approval. Submit the following in accordance with SECTION 01 33 00

SECTION 05 59 13.00 25 Page 8

SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Quality Control Plan (QCP); G

Material Tracking Log Template; G

Welding Procedure Specifications (WPS); G

Fracture Control Plan (FCP); G

Weld Tracking Log Template; G

Non Conformance Report Form Template; G

NDT Written Practice; G

NDT Equipment Calibration Records; G

Trunnion Hub Assembly Welding Technique; G

Mock-up Inspection and Acceptance Testing Results; G

SD-02 Shop Drawings

Shop Drawings; G

Assembly and Fabrication Sequencing Plan; G

Fabrication Quality Control Reports

Welding Repairs - Non-Fracture Critical Members; G

Welding Repairs - Fracture Critical Members; G

Heat Straightening Procedure

Delivery/Shipping Plan; G

SD-03 Product Data

Materials Disposition Record

Manufacturers' Product Data for Seal Material; G

SD-06 Test Reports

Certified Test Reports; G

Weld Tracking Log; G

Witness Points

Non Conformance Report

SD-07 Certificates

Work Plan; G

SECTION 05 59 13.00 25 Page 9

Qualification of Welders and Welding Operators; G

Inspector Qualifications; G

Qualification of Structural Steel Fabricator; G

SD-09 Manufacturer's Field Reports

Control Dimensions; G

Fabrication Record; G

1.5 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 must 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. 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. After the Contracting Officer and the Engineer of Record have 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 must be conducted after the first structure is completed. Final Fabrication Inspections of additional structures must 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.

1.5.1 Qualification of Welders and Welding Operators

Submit welder, welding operator and tacker qualification certification for each welder, welding operator or tack welder to the Contracting Officer and approved before fabrication is commenced in accordance with paragraph Welded Connections. Welder and welding operator qualification test records must be submitted on forms equivalent to the sample forms in AWS D1.5M/D1.5, Annex N. A CWI meeting the specified qualifications must approve all welder qualifications. Welders, welding operators, and tack welders must be limited to welding procedures for which they are certified. All welders performing fracture critical welds under this specification must be qualified according to Section 12 of AWS D1.5. All welders performing non fracture critical welds must be qualified according to Section 6 of AWS D1.5. All qualifications must 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.Test welds must be prepared, SECTION 05 59 13.00 25 Page 10 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 must 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 certification must be kept current for the duration of the contract.

1.5.2 Inspector Qualifications

All inspectors, performing structural steel inspection in accordance with these specifications, must 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 must be designated as having primary responsibility for all quality control in accordance with AWS D1.5 Section 6.1.2.2. The CWI who serves as the primary point of contact must provide evidence of having initially tested for certification in accordance with AWS D1.5M/D1.5 or possesses an AWS D1.5M/D1.5 endorsement. Alternately the CWI may be an SCWI to serve as this primary point of contact. Non-certified inspectors and certified associate weld inspectors (CAWI) must not be used for inspection under these specifications. All personnel who perform NDT must be qualified in accordance with: ANSI/ASNT CP-189 NDT Level II or III. All personnel performing NDT must be supervised by personnel possessing a Level III ASNT NDT certification in accordance with AWS D1.5 section 6.1.3.4 and section

12.16.1.2. An ASNT Level III may conduct tests if that person provides documentation of having passed a Level II practical examination within the last three years.

1.5.3 Qualification of Structural Steel Fabricator

a. The fabricating plant and fabricator must be certified under the AISC (American Institute of Steel Construction) Quality Certification Program with one of the following certifications and with a Fracture Critical endorsement (F):

(1) CBR: Major Bridge Fabrication

(2) IBR: Certified Bridge Fabricator - Intermediate

(3) ABR: Certified Bridge Fabricator - Advanced

b. The fabricating plant and fabricator must also possess five years documented experience on projects of similar scope. Similar scope must consist of having fabricated structures of similar size including total weight, member thicknesses and dimensions, geometry, tolerances, and handling requirements. Submit copies of the AISC certificate indicating that the fabrication plant meets the specified structural steelwork category and documented experience.

1.5.4 Quality Assurance 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 radiography,ultrasonic, magnetic partial, or any other test that will thoroughly investigate the part in question. The cost of such

SECTION 05 59 13.00 25 Page 11 investigation will be borne by the Government. Any defects will be cause for rejection and rejected materials or parts must be replaced and retested at the Contractor's expense.

1.5.5 Shop Drawings

a. Prior to performing any fabrication of the HSS structures listed in paragraph System Description above, complete, detailed shop drawings to the Contracting Officer and Engineer of Record for approval. Shop drawings must show complete details of materials, tolerances, connections, and proposed welding sequences. Shop drawings must include catalog cuts, templates, fabrication and assembly details, and type, grade, and class of materials, as appropriate. Utilize AWS A2.4, AWS A3.0M/A3.0, AISC 303, AISC 325, and AISC 326 for shop drawing preparation.

b. All FCM, including attachments that meet the FCM definition, must be identified on the shop drawings. All temporary and tack welds must be identified on the shop drawings. Each member must be identified following the numbering scheme shown on the drawings. A table must 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 must identify weld procedures and NDE required for each weld.

Any and all splices must be included in the shop drawings and clouded for engineer approval.

c. Elements of fabricated items inadvertently omitted on contract drawings must be returned to the Engineer of Record for detailing or must be detailed by the fabricator and so indicated on the shop drawings. Any and all details developed by the fabricator must be clouded on the shop drawings for separate approval by the Engineer of Record. Any items designed by the Contractor must be prepared and sealed by a Registered Professional Engineer. No splices must be included in the structure without approval of the Engineer of Record.

All field welds required must be identified on the shop drawings. Each weld, both shop and field welds, must be provided a unique identifier to permit tracking on the weld tracking log.

1.6 DELIVERY, STORAGE, AND HANDLING

Notify the Contracting Officer at least 28 days in advance of delivery of the structures. Store material above ground on platforms, skids, or other supports. Protect material from dirt, oil, and other foreign matter. Drain material so that water is never in constant contact with the surface.

Employ handling methods that do not result in damage to components during fabrication, assembly, loading, shipment, and unloading of components.

Replace damaged material with new material or repair using a procedure approved by the Engineer. Completed assemblies/structures must be protected from the environment. Shipping of the structures must be at the Contractor's expense. All structures must be delivered to The Dalles Dam navigational lock. Contractor coordination for delivery must be through the Portland District Contracting Officer. The structures must be arranged on the delivery vehicles such that no damage occurs during shipping. All sling lifting lugs must be directed up. Submit a Delivery/Shipping Plan showing orientation and locations of structures on the delivery vehicles prior to shipment for Government approval.

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PART 2 PRODUCTS

2.1 FABRICATION

2.1.1 Structural Fabrication

Material must be straight before being laid off or worked. If straightening is necessary, it must be done by methods that will not impair the metal. Sharp kinks or bends must 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 must be made by approved dies, press brakes or bending rolls. Cold bending of fracture critical members is prohibited. Where heating is required, precautions must be taken to avoid overheating the metal and it must 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, must be subject to approval and must be indicated on detail drawings. Shearing must be accurate and all portions of the work must be neatly finished.

Corners must be square and true unless otherwise shown. Re-entrant cuts must be filleted round to a minimum radius of 1 inch in accordance with AWS D1.5 section 3.2.4 unless otherwise indicated or approved. Members must be free of twists, bends and deformation. Straighten material without shearing, fracturing, stressing, or damaging the bolts, welds, or base metal. Use heat straightening methods approved by the Engineer. Replace material damaged during straightening operations with new material at no additional cost to the Government. Do not heat the metal unless allowed by the engineer, if allowed and before performing any straightening operations, submit a Heat Straightening Procedure to the engineer for review and approval. The Heat Straightening Plan must follow the FHWA publication "GUIDE FOR HEAT-STRAIGHTENING OF DAMAGED STEEL BRIDGE MEMBERS".

Do not heat metal to temperatures greater than 1200F. The use of cutting heads for heating and straightening will not be permitted. After heating and straightening, allow the metal to slowly cool to ambient before inspecting for evidence of fracture or other damage. If the Engineer determines it is not possible to straighten a member as part of an assembly, remove the bent material from the assembly, straighten, and re-assemble or replace the component as required by the Engineer. Cut steel and fabricate steel plates and splice plates for major structural components so the primary direction of rolling is parallel to the direction of the main tensile or compressive stresses. For CJP butt joint splices which will be ground flush, establish the center line of the weld on the components of the piece before welding by placing low-stress stamp punch marks 1 foot back from the center line of the weld and 1 inch from the edge of the plate on either side of the weld on both ends.

a. Dimensional Tolerances for Structural Work.

(1) Dimensions must be measured by an approved measuring system.

Submit the measuring system for approval with the Work Plan. The overall dimensions of an assembled structural unit must be within the tolerances indicated on the drawings or as specified for the item of work. Where tolerances are not specified in other sections of these specifications or shown, a variation of 1/32 inch is permissible in the overall length of component members with both ends milled and component members without milled ends must not deviate from the dimensions shown by not more than 1/16 inch for members 30 feet or less in length and by not more than 1/8 inch for members over 30 feet in length.

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(2) Structure dimensions indicated on the drawings are based on a structure temperature of 70 degrees F. The Contractor must be responsible for any and all dimensional adjustments to compensate for actual temperature variations during construction. Measure tolerances of the final assembly with the structure in the orientation in which it will be used.

b. Structural Steel Fabrication. Structural steel may be cut by mechanically guided or hand-guided torches, provided an accurate profile with a surface that is smooth and free from cracks and notches is obtained. Surfaces and edges must be prepared in accordance with AWS D1.5M/D1.5, Subsection 3.2. Hand-guided cuts must be chipped, ground or machined to sound metal.

2.1.2 Assembly and Fabrication Sequencing Plan

Provide drawings and detailed descriptions of the fabrication sequence of all components and subassemblies. Provide drawings and detailed descriptions of the assembly of components into the final structure. The assembly and fabrication sequencing plan must include details describing fit-up, welding and bolting sequences of individual components and the completed assembly, and required hold points necessary for weld inspection in accordance with the quality control plan or fracture control plan must be identified in the assembly plan. The Assembly and Fabrication sequence plan must be evaluated to show that the fabricator is sequencing the work to control distortion,shrinkage, residual stresses and to meet required tolerances.

2.1.3 Splicing Restriction

Fabricate and deliver the gate in one piece. Field splicing of the gate is not allowed.

2.1.4 Materials Disposition Record

Furnish the Contracting Officer three copies of all purchase and mill orders, shop orders for materials and work orders, including all new orders placed by Contractors and old orders extended for each supplier. Furnish, at the time of submittal of shop drawings, a list designating the material to be used for each item. Furnish a shipping bill or memorandum of each shipment of finished pieces or members to the project site, giving the designation mark and weight of each piece, the number of pieces, the total weight, and if shipped by rail in carload lots, the car initial and number. Provide materials from mills, warehouses, or processors with supporting certified MTRs meeting the requirements of applicable ASTM specifications. If the MTR does not contain sufficient information, provide copies of the test results to the Engineer for review and approval before fabrication. Track all material through fabrication with the use of material traveler records. Material traveler must be present on each assembled component in the fabrication shop.

2.1.5 Welded Connections

a. Welding Procedure.

(1) Welding must conform to the applicable provisions of AWS D1.5M/D1.5. Prior to the start of production welding, submit a complete schedule of welding procedures for a typical structure. The schedule must conform to the requirements

SECTION 05 59 13.00 25 Page 14 specified in the provisions of AWS D1.5M/D1.5. The schedule must provide detailed procedure specifications and tables or diagrams showing the procedures to be used for each required joint.

(2) Submit to the Contracting Officers Representative, a Welding Procedure Specifications (WPS) for each weld to be made. Submit Welding Procedure Specifications and Procedure Qualification Records (PQR) to the Contracting Officer for approval before fabrication is commenced. All WPS must be submitted with attached PQR and supporting test documentation on forms similar or equivalent to the sample forms in AWS D1.5M/D1.5, Annex III.

Copies of the Welding Procedure specification and the results of the procedure qualification test for each type of welding which requires procedure qualification must be submitted for approval.

Submit the WPS and PQR with the shop drawings. Supporting Procedure Qualification Records (PQR) for Welding Procedure Specifications (WPS) that require qualification must be submitted in addition to the WPS. Each WPS must be prepared and qualified in accordance with the applicable provisions of AWS D1.5M/D1.5.

Welding procedures must identify the weld as FCM when applicable.

A WPS is always required, even if the procedure is considered prequalified in accordance with AWS D1.5M/D1.5. All government approved WPS will receive a Government approval stamp and copies of the stamped WPS will be the only WPS allowed for use on this project.Each procedure must be clearly identified as being either prequalified or qualified by tests. If a welding procedure is qualified by testing, a representative of the Government must witness the test plate welding and the mechanical testing.

Approval of any procedure, however, will not relieve the Contractor of the responsibility for producing a finished structure meeting all requirements of these specifications.

Approved WPS bearing a government stamp, mark, identifier must be posted in work areas where welding is being performed such that a WPS is readily available for reference at all times. A CWI must approve all WPS's and PQR's Copies of approved WPS including approval stamps must be present at all work stations where welding is occurring so that the welder, QC staff and government QA staff have access to the WPS.

(3) Welding Procedure Specifications must include at a minimum the following; Indicate whether WPS is prequalified or qualified by testing, WPS ID Number, Revision Number, Date, Created by, Company Name, Supporting PQR Number, Joint Design information (to include dimensional tolerances), Base Metal information, Shielding information, Preheat information, Type of operation, Position, Electrical Characteristics, Technique, PWHT, Joint Sketch including all code required essential variables. Filler metal data sheets must be included with WPS and PQR. Weld repair procedures must be included on each WPS. All Welding Procedure Specifications for weldingASTM A709/A709M base metal to alternate base metal is required to be qualified through testing. Reduced section tensile tests and bend tests are always required when qualifying welding procedures.

b. Welding Process. Welding of structural steel must be by an electric arc welding process using a method which excludes the atmosphere from the molten metal and must conform to the applicable provisions of AWS D1.5M/D1.5 for all welds. Welding must be such as to

SECTION 05 59 13.00 25 Page 15 minimize residual stresses, distortion and shrinkage.

c. Welding Technique.

(1) Filler Metal - The electrode, electrode-flux combination and grade of weld metal must conform to the appropriate AWS specification for the base metal and welding process being used or must be as shown where a specific choice of AWS specification allowable is required. Weld metal toughness must meet the requirements of AWS D1.5M/D1.5, Tables, 4.1, 4.2, or 12.1 as applicable. The AWS designation of the electrodes to be used must be included in the schedule of welding procedures. Only low hydrogen electrodes must be used for manual shielded metal-arc welding regardless of the thickness of the steel. A controlled temperature storage oven must be used at the job site as prescribed by AWS D1.5M/D1.5, Subsection 12.6 to maintain low moisture of low hydrogen electrodes. Controlled temperature storage ovens must be powered at all times. FCAW filler metal must be subjected to the storage and handling requirements defined in AWS D1.5M/D1.5 section 12.6.7.4. Differing filler metals and processes must not be combined in the same joint or weld.

(2) Preheat and Interpass Temperature - Preheating must be performed as required by the applicable provisions of AWS D1.5M/D1.5 for all welds. Preheat must not produce moisture in the weld joint. Preheat for fracture critical welds must be as defined in Table 12.3 and in accordance with the WPS. The weldments to be preheated must be slowly and uniformly heated by approved means to the prescribed temperature, held at that temperature until the welding is completed and then permitted to cool slowly as required and in accordance with the approved WPS in order to prevent cracking or distortion. Preheating by use of oxygen cutting equipment will be restricted to the use of "rosebud"heads designed for heating. The use of cutting heads for preheating will not be allowed.

d. Workmanship. Workmanship for welding must be in accordance with AWS D1.5M/D1.5, Section 3 for all welds and other applicable requirements of these specifications

(1) Preparation of Base Metal. Prior to welding, inspect surfaces to be welded to ensure compliance with the applicable sections of

AWS D1.5M/D1.5.

(2) Tack and Temporary Welds. Tack and temporary welds required for fabrication and erection must be made in accordance with AWS D1.5M/D1.5 under the controlled conditions prescribed herein for permanent work. Tack welds that are to be incorporated into the permanent work must be subject to the same quality requirements as the permanent welds. Such tack welds must be cleaned and fused thoroughly with the permanent welds.

Multiple-pass tack welds must have cascaded ends. Defective tack welds must be removed before permanent welding. All welds must be made using low-hydrogen welding electrodes and by welders qualified for permanent work as specified elsewhere in these specifications. Preheat must be as required by AWS D1.5M/D1.5 for permanent tack welds. Preheat must not produce moisture in the weld joint. All tack welds which will be incorporated into the final weldment must be a maximum of 1/8 inch with a minimum length

SECTION 05 59 13.00 25 Page 16 of 1 inch long spaced at a maximum of 6 inch on center. In making temporary welds, arc strikes must not be struck in other than weld locations. Each temporary weld must be removed as required by AWS D1.5M/D1.5, Subsection 3.3.8. All arc strikes struck outside the weld zone must be ground out, and inspected by MT in accordance with AWS D1.5M/D1.5.

(3) Weld Access Holes. Weld access holes must be provided as shown on the shop drawings. If the oversite of intersecting out-of-plane welds is encountered, the fabricator must notify the Engineer and Contracting Officer for the approval of weld access hole additions in such locations. Payment for the addition of weld access holes not shown on plans will be the Contractor's responsibility.

(4) Weld Backing Removal. Unless otherwise indicated, all steel weld backing material must be removed from welded joints prior to testing. All weld backing material that cannot be removed must be identified on the shop drawings.

(5) Weld Backing Material. All weld backing material, other than steel, must be qualified by testing and must be included in submitted PQR/WPS. Variation from approved weld backing material will not be permitted and will require the development and testing of a new weld procedure which addresses the change in backing material. Components of the structure are not to be used as backing for complete joint penetration welds without the permission of the Engineer.

(6) Mock Up Testing. Mock up testing may be required for complex geometries where welding and inspections are difficult due to access restrictions or welding/NDT inspection positions. Testing procedures for connections which do not match typical fabrication practices may require alternate testing procedures to be developed by the fabricator and submitted for approval.

2.1.5.1 Additional Welded Connections Requirements for Trunnion Hub Assembly and Mock-up

a. General

The following requirements are for the trunnion hub assembly and are in addition to those already specified in this specification.

The trunnion hub assembly consists of the cylindrical hub and the built-up strut arm portions attached to it (approximately 4' in length).

b. Welding Technique Restrictions

(1) Fabrication of the trunnion hub assembly is limited to the following welding techniques. Submit prior to trunnion hub assembly mock-up fabrication the trunnion hub assembly welding technique that will be used in production welding of the trunnion hub assemblies. The chosen production welding technique must be successfully demonstrated on a trunnion hub assembly mock-up as described below. The chosen technique is considered successful when all acceptance testing and inspection as outlined within this specification have been performed and successfully passed. Submit all Mock-up Inspection and Acceptance Testing Results for

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Government approval. Do not commence production welding of actual trunnion hub assemblies until Government approval has been provided on this submittal. If the mock-up does not pass acceptance testing then another mock-up must be made and the acceptance testing process started over until the mock-up successfully passes acceptance testing.

(2) open-root welding process

(3) ceramic backers

(4) steel backing material which must be removed in its entirety before acceptance testing.

c. Trunnion Hub Assembly Mock-up

(1) Prior to fabrication, perform a full-size mock-up of the trunnion hub assembly. The mock-up must be of the same geometry, dimensions and space restrictions that will be present when welding on the production trunnion hub assembly.