05 59 13.01 26 Am-0001.pdf

PH1 Draft Tube Stoplog Replacement, Fort Peck Dam, MT FP84

SECTION TABLE OF CONTENTS

DIVISION 05 - METALS

SECTION 05 59 13.01 26

FABRICATION OF HYDRAULIC STEEL STRUCTURES

PART 1 GENERAL

1.1 GENERAL INFORMATION

1.2 REFERENCES

1.3 SUBMITTALS

1.4 DEFINITIONS

1.5 WORK PLAN

1.5.1 Assembly and Fabrication Sequencing Plan

1.5.2 Field Verification of Control Dimensions

1.6 PRE-FABRICATION CONFERENCE

1.7 QUALITY ASSURANCE

1.7.1 Quality Control Plan

1.7.2 NDT Written Practice and NDT Equipment Calibration Records

1.7.3 Inspection Witness Points

1.8 CONTRACTOR QUALIFICATIONS

1.8.1 Qualification of Welders and Welding Operators

1.8.2 Inspector Qualifications

1.8.3 Qualification of Structural Steel Fabricator

1.8.3.1 Similar Scope

1.9 WELDING PROCEDURE SPECIFICATIONS (WPS)

1.9.1 WPS Schedule

1.9.2 WPS Requirements

1.9.3 Government Witness of WPS Qualification

1.10 SHOP DRAWINGS

1.11 DELIVERY AND STORAGE

1.12 STOPLOG HANDLING

1.13 LIFTING BEAM VERIFICATION TEST

1.14 FIELD WELDING OF DOGGING DEVICES

PART 2 PRODUCTS

2.1 FRACTURE CRITICAL MEMBERS (FCM)

2.2 NON-FRACTURE CRITICAL MEMBERS

2.3 FABRICATION

2.3.1 Structural Fabrication

2.3.2 Heat Straightening

2.3.3 Materials Disposition Record

2.3.3.1 Material Test Reports

2.3.4 Welded Connections

2.3.5 Bolted Connections

2.3.5.1 Bolts, Nuts, and Washers

2.3.5.2 Bolt Holes

2.3.6 Miscellaneous Provisions

2.3.7 Shop Assembly

2.4 QUALITY ASSURANCE TESTING BY THE GOVERNMENT

2.5 SEALS

SECTION 05 59 13.01 26 Page 1

Am-0001

2.6 TESTING AND INSPECTION

2.6.1 General

2.6.2 Inspection of Structural Steel Welding

2.6.3 Welds to be Subject to Nondestructive Examination

2.6.4 Test Coupons

2.6.5 Supplemental Examination

2.6.6 Structural Steel Welding Repairs

2.6.7 Discontinuity Acceptance In Base Metal

2.7 STOPLOG IDENTIFICATION

PART 3 EXECUTION

3.1 INSTALLATION

3.1.1 General

3.1.2 Cleaning

3.1.3 Alignment and Setting

3.2 PROTECTION OF FINISHED WORK

3.3 PAINTING

3.3.1 Painting Verification

3.4 CONTROL DIMENSIONS

3.4.1 Shop Dimensional Conformance Test

3.4.2 At-Site Dimensional Conformance Test

3.5 FUNCTIONALITY TEST

3.5.1 Acceptance Criteria

3.5.2 Reporting

-- End of Section Table of Contents --

SECTION 05 59 13.01 26 Page 2

SECTION 05 59 13.01 26

FABRICATION OF HYDRAULIC STEEL STRUCTURES

PART 1 GENERAL

1.1 GENERAL INFORMATION

Perform the fabrication of the following listed structures under this Contract according to this Section of the specifications:

a. Four sets of Draft Tube Stoplogs.

One top stoplog and one bottom stoplog forms one set.

b. Stoplog Lifting Beam.

New lifting beam is to engage with the new draft tube stoplogs and be compatible with the existing tailrace gantry crane. Design in accordance with 41 22 13.75 26 NEW LIFTING BEAM.

c. Field welding to replace dogging devices.

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 (2016) Code of Standard Practice for Steel Buildings and Bridges

AISC 325 (2017) Steel Construction Manual

AISC 326 (2009) Detailing for Steel Construction

AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING (ASNT)

ANSI/ASNT CP-189 (2020) ASNT Standard for Qualification and Certification of Nondestructive Testing Personnel

ASTM INTERNATIONAL (ASTM)

ASTM A36/A36M (2019) Standard Specification for Carbon Structural Steel

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

ASTM A354 (2017; E 2017; E 2018) Standard Specification for Quenched and Tempered

SECTION 05 59 13.01 26 Page 3

Alloy Steel Bolts, Studs, and Other Externally Threaded Fasteners

ASTM A435/A435M (2017) Standard Specification for Straight-Beam Ultrasonic Examination of Steel Plates

ASTM A449 (2014; R 2020) Standard Specification for Hex Cap Screws, Bolts, and Studs, Steel, Heat Treated, 120/105/90 ksi Minimum Tensile Strength, General Use

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

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

ASTM E165 (2012) Standard Test Method for Liquid Penetrant Examination

ASTM E709 (2015) Standard Guide for Magnetic Particle Examination

ASTM F436 (2011) Hardened Steel Washers

AMERICAN WELDING SOCIETY (AWS)

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

AWS QC1 (2016) Specification 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

RESEARCH COUNCIL ON STRUCTURAL CONNECTIONS (RCSC)

RCSC S348 (2014) RCSC Specification for Structural Joints Using ASTM A325 or A490 Bolts

U.S. ARMY CORPS OF ENGINEERS (USACE)

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

1.3 SUBMITTALS

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

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

SD-01 Prefabrication and Assembly Submittals

SECTION 05 59 13.01 26 Page 4

Work Plan; G HDC

Field Verification of Control Dimensions; G HDC

Measuring Plan; G HDC

Quality Control Plan (QCP); G HDC

Material Tracking Log Template; G HDC

Weld Tracking Log Template; G HDC

Nonconformance Report Form Template; G HDC

NDT Written Practice; G

NDT Equipment Calibration Records; G HDC

Witness Points; G HDC

Welding Procedure Specifications (WPS); G HDC

Fracture Control Plan (FCP); G HDC

Welding Repairs - Non-Fracture Critical Members; G HDC

Welding Repairs - Fracture Critical Members; G HDC

Heat Straightening Procedure; G HDC

WPS Schedule; G HDC

Random Testing; G HDC

Handling Plan; G HDC

Stress Relief Heat Treatment Plan; G HDC

Procedure Qualification Records (Pqr); G, HDC

SD-02 Shop Drawings

Shop Drawings; G HDC

Delivery/Shipping Plan; G

Assembly and Fabrication Sequencing Plan; G HDC

Bolt Tensioning Sequence; G HDC

Bolt Inspection and Testing Log; G HDC

SD-03 Product Data

Materials Disposition Record; G HDC

Antigalling Compound; G HDC

Filler Metal; G, HDC

SECTION 05 59 13.01 26 Page 5

SD-06 Test Reports

Certified Test Reports; G

Weld Tracking Log; G HDC

Nonconformance Report; G HDC

Fabrication Quality Control Reports

Shop Dimensional Conformance Test; G HDC

At-Site Dimensional Conformance Test; G HDC

Mock Up Testing; G HDC

Functionality Test; G

Control Dimensions; G HDC

Painting Verification; G

Fabrication Record; G HDC

SD-07 Certificates

Qualification of Welders and Welding Operators; G HDC

Inspector Qualifications; G HDC

Qualification of Structural Steel Fabricator; G HDC

1.4 DEFINITIONS

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

b. Fracture Critical Members (FCM) are as shown on the Contract Drawings and include all attachments and connections to these members as defined in AWS D1.5M/D1.5 .

c. Failure Critical Members are any member for which failure would cause collapse, partial collapse, or loss of functionality of the structure.

d. Ancillary Items are as defined in AWS D1.5M/D1.5 . There are no ancillary items on the stoplogs.

1.5 WORK PLAN

Submit 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. Provide procedures which ensure 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

SECTION 05 59 13.01 26 Page 6 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 for all onsite work. Include the recommended measuring system for ensuring dimensional tolerances in the Work Plan. Include detailed distortion control methods and procedures in the Work Plan.

1.5.1 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.

Include details in the assembly and fabrication sequencing plan describing fit-up, welding and bolting sequences of individual components and the completed assembly, and identify required hold points necessary for weld inspection in accordance with the quality control plan or fracture control plan in the assembly plan. The Assembly and Fabrication sequence plan will be evaluated to show that the fabricator is sequencing the work to control distortion, shrinkage, residual stresses and to meet required tolerances.

1.5.2 Field Verification of Control Dimensions

Perform field verification of control dimensions of existing draft tube stoplogs prior to beginning fabrication. Submit a measuring plan for approval prior to field verification of control dimensions. Include in the measuring plan the equipment, process of how dimensions will be measured, and unique identifiers for each stoplog. Submit findings of the field verification of control dimensions using the unique identifiers for Government approval. Document all variances in shop drawings with variances clouded.

Perform field verificaiton of the Stoplog LIfting Beam in accordance with

SECTION 41 22 13.75 26.

1.6 PRE-FABRICATION CONFERENCE

Following approval of Contractor prepared shop drawings and prior to any fabrication, schedule and hold a Prefabrication Conference as soon as possible after Notice to Proceed. Include in the Prefabrication Conference, at a minimum, the Prime Contractor, Fabricator, the Fabricator's primary QC representative, representative from the third party testing lab if applicable, the COR, the Government Quality Assurance Representative, and the Engineer of record for the structure or structures being fabricated. The Prefabrication Conference is required to occur either at the Fabrication Facilities or a similar location as deemed appropriate. Include, at a minimum, in the prefabrication conference the review of the Contract and Shop drawings, the review of these specifications, discussion of the fabricator's QCP, identification of roles and responsibilities including roles and responsibilities of fabrication subcontractors. 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 requirements and required witnessing of testing. Submit the fracture control plan (FCP) and the welding procedure specifications (WPS) a minimum of 14 calendar days prior to the pre-fabrication conference. Discuss feasibility of all welds and detailing; clarity of weld symbols; methods needed to prevent distortion. Identify and be prepared to discuss complicated connections that may require prototyping for both welding and inspection. In addition, hold points/witness points are required to be established during the

SECTION 05 59 13.01 26 Page 7 prefabrication conference. Notify the Government a minimum of 14 days prior to each hold point. At a minimum, hold points will include, but are not limited to:

a. At 100 percent weld complete of each structure

b. Hold points for paint. See 09 97 02.13 26 PAINTING: HYDRAULIC

STRUCTURES.

c. Control Dimensions

1.7 QUALITY ASSURANCE

1.7.1 Quality Control Plan

Before the start of work, the fabricator is to supply a Quality Control Plan (QCP) to the CO and Engineer for approval. Ensure the QCP describes the methods, equipment, and procedures 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. The QCP will clearly address differences with these Specifications. These Specifications will govern between any discrepancies.

a. Submit a Material Tracking Log Template a minimum of 30 days prior to fabrication. Identify how all material will be tracked in the fabrication shop from receiving through complete assembly in the material tracking log. Label each component 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. 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. Submit Nonconformance Report Form Template a minimum of 30 days prior to the commencement of fabrication. Use the Nonconformance Report Template during fabrication to record and submit all Nonconformance's.

c. 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.

1.7.2 NDT Written Practice and NDT Equipment Calibration Records

Submit the NDT written practice for the qualification of NDT personnel, NDT procedures for each method being used, including testing procedures for prototype complex geometries submitted a minimum of 30 days prior to commencement of fabrication. Establish in the written practice the minimum requirements for education, training, experience, examination and certification of personnel responsible for conducting nondestructive testing. 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

SECTION 05 59 13.01 26 Page 8

Calibration Records for all NDT equipment used by both the fabricator and any subcontractors performing NDE. NDT calibrations required on a basis less than bimonthly will be submitted with test results. Bimonthly or greater calibration requirements will be submitted prior to testing.

1.7.3 Inspection Witness Points

a. Establish Witness Points for the Initial QA Inspection, Intermediate QA Inspections, and Final Inspection as follows and prepare a detailed schedule showing the progression of work and completion of components with the Witness Points identified. 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 will be determined at the Prefabrication Conference by the Government after discussion with the Contractor.

b. Update the inspection witness point schedule weekly and provided by e-mail to the CO. Give the CO two weeks minimum notice prior to the predetermined date for the Initial QA Inspection, including adjustments for changes in schedule. Conduct Intermediate QA Inspections 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 ten working days to inspect the structure. After the Government Quality Assurance Representative and the Engineer of Record have inspected the structure, make any changes required to the structure as directed by the CO 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 CO. Each structure fabricated is subject to a Final Fabrication Inspection prior to painting. Conduct a Final Fabrication Inspection after each structure is completed. Schedule and coordinate with the CO and the Engineer of Record the Final Fabrication Inspections of each structures. Give the CO a minimum notice of two weeks prior to the Final Fabrication Inspection.

1.8 CONTRACTOR QUALIFICATIONS

1.8.1 Qualification of Welders and Welding Operators

Submit Welder Qualification records for each welder, welding operator and tack welder to the Government for approval prior to commencing fabrication. All qualifications are to be current and the submitted records approved prior to commencing any work and be kept current for the duration of the Contract. State in the welder qualification record 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. Include welder continuity documents for all welders, welding operators, or tackers. Provide qualification records in accordance with AWS D1.5M/D1.5 . Submit welder and welding operator qualification test records on forms similar or equivalent to the sample forms in AWS D1.5M/D1.5 . Limit welders, welding operators, and tack welders to welding procedures for which they are qualified. Prepare, weld, and test all test welds in accordance with the requirements of AWS D1.5M/D1.5 . Approve all welder qualifications by a CWI. The Government reserves the right to reject a welder's qualification for poor performance.

SECTION 05 59 13.01 26 Page 9

a. Qualify all welders performing fracture critical welds under this specification according to Clause 12 of AWS D1.5M/D1.5 .

b. Qualify all welders performing non fracture critical welds according to Clause 5 of AWS D1.5M/D1.5 .

1.8.2 Inspector Qualifications

a. Quality control personnel can be assigned to more than one task, provided they are qualified and able to fully perform the duties of each position. Individual(s) responsible for quality assurance/quality control may not serve as or report to production management. If the ability of QC is in doubt, the Government reserves the right to have QC personnel removed from the project.

b. All welding inspectors are required to be currently certified in accordance with these specifications and AWS QC1 as a Certified Welding Inspector (CWI) or Senior Certified Welding Inspector (SCWI) and be in good standing. Non-certified inspectors and Certified Associate Welding Inspectors (CAWI) are not qualified to be used for inspection under these specifications. Designate an individual inspector as the "lead" inspector to be the primary point of contact for quality control of welding and fabrication. This individual will be responsible for all quality control functions. Submit copies of certification documentation as provided by AWS. Qualifications for the lead inspector are to conform to one of the following:

(1) Currently certified as an AWS SCWI.

(2) Currently certified as an AWS CWI and holds an AWS D1.5 endorsement.

(3) Currently certified as an AWS CWI and have taken the part C portion of the exam under AWS D1.5M/D1.5 .

c. Qualify Non-Destructive Testing technicians in accordance with ANSI/ASNT CP-189 to level II or III for each applicable method. In the event that a level III be required to perform NDT, a level II practical examination (conducted within the last three years) will be required in addition to the level III qualifications. Submit level II qualification/certification documentation in a format similar to Appendix C: Sample Certification Form ANSI/ASNT CP-189 and current eye exam. Submit qualifying level III certification as provided by ASNT.

1.8.3 Qualification of Structural Steel Fabricator

Each fabricating plant where the work is to take place is required to be certified under the AISC (American Institute of Steel Construction) Quality Certification Program with one of the following certifications:

a. CBR: Major Steel Bridges

b. ABR: Certified Bridge Fabricator - Advance

c. IBR: Certified Bridge Fabricator - Intermediate

d. HYD: Certified Metal Hydraulic Fabricator

SECTION 05 59 13.01 26 Page 10

In addition, the fabricator is required to be certified with Fracture Critical endorsement (F) and possess five years documented experience on projects of similar scope. Submit copies of the AISC certificate(s) indicating that the fabrication plant meets the specified structural steelwork category and documented experience. The rubber seals are excluded from the AISC fabricator certification requirements.

1.8.3.1 Similar Scope

In addition to AWS D1.5M/D1.5 fabrication, projects of similar scope consists of having fabricated structures with the following minimum requirements:

a. Geometry of structure 5-ft by 10-ft or greater.

b. Fabrication tolerances within +/- 1/8-inch out of parallel over at least 15-ft.

c. Adequate crane capacity and overhead clearance capable of picking and maneuvering the stoplogs within fabrication building. Maneuvering the individual stoplog sections includes any rotating about any axis of the structure that may be required for fabrication and weld distortion control. Overhead clearance requirements must be capable of performing the stacking stoplogs as required in paragraph CONTROL

DIMENSIONS.

1.9 WELDING PROCEDURE SPECIFICATIONS (WPS)

Submit a Welding Procedure Specification (WPS) for each weld, which account for all welding on the structure, including prequalified welds, prior to commencing fabrication. Submit WPS's and Procedure Qualification Records (PQR) to the Government Representative/CO for approval before fabrication is commenced. Approved WPS are required prior to commencing fabrication. Approve all WPS's and PQR's submitted for Government approval by an approved CWI. Submit the WPS and PQR with the shop drawings and reference WPS on the shop drawings. Individually identify and reference Welding Procedure Specifications on the shop drawings.

1.9.1 WPS Schedule

Prior to the start of production welding, submit a complete schedule of welding procedures for the structure which conforms to the requirements specified in the provisions of AWS D1.5M/D1.5 . Provide detailed procedure specifications and tables or diagrams showing the procedures to be used for each required joint in the schedule.

1.9.2 WPS Requirements

Prepare and qualify each WPS in accordance with the applicable provisions of AWS D1.5M/D1.5 . In case of conflict between this specification and AWS D1.5M/D1.5 as applicable, this specification governs. A WPS is always required, even if the procedure is considered prequalified in accordance with AWS D1.5M/D1.5 . Qualify all non-prequalified WPS by testing in the applicable process and position to be utilized. Qualify all combinations of required base metal by testing. Perform all tests in Figure 5.1 of AWS D1.5M/D1.5 regardless of differing base metals. Clearly identify each procedure as being either prequalified or qualified by tests. Individually identify Welding Procedure Specifications. Include in the Welding Procedure Specifications at a minimum the following; Indicate whether WPS

SECTION 05 59 13.01 26 Page 11 is prequalified or qualified by testing, WPS ID#, Revision #, Date, Created by, Company Name, Supporting PQR#, 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, and labeling whether WPS is for FCM. Include filler metal data sheets with WPS and PQR. Submit all WPS with attached PQR and supporting test documentation on forms similar or equivalent to the sample forms in AWS D1.5M/D1.5 .

1.9.3 Government Witness of WPS Qualification

Notice will be provided a minimum of 30 calendar days in advance for Government witness of WPS qualification welding. Government witness of WPS qualification and subsequent destructive testing is required and will be coordinated with the engineer. Approval of any procedure, however, will not relieve the Contractor of the responsibility for producing a finished structure meeting all requirements of these specifications.

1.10 SHOP DRAWINGS

a. Prior to performing any fabrication of HSS structures submit detailed shop drawings to the CO and Engineer of Record for approval.

Show complete details of materials, tolerances, connections, and proposed welding sequences on shop drawings. Include catalog cuts, templates, fabrication and assembly details, and type, grade, and class of materials, as appropriate on shop drawings. Utilize AWS A2.4 , AWS A3.0M/A3.0 , AISC 303 , AISC 325 , and AISC 326 for shop drawing preparation. Fabricator is required to provide an 11x17 printed copy of the approved set of fabrication drawings to the Government Quality Assurance Representative prior to the start of fabrication.

b. Identify on the shop drawings all Fracture Critical Members, including attachments that meet the FCM definition. Identify all temporary and tack welds on the shop drawings which are not fully consumed during final welding. Identify each member following the numbering scheme shown on the drawings.

c. Provide a table containing a list of all members and a reference to each material certificate and test report that applies to that member.

d. Identify on the shop drawings weld procedures and NDE required for each weld. Include any and all splices in the shop drawings and clouded for engineer approval. Do not include splices in the structure without approval of the Engineer of Record.

e. Prepare all shop drawings. Elements of fabricated items inadvertently omitted on contract drawings are to be returned to the Engineer of Record for detailing or be detailed by the fabricator and so indicated on the shop drawings. Cloud any and all details developed by the fabricator on the shop drawings for separate approval by the Engineer of Record. Utilize an approved Registered Professional Engineer for any items designed by the Contractor. Contractor designed items are to be stamped by the approved Engineer who performed or oversaw the design.

f. Identify all field welds required on the shop drawings. Provide a unique identifier for each weld, both shop and field welds, to permit tracking on the weld tracking log.

SECTION 05 59 13.01 26 Page 12

1.11 DELIVERY AND STORAGE

Notify the CO 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. Protect material so that water is not permitted to collect and pool. 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. Protect completed assemblies/structures from the environment. Shipping of the structures is to be at the Contractor's expense. Deliver all structures to Fort Peck Powerhouse 1 per 01 22 00.00 26 MEASUREMENT AND PAYMENT and in accordance with Section 01 12 00 CONSTRUCTION GENERAL. Coordinate through the Omaha District CO for deliveries. Arrange the structures on the delivery vehicles such that no damage occurs during shipping. Direct all slings and lifting lugs up.

Submit Delivery/Shipping Plan drawings providing descriptions of methods of delivering the completed structural units, including details for support during shipment to prevent distortion or other damages, and orientation and location of the structures on the delivery vehicles prior to shipment for Government approval.

1.12 STOPLOG HANDLING

Take care while lifting the stoplog assembly from horizontal position to vertical position. Submit a Handling Plan for approval. Include details, diagrams and/or drawings that identify the plan for lifting the stoplogs from a horizontal to a vertical position. Include the locations, method of lift and all attachments to the stoplogs in the handling plan. Government Cranes are only equipped to handle stoplogs in the vertical position and will be operated by Government Crane operators. Contractor to deliver stoplogs from the delivery truck to the tailrace deck in the upright position dogged in such a manner that the existing crane and lifting beam can reach and handle the stoplogs.

1.13 LIFTING BEAM VERIFICATION TEST

Verify the new Draft Tube Stoplog Lifting Beam for correct fit up with each of the new Draft Tube Stoplogs to be provided. Test the new lifting beam in the shop after fabrication of the stoplogs to verify that it reliably latches to the new stoplogs. A Government witness will be present for the lifting beam verification test, unless notified in writing otherwise. Provide a minimum 30 calendar days notification to the Government prior to the lifting beam verification test. Notify the Engineer of Record and COR if any fit up problems occur. Government approval is required prior to any corrective action taken due to fit up problems. Retest any section that had any corrective action taken.

Additional testing requirements are contained in SECTION 41 22 13.75 26.

1.14 FIELD WELDING OF DOGGING DEVICES

Field welding of new dogging devices are to be in accordance with these specifications, except as noted. Only one unit (2 slots) will be available at a time for the purposes of dogging device replacement. New dogging devices must be accepted by the Government, which includes: weld inspection, NDT, touch up paint, and be fully functional prior to proceeding to the next Unit. On-site work for dogging devices must be scheduled with the COR a minimum of 3-weeks in advance. Material

SECTION 05 59 13.01 26 Page 13 specifications for existing embedded angles are unknown and may be assumed to be equivalent to ASTM A36/A36M.

PART 2 PRODUCTS

2.1 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 . Provide ASTM A709/A709M , grade as specified or shown on the drawings, using killed fine-grain mill practice, unless otherwise shown or specified. Weathering steel is prohibited, including steel with multiple certifications. Mill repairs of base metal are prohibited. Meet toughness requirements of ASTM A709/A709M , Table 10, for Zone 2, unless otherwise indicated or specified. Meet the requirements of Section 10 of ASTM A709/A709M for all materials used for the construction of fracture critical components and include mill certification showing that the material meets the necessary toughness requirements. Meet all requirements of AWS D1.5M/D1.5 Clause 12 for welding fracture critical members, including:

a. Welding Processes. Qualify all welding procedures in accordance with Clause 12.5 of AWS D1.5M/D1.5 .

b. Consumable Requirements. Heat or lot-test all welding consumables, by the manufacturer, to determine conformance with the requirements of the Fracture Control Plan (FCP) in accordance with AWS D1.5M/D1.5 Clause 12.6. Meet the values specified in Table 12.1 of AWS D1.5M/D1.5 for Toughness test results.

c. A Fracture Control Plan (FCP) for welding on all Fracture Critical Members (FCM) in accordance with AWS D1.5M/D1.5 , Clause 12. Submit Welding Procedures, qualifications, and certifications showing compliance with FCP requirements.

d. Welding Procedure Specifications (WPS). Ensure all procedures, including repair welds, are prequalified or qualified by test as required and documented in the WPS and Procedure guidelines of

AWS D1.5M/D1.5 .

e. Certification and Qualification. Utilize welders and welding operators which meet the applicable requirements of AWS D1.5M/D1.5 .

f. Meet the applicable requirements of AWS D1.5M/D1.5 for material handling and preparation, including thermal cutting, preparation of base metal, and straightening, curving, cambering.

g. Tack Welds and Temporary Welds. Locate all welds within the joint and 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.) shall be submitted for Engineer approval prior to use.

h. Meet the applicable requirements of AWS D1.5M/D1.5 for welding processes, including preheat, interpass temperatures, and postweld thermal treatment.

i. Weld Inspection. Document the Quality Control inspection program in the FCP. Do not perform NDT examination until welds have been visually

SECTION 05 59 13.01 26 Page 14 accepted by an approved CWI. Qualify all inspectors and NDT technicians as required. Test all butt joints with UT and RT. Encoded PAUT can be used as an alternate to RT. All indications found by encoded PAUT are to be confirmed by conventional UT and meet UT acceptance criteria. Inspection procedures and documentation are as specified in the applicable sections of AWS D1.5M/D1.5 . Strictly adhere to cooling times.

j. Repair Welding. Repair welds are classified as "critical repairs" or "non-critical repairs" for all repair welding. Follow the minimum provisions, unless specified otherwise, for repair procedures. Qualify and approve repair procedures which are subject to the same QA/QC inspection requirements as other welds. Minimum preheat for repair welding is as defined in AWS D1.5M/D1.5 . All weld repairs to fracture critical members are considered critical welds and are to be approved by the engineer of record.

2.2 NON-FRACTURE CRITICAL MEMBERS

All items not labeled as Fracture Critical are Non-Fracture Critical Members. Provide 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. Meet toughness requirements of ASTM A709/A709M , Table 9, for Zone 2, unless otherwise indicated or specified. Meet the requirements of Section 10 of ASTM A709/A709M for all materials used for the construction of non-fracture critical components and include mill certification showing that the material meets the necessary toughness requirements. Meet all requirements of AWS D1.5M/D1.5 for welding non-fracture critical members.

2.3 FABRICATION

2.3.1 Structural Fabrication

Material must be straight before being laid off or worked. If necessary, straighten by methods that will not impair the metal. Sharp kinks or bends are cause for rejection of the material. Material with welds will not be accepted unless the welding is specified or indicated on the drawings or otherwise approved. Do not commence welding until welding procedures, inspectors, nondestructive testing personnel, welders, welding operators, and tackers have been qualified and approved. Make bends by approved dies, press brakes or bending rolls. Where heating is required, take precautions to avoid overheating the metal and allow to slowly cool in still air in a manner that will not impair the original properties of the metal. Proposed flame cutting of material other than structural steel is subject to approval. Indicate proposed flame cutting on shop drawings. Provide neatly finished work with accurate shearing for all portions of the work. Provide square and true corners unless otherwise shown. Provide filleted re-entrant cuts with a minimum radius of 1 inch in accordance with AWS D1.5M/D1.5 unless otherwise indicated or approved. Provide finished members free of twists, bends and open joints. 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 before welding by placing four low-stress stamp punch marks. Place low-stress stamp punch marks 1-ft back from the center line of the weld, on each side of the weld, and 1-in from the edge of the plate, at each end of the plate.

SECTION 05 59 13.01 26 Page 15

a. Dimensional Tolerances for Structural Work.

(1) Measure dimensions by an approved measuring system. Submit the measuring system for approval with the work plan. The overall dimensions of an assembled structural unit are required to 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 on drawings, 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 are not permitted deviate from the dimensions shown by more than 1/16 inch for members 30 feet or less in length and more than 1/8 inch for members over 30 feet in length.

(2) Structure dimensions indicated on the drawings are based on a structure temperature of 70 degrees F. The Contractor is responsible for any and all dimensional adjustments to compensate for actual temperature variations during construction. Measure tolerances of the final assembly with the structure hanging 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. Prepare surfaces and edges in accordance with AWS D1.5M/D1.5 . Chip, grind or machine hand-guided cuts to sound metal.

2.3.2 Heat Straightening

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 of Record. If allowed and before performing any straightening operations, submit a Heat Straightening Procedure to the engineer for review and approval for any application where heat may be applied to correct or remedy dimensions. Follow the FHWA publication "GUIDE FOR HEAT-STRAIGHTENING OF DAMAGED STEEL BRIDGE MEMBERS" for the Heat Straightening Plan. Do not heat metal to temperatures greater than 1000F. The use of cutting heads for heating and straightening will not be permitted. After heating and straightening, allow the metal to slowly cool in still air 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.

2.3.3 Materials Disposition Record

Furnish the CO three hard copies, along with a digital PDF copy, 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, SECTION 05 59 13.01 26 Page 16 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.

2.3.3.1 Material Test Reports

During each stage of fabrication of major structural components, ensure the fabricator provides and maintains 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 identity unless the identity can be re-established to the satisfaction of the Engineer. Submit Material Test Reports or Certified Test Reports for all material used in fabrication prior to incorporation into the structure. Submit reports of tests, inspections, and verifications of all materials used under this Contract approved by the Government before incorporation into the structure. All steel used in this Contract is required to be tested by the steel mill to ensure that it meets the required standards.

2.3.4 Welded Connections

Material with welds will not be accepted unless the welding is specified or indicated on the drawings or otherwise approved. Do not begin welding until welding procedures, inspectors, nondestructive testing personnel, welders, welding operators, and tackers have been qualified and approved.

a. Welding Procedure. Weld to the applicable provisions of AWS D1.5M/D1.5 per the approved Welding Procedures.

b. Qualification of Welders and Welding Operators. Qualify and requalify, if necessary, welding operators, welders, and tack welders for the particular type of work to be done. Welder Qualification are required to be in accordance with AWS D1.5M/D1.5 and these specifications. Require the welder and welding operators to repeat the qualifying tests when, in the opinion of the Government Representative/CO's Representative/Engineer, the work indicates a reasonable doubt as to proficiency. In such cases, the welder is required to repeat the qualification process in its entirety. The welder's qualification will be re-established upon successful completion of the test. The welder will be disqualified until successfully passing a retest. A Government representative is required to be present during requalification. The period of effectiveness for all welder and welding operator performance qualifications is required to be in accordance with AWS D1.5M/D1.5 . Keep the certification current for the duration of the Contract. All expenses in connection with qualification and requalification are borne by the Contractor.

c. Welding Process. For welding of structural steel, perform welding using an electric arc welding process which excludes the atmosphere from the molten metal and conforms to the applicable provisions of AWS D1.5M/D1.5 for all welds. Welding must be such as to minimize residual stresses, distortion and shrinkage.

d. Weld Tracking Log. A weld-tracking log will be developed and

SECTION 05 59 13.01 26 Page 17 maintained by the Contractor as described herein. Provide a log capable of individually identifying and tracking every weld on the project. Follow the numbering scheme shown on the shop drawings for member identification. At a minimum, include the following in the log;

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. Match weld identification between the shop drawing and weld tracking log. Continually maintain the weld tracking log. Ensure the weld tracking log, including draft copies of NDT testing, is available on the shop floor during any inspection. Provide a bound, completed log for each structure included in the Fabrication Record upon completion of the fabrication of each structure.

e. Welding Technique.

(1) Filler Metal - Utilize electrodes, electrode-flux combination and grade of weld metal conforming to the appropriate AWS specification for the base metal and welding process being used or as shown where a specific choice of AWS specification allowable is required. Meet weld metal toughness requirements of AWS D1.5M/D1.5 , Tables, 4.1, 4.2, or 12.1 as applicable. Include the AWS designation of the electrodes to be used in the schedule of welding procedures. Use only low hydrogen electrodes for manual shielded metal-arc welding regardless of the thickness of the steel. Use a controlled temperature storage oven at the job site as prescribed by AWS D1.5M/D1.5 , Clause 12.6 to maintain low moisture of low hydrogen electrodes. Electrode storage ovens are to be powered and operating within required temperature ranges at all times electrodes are being stored. Store and handle FCAW filler metal per requirements defined in AWS D1.5M/D1.5 Clause

12.6.6.4. Comply with AWS D1.5M/D1.5 for the combination of

differing filler metals and processes in the same joint or weld.

(2) Preheat and Interpass Temperature - Perform preheating as required by the applicable provisions of AWS D1.5M/D1.5 for all welds. Preheat must not produce moisture in the weld joint.

Perform preheat for fracture critical welds as defined in Table

12.3 and in accordance with the PQR/WPS. Slowly and uniformly heat the weldments to be preheated by approved means to the prescribed temperature, held at that temperature until the welding is completed and then permitted to cool slowly in still air 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 is not permitted.

f. Workmanship. Perform workmanship for welding in accordance with AWS D1.5M/D1.5 , Clause 3 for all welds and other applicable requirements of these specifications.

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

AWS D1.5M/D1.5 .

(2) Tack and Temporary Welds. Make tack and temporary welds required for fabrication and erection 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 are subject to the same quality requirements as the permanent welds. Clean and fuse such tack welds thoroughly with the permanent welds. Multiple-pass tack welds are required to have cascaded ends. Remove defective tack welds before permanent welding. Use low-hydrogen welding electrodes and by welders qualified for permanent work as specified elsewhere in these specifications for all welds. Preheat as required by AWS D1.5M/D1.5 for permanent tack welds. Preheat must not produce moisture in the weld joint. In making temporary welds, do not strike arcs outside weld locations. Remove each temporary weld as required by AWS D1.5M/D1.5 , Clause 3.3.8. Grind out all arc strikes struck outside the weld zone, and inspect by MT in accordance with

AWS D1.5M/D1.5 .

(3) Weld Access Holes. Provide weld access holes as shown on the shop drawings. If the oversite of intersecting out-of-plane members is encountered, the fabricator is required to notify the CO and engineer 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, remove all weld backing material from welded joints prior to testing.

Identify all weld backing material that cannot be removed on the shop drawings.

(5) Weld Backing. Qualify all weld backing material, other than steel, by testing and include in submitted PQR/WPS. Variation from approved weld backing material will not be permitted and will require the development and testing a new weld procedure which addresses the change in backing material. Metallic weld backing will not exceed 3-inch in width without Engineer approval.

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 or prototyping 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.

g. Nonconformance. Properly document all nonconformance's using a Nonconformance Report form. Submit a Nonconformance Report (NCR) on the approved form to the Engineer documenting any deviation from the QCP, approved shop drawings, code, Work Plan and/or specifications.

Submit Nonconformance Report forms to the Engineer documenting deviation from the QCP, approved shop drawings, the plans, or specifications. Submit the completed Nonconformance Report for each

SECTION 05 59 13.01 26 Page 19

Nonconformance as required for tracking purposes. Utilize the approved NCR template for each Nonconformance Report. Submit Nonconformance Reports as generated. Include the following in the Nonconformance Report form:

(1) Company name and address.

(2) Report title.

(3) Nonconformance 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 nonconformance.

(12) Photo, sketch, or drawing.

(13) Proposed repair/disposition of the nonconformance.

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

(15) Resolution to Nonconformance.

The contractor/fabricator has the responsibility to ensure that all work performed complies…