W912BU-17-B-0001.pdf

CODE

(Hour)

PAGE(S)

until 02:00 PM local time 21 Oct 2016

A X B X C

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X G F 68 - 85

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JUSTIN.CHUNG@USACE.ARMY.MIL

RATING PAGE OF PAGES

7. ISSUED BY

(Date)

IMPORTANT - Award will be made on this Form, or on Standard Form 26, or by other authorized official written notice.

Previous Edition is Unusable 33-134 STANDARD FORM 33 (REV. 9-97)

Prescribed by GSA FAR (48 CFR) 53.214(c)

1 86

(If other than Item 7)

15A. NAME 16. NAME AND TITLE OF PERSON AUTHORIZED TO

AND

ADDRESS

SIGN OFFER (Type or print)

OF

OFFEROR

AMENDMENT NO. DATE

15B. TELEPHONE NO (Include area code) 17. SIGNATURE15C. CHECK IF REMITTANCE ADDRESS

IS DIFFERENT FROM ABOVE - ENTER

SUCH ADDRESS IN SCHEDULE.

18. OFFER DATE

1. THIS CONTRACT IS A RATED ORDER

UNDER DPAS (15 CFR 700)

2. CONTRACT NO.

W912BU 8. ADDRESS OFFER TO

See Item 7

9. Sealed offers in original and 1 copies for furnishing the supplies or services in the Schedule will be received at the place specified in Item 8, or if handcarried, in the depository located in

CAUTION - LATE Submissions, Modifications, and Withdrawals: See Section L, Provision No. 52.214-7 or 52.215-1. All offers are subject to all terms and

USACE Philadelphia District conditions contained in this solicitation.

10. FOR INFORMATION

CALL:

A. NAME (NO COLLECT CALLS)

JUSTIN CHUNG 215-656-6773

11. TABLE OF CONTENTS

SOLICITATION/ CONTRACT FORM

SUPPLIES OR SERVICES AND PRICES/ COSTS

2 - 3

X I CONTRACT CLAUSES

DESCRIPTION/ SPECS./ WORK STATEMENT X

PACKAGING AND MARKING

4 - 31 J LIST OF ATTACHMENTS

INSPECTION AND ACCEPTANCE

DELIVERIES OR PERFORMANCE

X K

REPRESENTATIONS, CERTIFICATIONS AND

OTHER STATEMENTS OF OFFERORS

CONTRACT ADMINISTRATION DATA X

SPECIAL CONTRACT REQUIREMENTS

OFFER (Must be fully completed by offeror) M

L INSTRS., CONDS., AND NOTICES TO OFFERORS

EVALUATION FACTORS FOR AWARD

NOTE: Item 12 does not apply if the solicitation includes the provisions at 52.214-16, Minimum Bid Acceptance Period.

is inserted by the offeror) from the date for receipt of offers specified above, to furnish any or all items upon which prices are offered at the price set opposite each item, delivered at the designated point(s), within the time specified in the schedule.

13. DISCOUNT FOR PROMPT PAYMENT

(See Section I, Clause No. 52.232-8)

14. ACKNOWLEDGMENT OF AMENDMENTS

(The offeror acknowledges receipt of amendments

AMENDMENT NO. DATE

to the SOLICITATION for offerors and related documents numbered and dated):

FACILITY

12. In compliance with the above, the undersigned agrees, if this offer is accepted within calendar days (60 calendar days unless a different period

SOLICITATION, OFFER AND AWARD

X

(X) SEC. DESCRIPTION (X) SEC. DESCRIPTION PAGE(S)

PART I - THE SCHEDULE

26. NAME OF CONTRACTING OFFICER (Type or print) 27. UNITED STATES OF AMERICA 28. AWARD DATE

EMAIL:TEL: (Signature of Contracting Officer)

CODE CODE

B. TELEPHONE (Include area code) C. E-MAIL ADDRESS

AWARD (To be completed by Government)

19. ACCEPTED AS TO ITEMS NUMBERED 20. AMOUNT 21. ACCOUNTING AND APPROPRIATION

22. AUTHORITY FOR USING OTHER THAN FULL AND OPEN COMPETITION:

10 U.S.C. 2304(c)( ) 41 U.S.C. 253(c)( ) (4 copies unless otherwise specified)

23. SUBMIT INVOICES TO ADDRESS SHOWN IN ITEM

24. ADMINISTERED BY (If other than Item 7) CODE 25. PAYMENT WILL BE MADE BY CODE

PART IV - REPRESENTATIONS AND INSTRUCTIONS

PART III - LIST OF DOCUMENTS, EXHIBITS AND OTHER ATTACHMENTS

34 - 56

PART II - CONTRACT CLAUSES

US ARMY ENGINEER DISTRICT, PHILADELPHIA

POC: JUSTIN CHUNG

WANAMAKER BUILDING

100 PENN SQUARE EAST

PHILADELPHIA PA 19107-3390

215-656-6773

215-656-6780FAX:

TEL:

FAX:

TEL:

NOTE: In sealed bid solicitations "offer" and "offeror" mean "bid" and "bidder".

SOLICITATION

57 - 67

6. REQUISITION/PURCHASE NO.5. DATE ISSUED

14 Oct 2016

4. TYPE OF SOLICITATION

SEALED BID (IFB)

NEGOTIATED (RFP)

[ X ]

3. SOLICITATION NO.

W912BU-17-B-0001

Section B - Supplies or Services and Prices

ITEM NO SUPPLIES/SERVICES QUANTITY UNIT UNIT PRICE AMOUNT

0001 1 Job Install Stop Logs

FFP

The contractor shall install Government furnished stop logs, including the use of diving services in accordance with the Statement of Work.

FOB: Destination

NET AMT

0002 1 Job Remove Stop Logs

FFP

The contractor shall remove the Government furnished stop logs, including the use of diving services in accordance with the Statement of Work.

0003 1 Job Gate Reapir at F.E. Walter Dam

FFP

The inspection, rehabilitiation, and repair of the Left Service Gate at F.E. Walter Dam in accordance with the Statement of Work.

Section C - Descriptions and Specifications

STATEMENT OF WORK

1 GENERAL

1.1 PROJECT BACKGROUND

Francis E. Walter Dam, is located on the Lehigh River above the borough of White Haven, PA. It is constructed as an earthen embankment dam with an outlet works that consists of an approach channel, intake tower, conduit, outlet structure, and outlet channel. Three intake conduits draw water through the tower and merge into the main conduit section and out through the outlet structure. The intake conduits are each controlled by two (2) sluice gates, one service and one emergency, for a total of six (6). Each of the sluice gates is a 10’-5 ¾” high by 6’-8” wide cast steel structure, constructed in 1956 and made of Grade 65-30 steel. There are also three (3) bulkhead stop logs that can be placed together in a single intake conduit to dewater the gates for that conduit and perform maintenance and inspection work on them. The gates are not redundant so they are considered fracture critical. Prior to performing any maintenance work on the service gates, the emergency gate must be closed and the stop logs in place.

1.2 DESCRIPTION OF WORK

The contract work includes, but is not limited to, the following:

1.2.1 The inspection and rehabilitation of the Left Service Gate including hydraulic cylinder and piston, stems, water and oil seals, gate bonnet, gate leaf, and gate frame seals;

1.2.2 Installation and removal of Government furnished stop logs, including the use of diving services;

1.2.3 Forging and machining one new gate stem;

1.2.4 Removal of lead-based paint on gate leaf and repainting;

1.2.5 Non-destructive testing (NDT) of cast steel gate leaf.

1.3 ACCESS TO TOWER

A. Service Bridge: The service bridge has a rating of H20.

B. Entrance Door: A structure comprised of a stainless steel rollup door with a swing out man door

(elevation 1473.92) can be used for delivery and removal of materials or equipment to and from the tower. The Contractor shall not leave the tower unsecured overnight.

C. Removal of Gates and Cylinders: The Contractor shall provide all rigging and equipment necessary to remove the gates and cylinders from the tower. The Contractor shall note that there is piping, electrical conduits, equipment, etc. located throughout the tower, and little space for removing the gates and cylinders. The Contractor shall be responsible for repairs of any items damaged due to these removal operations.

1.4 COORDINATION

Contractor shall notify the Contracting Officer 3 days prior to requiring access to the conduit and closing or opening of service and emergency flood control gates. Hydraulic conditions may at any time require the Contracting Officer to deny the request. In addition, the Contractor’s access to the conduit shall be limited to a maximum of 2 hours each access. The Contracting Officer will direct the Contractor to exit the conduit at that time to allow the reopening of the dam

1.5 STOP LOGS, AS DIRECTED

Contractor shall install stop logs as directed by the Contracting Officer prior to accessing the conduit or beginning any disassembly or removal operations. See Section 4.3 STOP LOGS.

1.6 ACCESS TO FLOOD CONTROL GATES

Contractor shall provide small motor-powered boat for transporting workers and equipment up the conduit to the gates. No gas-powered boat shall be permitted. There is a gravel surfaced road to gravel boat ramp located on the outlet channel just downstream of the stilling basin. The use of a heavy duty or 4x4 vehicle may be required to haul trailer.

1.7 RESTRICTIONS

a. WARNING: Freezing in the lake can be expected as early as the beginning of December. Stop logs must be removed before the lake freezes which may occur in mid to late December.

b. Reference drawings of the existing facility and the gate operating system are included in Attachment 1.

NOTE: Gate hangers shown in the reference drawings are not functioning and, therefore, not available for use. Also, it should be noted that not all of the gasket and packing materials shown on the reference drawings are the same materials required by these specifications.

c. There are two (2) new 2-ton capacity portable chain hoists, lifting beam, and stop logs available for use by the Contractor. The portable hoists, lifting beam and stop logs are currently located in the storage building on site.

d. All required operation of the hydraulic operating system for the gate and any associated supporting systems needed to perform the work shall be done by Government dam personnel only. The Contractor shall coordinate closely with dam personnel to arrange for all such operation.

e. Only one flood control gate may be out of service at a time.

1.8 ORIGINAL GATE SPECIFICATIONS

The original specifications for the gates is included in Attachment 2. This is provided for informational purposes only.

1.9 MATERIALS AND WORKMANSHIP

All materials shall be of the highest quality, free from defects and imperfections, unused and of recent manufacture, and of the classification and grades specified herein. Material not specifically described herein shall, as far as practicable, conform to the latest Government and industry standards covering the class or kinds of materials to be used. Workmanship shall be of the highest quality and in accordance with the best current standard practice.

2 REFERENCES

The publications listed below form a part of this scope of work to the extent referenced.

U.S. ARMY CORPS OF ENGINEERS (USACE)

EM 385-1-1 (2014) U.S. Army Corps of Engineers Safety and Health Requirements Manual

ANSI Z87.1 AMERICAN NATIONAL STANDARDS INSTITUTE

(ANSI)

(1989; R 1998)

Occupational and Educational Eye and Face Protection

ANSI Z88.2 (1992) Respiratory Protection

ASTM INTERNATIONAL (ASTM)

ASTM A 36 (1992) Structural Steel ASTM A 106 (2002a) Seamless Carbon Steel Pipe for High-Temperature

Service ASTM A 307 (2004) Carbon Steel Bolts and Studs, 60000 PSI Tensile

Strength ASTM A 325 (2004b) Structural Bolts, Steel, Heat Treated, 120/105 ksi

Minimum Tensile Strength ASTM A 564 (1992a) Hot-Rolled and Cold-Finished Age-Hardening

Stainless and Heat-Resisting Steel Bars and Shapes ASTM B 148 (1997; R 2003e1) Aluminum-Bronze Sand Castings ASTM F 912 (2004; R 2006) Alloy Steel Socket Set Screws ASTM B 23 (2000) White Metal Bearing Alloys (Known Commercially as

"Babbitt Metal") ASTM D 153 (1984; R 1996el) Specific Gravity of Pigments ASTM D 281 (1995; R 2002) Oil Absorption of Pigments by Spatula Rub-

Out ASTM D 520 (2000) Zinc Dust Pigment ASTM D 561 (1982; R 1996e1) Carbon Black Pigment for Paint ASTM D 740 (1994; R 2001) Methyl Ethyl Ketone ASTM D 841 (2002) Nitration Grade Toluene ASTM D 1045 (1995; R 2001) Sampling and Testing Plasticizers Used in

Plastics ASTM D 1152 (1997; R 2001) Methanol (Methyl Alcohol) ASTM D 1153 (1994; R 2001) Methyl Isobutyl Ketone ASTM D 1186 (2001) Nondestructive Measurement of Dry Film Thickness of Nonmagnetic Coatings Applied to a Ferrous Base ASTM D 1200 (1994; R 1999) Viscosity by Ford Viscosity Cup ASTM D 1210 (1996) Fineness of Dispersion of Pigment-Vehicle Systems by

Hegman-Type Gage ASTM D 2917 (1991; R 1998) Methyl Isoamyl Ketone ASTM D 3721 (1983; R 1999) Synthetic Red Iron Oxide Pigment ASTM D 4417 (1993; R 1999) Field Measurement of Surface Profile of Blast

Cleaned Steel ASTM E 1347 (1997) Color and Color Difference Measurement by

Tristimulus (Filter) Colorimetry ASTM E 709 (2008) Standard Guide for Magnetic Particle Examination ASTM E 2375 (2008; R 2013) Standard Practice for Ultrasonic Testing of

Wrought Products

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1 (2006) Structural Welding Code – Steel

U.S. DEPARTMENT OF HOUSING AND URBAN DEVELOPMENT (HUD)

HUD 6780 (1995; Errata Aug 1996; Rev Ch. 7 - 1997)Guidelines for the Evaluation and Control of Lead-Based Paint Hazards in Housing

U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)

29 CFR 1910 Occupational Safety and Health Standards 29 CFR 1910.20 Access to Employee Exposure and Medical Records 29 CFR 1910.94 Ventilation 29 CFR 1910.134 Respiratory Protection 29 CFR 1910.146 Permit-required Confined Spaces 29 CFR 1910, Subpart I Personal Protective Equipment 29 CFR 1926 Safety and Health Regulations for Construction 29 CFR 1926.103 Respiratory Protection 29 CFR 1926.21 Safety Training and Education 29 CFR 1926.33 Access to Employee Exposure and Medical Records 29 CFR 1926.55 Gases, Vapors, Fumes, Dusts, and Mists 29 CFR 1926.59 Hazard Communication 29 CFR 1926.62 Lead 29 CFR 1926.65 Hazardous Waste Operations and Emergency Response 40 CFR 260 Hazardous Waste Management System: General 40 CFR 261 Identification and Listing of Hazardous Waste 40 CFR 262 Standards Applicable to Generators of Hazardous Waste 40 CFR 263 Standards Applicable to Transporters of Hazardous Waste 40 CFR 264 Standards for Owners and Operators of

Hazardous Waste Treatment, Storage, and Disposal Facilities

40 CFR 265 Interim Status Standards for Owners and Operators of Hazardous Waste Treatment, Storage and Disposal Facilities

40 CFR 268 Land Disposal Restrictions 40 CFR 745 Lead-Based Paint Poisoning Prevention in Certain Residential

Structures 49 CFR 172 Hazardous Materials Table, Special Provisions, Hazardous

Materials Communications, Emergency Response Information, and Training Requirements

49 CFR 178 Specifications for Packagings

U.S. GENERAL SERVICES ADMINISTRATION (GSA)

FED-STD-595 (Rev B) Colors, Volume 1

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2014) National Electrical Code

THE SOCIETY FOR PROTECTIVE COATINGS (SSPC)

SSPC QP 1 (1998; R 2000) Standard Procedure for Evaluating Painting Contractors (Field Application to Complex Industrial Structures)

SSPC SP 1 (1982; R 2000) Solvent Cleaning SSPC SP 5 (2000) White Metal Blast Cleaning

UNDERWRITERS LABORATORIES (UL)

UL 586 (1996; Rev thru Aug 2004) Standard for High-Efficiency

Particulate, Air Filter Units

PENNSYLVANIA DEPARTMENT OF LABOR AND INDUSTRY

PA Chapter 203 Lead-Based Occupation Accreditation and Certification Regulations - http://www.dli.state.pa.us

3 PRODUCTS

3.1 GATE STEM: Provide one (1) new gate stem made of 17-4ph Stainless steel and chrome plating. Material shall conform to ASTM A564 (630). Stem dimensions can be found in Attachment 1, Reference Drawing 18456. Note the original stem material on the drawing is different than what is specified herein.

3.2 PACKING: New oil packing rings in the cylinder head and in the top of the bonnet cover, and water packing rings in the bottom of the bottom cover, shall be Chesterton 11K EZ Stack Pack seals, or approved equal, dimensions as indicated on the drawings, except rings shall not be cut, but shall be continuously round.

3.3 HYDRAULIC OIL: Contractor shall work in such a manner that very little of the hydraulic oil currently in the operating system is lost during the repairs. However, should more than the typically minimal amount of oil be lost during execution of the work, the Contractor shall be prepared to replenish up to at least 5 gallons of hydraulic oil. Product shall be biodegradable antiwear hydraulic oil, type Biodegradable AW Hydraulic ISO 46, Product Code 33435, as manufactured by LSC, Technolube Products, Pico Rivera, CA or an approved equal.

3.4 PAINT: Special paint formulations for flood control gates and recess covers shall be Formula V-766e, Vinyl-

Type White (or Gray) Paint.

A. Formula V-766e, Vinyl-Type White (or Gray) Paint

INGREDIENTS PERCENT BY WEIGHT

Vinyl Resin, Type 3 5.6 Vinyl Resin, Type 4 11.6 Titanium Dioxide and (for Gray)

Carbon Black 13.0 Diisodecyl Phthalate 2.9 Methyl Isobutyl Ketone 32.0 Toluene 34.7 Ortho-Phosphoric Acid 0.2

100.0

i. The dispersion of pigment shall be accomplished by means of pebble mills or other approved methods to produce a fineness of grind (ASTM D 1210) of not less than 7 on the Hegman scale. Grinding in steel-lined or steel-ball mills will not be permitted. No grinding aids, antisettling agents, or any other materials except those shown in the formula will be permitted. The paint shall show the proper proportions of specified materials when analyzed by chromatographic and/or spectrophotometric methods. The ortho-phosphoric acid shall be measured accurately and diluted with at least four parts of ketone to one part of acid and it shall be slowly incorporated into the finished paint with constant and thorough agitation.

ii. The viscosity of the paint shall be between 60 and 90 seconds using ASTM D 1200 and a No. 4 Ford cup.

iii. The white and gray paints shall be furnished in the volume ratio designated by the purchaser. The gray paint shall contain no pigments other than those specified. Enough carbon black shall be included to produce a dry paint film having a reflectance of 20-24 (ASTM E 1347). The resulting gray color shall approximate Munsell color 2.5PB 5/2 identified in MD-40219.

Formula VZ-108d, Vinyl-Type Zinc-Rich Primer

INGREDIENTS PERCENT BY WEIGHT POUNDS

GALLONS

COMPONENT A

Vinyl Resin, Type 3 16.6 109.2 9.65 Methyl Isobutyl Ketone 80.6 528.9 79.30 Suspending Agent E 0.7 4.6 0.28 Suspending Agent F 0.4 2.7 0.19 Methanol 0.5 3.3 0.50 Synthetic Iron Oxide (Red) 1.2 7.9 0.19

100.0 656.6 90.11

COMPONENT B

Silane B 100.0 4.1 0.47

COMPONENT C

Zinc Dust 100.0 550.0 9.42 100.0

(mixed paint)

i. The iron oxide and suspending agents shall be dispersed into the vehicle (Component A) to a fineness of grind of not less than 4 on the Hegman scale (ASTM D 1210). Grinding in steel-lined containers or using steel-grinding media shall not be permitted. The sole purpose of the iron oxide pigment is to produce a contrasting color. A red iron oxide-type 3 vinyl resin vehicle paste may be used in place of dry iron oxide provided compensating adjustment are made in the additions of Type 3 resin and methyl isobutyl ketone. The finished product with zinc dust added shall produce a paint which has a red tone upon drying and a reflectance of not more than 16 (ASTM E 1347).

ii. VZ-108d paint shall be supplied as a kit. Each kit shall consist of 4.5 gallons (33.1 pounds) of Component A in a 5-gallon lug closure type pail, 27.5 pounds of zinc dust (Component C) packaged in a 1-gallon plastic pail, and 3 fluid ounces of silane (Component B) packaged in a glass bottle of suitable size having a polyethylene lined cap. The bottle of silane shall be placed on the zinc dust in the gallon pail. In addition to standard labeling requirements, each container of each component shall be properly identified as to component type and each container label of Component A shall carry the following: MIXING AND

APPLICATION INSTRUCTIONS: WARNING - THIS PAINT WILL NOT ADHERE TO STEEL

SURFACES UNLESS COMPONENT B IS ADDED. Remove the 3 ounces of bottled Component B (silane) from the Component C (zinc dust) container and add to the base paint Component A) with thorough stirring.

Then sift the zinc dust into the base paint while it is being vigorously agitated with a power-driven stirrer and continue the stirring until the zinc dust has been dispersed. The mixed paint shall at some point be strained through a 30-60 mesh screen to prevent zinc dust slugs from reaching the spray gun nozzle. The paint shall be stirred continuously during application at a rate that will prevent settling. If spraying is interrupted for longer than 15 minutes, the entire length of the hose shall be whipped vigorously to redisperse the zinc. If the spraying is to be interrupted for more than 1 hour, the hose shall be emptied by blowing the paint back into the paint pot. Thinning is not normally required when ambient temperatures are below about 80 degrees F, but when the ambient and steel temperatures are higher, methyl isoamyl ketone (MIAK) or methyl isobutyl ketone (MIBK) shall be used. If paint is kept covered at all times, its pot life is about 8 days.

4 EXECUTION

4.1 SERVICE GATE INSPECTION

4.1.1 GENERAL

Contractor shall remove and install the left flood control service gate from the tower for rehabilitation and inspection off-site. Contractor shall note the restrictions specified in Section 1 GENERAL.

4.1.2 REMOVAL PROCEDURES

The Contractor shall install the stop logs in the slot for the left conduit prior to any removal operations. The Contractor is permitted to use the 7.5 ton trolley hoist, to deliver and remove materials between the gate chamber and tower bridge roadway levels. Steps in the removal of the gates and cylinders shall be as follows:

A. All operation of the gate operating system required for this project, including the operation of all valves, shall be performed by Government dam personnel only. The Government will lower the left emergency gate into the fully closed position.

B. The Government will raise the left service gate, by hydraulic pressure, as high as possible; and will close the high pressure gate valves between the 4-way valve and cylinder. The Contractor shall then remove the 1/4" bronze pipe plug from the air vent in the cylinder head.

C. Prior to the Government lowering the gate, the Contractor shall access the gate from the downstream side via the tunnel. The gate is currently blocked open with 4x4 pressure treated lumber.

Blocking must be removed prior to the next step. NOTE: This is done from inside the conduit which is considered a confined space. Therefore a confined space entry permit, confined space training and an appropriate confined space escort shall be required for Contractor personnel to enter the tunnel.

Contractor shall closely coordinate entry to the tunnel with dam personnel. Contractor shall have a 3-way communications system to use amongst personnel inside the tunnel, in the stilling basin at the end of the tunnel, and in the tower or other areas of the facility. A communication system is available at the project. If the Contractor chooses to utilize the project communication system, all coordination must be completed through Mr. David Williams prior to tunnel access. If Contractor chooses to purchase such a system for this project, that communications system shall become the property of the Corps of Engineers Philadelphia District at the completion of the project.

D. The Government will open the high pressure drain valve and the gate will lower by gravity, forcing the hydraulic fluid from the cylinders to the oil reservoir. While the gate is lowering the Contractor shall place sufficient blocking under the gate so that the bottom of the gate shall remain approximately one foot above the floor of the tunnel and any leakage from the emergency gate may pass through during removal operations. Once the gate is fully lowered, the Government will close the valve on the drain line.

E. The Contractor shall remove the recess cover on the downstream side of the gate and remove the lower leaf nut.

F. The Contractor shall disconnect the oil line to the top of the cylinder, remove the safety stud cap, gate leaf position indicator and target.

G. The Contractor shall remove the cylinder head bolts and cylinder head. The Contractor shall remove the bolts between the bonnet and cylinder and raise the cylinder.

H. The Contractor shall loosen the extension stem nut, raise the key retainer, remove the key, turn the stem extension from the piston, and remove the stem extension.

I. The Contractor shall remove the cylinder and bolts between the bonnet cover and bonnet and disconnect the oil lines to the bonnet cap.

J. The Contractor shall raise the bonnet cover, piston, and stem in one piece.

K. The Contractor shall lower the hoist chain through the stem hole in the gate leaf and anchor the chain. The Contractor shall remove the gate leaf.

L. To replace the gate and cylinder, reverse the above procedure.

NOTE: Contractor's proposed procedures shall be submitted and approved prior to start of work.

4.1.3 INSTALLATION OF BLIND FLANGE

Contractor shall install a blind flange over bonnet opening, immediately after the gate has been removed.

The blind flange is currently stored in the tower. The Contractor shall reuse the existing bonnet cover gasket and existing flange studs for fastening the blind flange to the bonnet.

4.1.4 INSPECTION REQUIREMENTS AND CONDITION REPORT

4.1.4.1 GENERAL

After the gate is removed offsite, the Contractor shall conduct a complete visual inspection of all gate components to determine their condition. As part of the visual inspection, the contractor shall compare actual dimensions of the accessible portions of the gate with original dimensions as per the reference drawings. The contractor shall also conduct nondestructive testing per 4.1.4.2. Results and recommendations based on the visual inspection and non-destructive (NDT) testing, shall be provided as outlined in Section 4.1.4.3

The Contractor shall notify the Contracting Officer of the offsite location(s) where the gates and cylinders shall be inspected and rehabilitated. The Contracting Officer will conduct an on-site visit(s) at that location to observe the condition of the gate system components and to conduct quality assurance inspections of the Contractor's work. The Contractor shall provide the Contracting Officer with the use of a desk, telephone (with outside line), facsimile machine, and toilet facilities.

4.1.4.2 NON-DESTRUCTIVE TESTING

Non-destructive testing shall include Phased-Array Ultrasonic Testing (PAUT) and magnetic particle examination (MT). All such testing shall be completed by an ASNT certified Level II or III NDT technician. The downstream surface of the gate shall be inspected with MT in accordance with ASTM E709 (2008) “Standard Guide for Magnetic Particle Examination” to explore overall integrity of the casting. At intersections of internal stiffening elements and the downstream skin, PAUT shall be utilized to inspect the integrity of casting where material intersects.

A plan for all NDT shall be submitted for approval prior to testing. For the PAUT inspection, the contractor shall develop calibration and testing procedures and these shall be included in the plan. ASTM E2375 and ASME criteria provides guidance on PAUT. For the PAUT, acceptability of welds shall be in accordance with ASTM E2375 (2013), Table 1. NDT test reports shall identify the location of flaws that do not meet the acceptance criteria and the actual location of flaws shall be marked on the gate leaf using indelible ink visible for photos. The NDT technician shall photograph all tested locations that contain defects. The photos shall show the location of defects on the structure. Written report shall provide enough information sufficient to allow analysis of weld deficiency and location of flaw for structural repairs. An

NDT inspection report shall be submitted as an attachment to the condition report.

4.1.4.3 CONDITION REPORT

Based on the visual and NDT inspections, the Contractor shall submit a condition report to the Contracting Officer within 15 working days of removal of the gate from the Walter Dam Tower. This report shall include results of MT and PAUT, recommendations for required rehabilitation, and a cost estimate for items recommended for rehabilitation shall be included.

4.1.5 LEAD BASED PAINT REMOVAL AND PAINTING

Gate leaf shall be cleaned of lead-based paint, and painted as specified in Section 4.4 REMOVAL CONTROL AND DISPOSAL OF PAINT WITH LEAD and Section 4.5 PAINTING.

4.1.6 GATE LEAF SEATS

Horizontal and vertical gate leaf seats shall be removed prior to lead-based paint removal. Seats shall be inspected and condition shall be included in condition report specified above. Report shall include measurements of existing, worn seats and a comparison to original dimensions of seats. Gate leaf seats and cap screws shall be replaced, in kind (see Reference Drawing Number 18462). Manufacturer's data shall be submitted and approved prior to replacement of gate leaf seats.

4.2 HYDRAULIC CYLINDER AND PISTON REHABILITATION

4.2.1 REMOVAL AND REPLACEMENT OF GATE LEAF RECESS COVER

Contractor shall remove gate leaf recess cover for access to stem's bottom leaf nut. Gate leaf recess cover shall be disposed of properly, in accordance with local, State, and Federal regulations. NOTE: Gate leaf recess cover contains lead-based paint. Lead-based paint shall be removed and disposed of as specified in Section 4.4 REMOVAL CONTROL AND DISPOSAL OF PAINT WITH LEAD.

New gate leaf recess cover shall be 1-inch thick, ASTM A 36 steel, painted as specified in Section 4.5 PAINTING. Slotted cap screws shall be replaced in kind, as shown on Reference Drawing No. 18462.

New access cover shall be fabricated with the same number of holes, drilled and spaced, as existing recess cover and gate leaf. Removal/Installation procedures and shop drawing of recess cover shall be submitted and approved prior to installation.

4.2.2 REMOVAL, INSPECTION, AND REINSTALLATION OF HYDRAULIC CYLINDER

A. Removal Procedures: Contractor shall remove hydraulic cylinder from the tower to inspect and rehabilitate the cylinder off-site. Contractor shall note the restrictions specified in Section 1 GENERAL.

See also Section 4.1 FLOOD CONTROL GATE REHABILITATION, paragraph 4.1.2 REMOVAL

PROCEDURES.

B. Inspection: Contractor shall inspect cylinder for wear and take clearance measurements at locations on the pistons, and, on the inside of the cylinders. Locations and data reporting format for clearance measurements is attached to this section. The Contractor shall notify the Contracting Officer of the offsite location(s) where the gates and cylinders shall be inspected and rehabilitated prior to start of work. The Contracting Officer will conduct an on-site visit(s) at that location to observe the condition of the gate system components and to conduct quality assurance inspections of the Contractor's work. The Contractor shall provide the Contracting Officer with the use of a desk, telephone (with outside line), facsimile machine, and toilet facilities. Contractor shall submit a condition report, including rehabilitation recommendations, to the Contracting Officer, within 10 working days of removal of the gate from the Walter Dam Tower see Section XX CONDITION REPORT.

C. Reinstallation: Contractor shall recalibrate gate position indicator after reinstalling the hydraulic cylinder. All studs and nuts shall be replaced as specified, below.

D. Submittals: Manufacturer's descriptive data and technical literature shall be submitted and approved prior to installation of any new items.

4.2.3 CYLINDER GASKETS

Contractor shall replace all gaskets, in kind, as shown on Reference Drawing Number 18456.

4.2.4 WATER PACKING GLAND

Contractor shall replace all water packing and glands with Chesterton 11K EZ Stack Pack seals, or approved equal. Dimensions can be found on Reference Drawing Number 18456 Cap screws and nuts shall be replaced as specified below.

4.2.5 OIL PACKING GLAND

Contractor shall replace all oil packing and glands. Oil packing shall be Chesterton 11K EZ Stack Pack seals, or approved equal, to the dimensions shown on Reference Drawing Number 18456. The glands shall be replaced in kind, as shown on Reference Drawing Number 18456. Cap screws and nuts shall be replaced as specified, below.

4.2.6 STUDS AND NUTS

Contractor shall replace all steel studs and nuts, incidental to a line item, to the dimensions given on the Reference Drawings, except material shall be steel conforming with ASTM A 325.

4.2.7 CAP SCREWS AND NUTS

Contractor shall replace all naval brass cap screws and nuts, incidental to a line item, in kind, to the dimensions given on the Reference Drawings.

4.2.8 STEM EXTENSION

Contractor shall replace stem extension. Dimensions shall be as shown on Reference Drawing Number 18456, except material shall be stainless steel conforming to ASTM A 564/A. Contractor shall measure the outside diameter of the complete length of stem, stem and stem extension. Measurements shall be compared with original dimensions and presented in a condition report.

4.2.9 SAFETY STUD

Contractor shall replace safety stud, at top of stem extension, to the dimensions shown on Drawing Number 18463, except the material shall be ASTM A 325 steel.

4.2.10 STEM

Contractor shall replace stem, including top and bottom leaf nuts. Dimensions shall be as shown on Reference Drawing Number 18456, except material shall be chrome plated 17-4ph stainless steel conforming to ASTM A 564.

4.2.11 PISTON RINGS

Contractor shall take measurements of pistons and cylinders, as specified, above. Based on those measurements taken, the Contractor shall select and install properly sized piston rings. Materials shall be in kind, as shown on Reference Drawing Number 18456.

4.2.12 PAINTING

Lead-paint has already been removed from cylinders, cylinder heads, bonnets, and bonnet covers in a previous contract. Contractor shall repair any chipped or peeling paint per Section 4.4 REMOVAL

CONTROL AND DISPOSAL WITH LEAD PAINTING.

4.3 STOP LOGS

The Contractor shall transport the three (3) Government-furnished stop logs to the working platform from the Government's operational facility as directed by the Contracting Officer. There is a 20-foot wide, crushed aggregate, access road to the working platform. There are existing 2-ton hand hoists, as well as a chain for securing the existing, Government-furnished lifting beam (see Reference Drawing number 26949) available for use by the

Contractor. Using the portable hoist mounted on the existing monorail hoist framing, a chain, and the lifting beam, the stop logs shall be slowly lowered into the stop log recess of the applicable conduit. The Contractor shall provide divers, as directed by the Contracting Officer, as specified in Section 4.6 DIVING SERVICES, to assist in the installation operation and to ensure the stop logs are seated properly. Divers shall also be required for stop log removal operations. If necessary, the Government will equalize pressure on both sides of the stop logs prior to the Contractor removing the stop logs.

4.4 REMOVAL CONTROL AND DISPOSAL OF PAINT WITH LEAD AND PAINTING

4.4.1 GENERAL

The Contractor shall perform all painting operations off-site prior to delivery to the dam site, with the exception of any on-site touch-up painting required after installation. The estimated area to be painted is approximately 110 square ft.

4.4.2 WORK PERFORMANCE

Work shall be performed in accordance with the requirements of 29 CFR 1910, 29 CFR 1926, EM 385-1-1, and other references as listed herein. Matters of interpretation of the standards shall be submitted to the Contracting Officer for resolution before starting work. Where the regulations conflict, the most stringent requirements shall apply.

4.4.3 LEAD PROTECTION PROGRAM

A. General: The items to be blast cleaned and repainted have not been tested for lead-based paint.

Consequently, the Contractor shall conduct all paint removal operations as if lead-based paint is present.

For bidding purposes, the Contractor shall assume that the waste is hazardous. The Contractor shall sample and test the waste, using TCLP, to characterize the waste for disposal.

B. Lead Protection: The Contractor shall enforce a lead protection program in accordance with 29 CFR

1926.62. The program shall include a containment plan, a visible emissions monitoring plan, a water quality plan, and a soil quality plan, as necessary, based on the location of the paint removal and repainting

4.4.4 QUALIFICATIONS

Qualifications and experience shall comply with the following.

A. Certified Professional: The Contractor shall provide a person who is qualified and competent as defined in Section 01 of EM 385-1-1, shall develop the required safety and health submittal, and will be responsible for on-site safety and health during the contract period. The person overseeing the health and safety issues associated with the paint removal and repainting operations shall be an Industrial Hygienist (IH) with a minimum of 3 years of demonstrated experience in similar related work. The Contractor shall certify that the IH is considered board eligible by written confirmation from the ABIH. The IH may utilize other qualified and competent persons, as defined in EM 385-1-1, to conduct on-site safety and health activities as long as these persons have a minimum of 3 years of demonstrated experience in similar related work and are under the direct supervision of the IH. The competent and qualified person shall have successfully completed an EPA or state accredited lead-based paint abatement Supervisor course specific to the work to be performed and shall possess current and valid state and/or local government certification, as required.

B. Certified Laboratory: The Contractor shall provide documentation which includes the name, address, and telephone number of the laboratories to be providing services. In addition, the documentation shall indicate that each laboratory is an EPA National Lead Laboratory Accreditation Program (NLLAP) accredited laboratory and that each is rated proficient in the NIOSH/EPA Environmental Lead Proficiency Analytical Testing Program (ELPAT) and shall document the date of current accreditation. Certification shall include accreditation for heavy metal analysis, list of experience relevant to analysis of lead in air, and a Quality Assurance and Quality Control Program.

4.4.5 SAMPLING AND TESTING

The Contractor shall sample and test the paint. Sampling may be at the jobsite or source of supply.

Sampling of each batch shall be witnessed by the Contracting Officer unless otherwise specified or directed. A 1-quart sample of paint and thinner shall be submitted for each batch proposed for use. The sample shall be labeled to indicate formula or specification number and nomenclature, batch number, batch quantity, color, date made, and applicable project contract number.

4.4.6 SAFETY AND HEALTH PROVISIONS

Paragraph SAFETY AND HEALTH PROVISIONS supplements the requirements of EM 385-1-1, paragraph (1). In any conflict between Section 01 of EM 385-1-1 and this paragraph, the provisions herein shall govern.

A. Abrasive Blasting: The Contractor shall comply with the requirements in Section 06.H of EM 385-1-1.

i. Hoses And Nozzles: In addition to the requirements in Section 20 of EM 385-1-1, hoses and hose connections of a type to prevent shock from static electricity shall be used. Hose lengths shall be joined together by approved couplings of a material and type designed to prevent erosion and weakening of the couplings. The couplings and nozzle attachments shall fit on the outside of the hose and shall be designed to prevent accidental disengagement.

ii. Workers Other Than Blasters: Workers other than blasting operators working in close proximity to abrasive blasting operations shall be protected by utilizing MSHA/NIOSH- approved half-face or full-face air purifying respirators equipped with high-efficiency particulate air (HEPA) filters, eye protection meeting or exceeding ANSI Z87.1 and hearing protectors (ear plugs and/or ear muffs) providing at least 20 dBA reduction in noise level.

B. Cleaning with Compressed Air: Cleaning with compressed air shall be in accordance with Section 20.B.5 of EM 385-1-1 and personnel shall be protected as specified in 29 CFR 1910.134.

C. Cleaning with Solvents: Ventilation shall be provided where required by 29 CFR 1910.146 or where the concentration of solvent vapors exceeds 10 percent of the Lower Explosive Limit (LEL). Ventilation shall be in accordance with 29 CFR 1910.94, paragraph (c)(5). Personal protective equipment shall be provided where required by 29 CFR 1910.146 and in accordance with 29 CFR 1910, Subpart I.

D. Mixing Epoxy Resin Formulations: Local exhaust ventilation shall be provided in the area where the curing agent and resin are mixed. This ventilation system shall be capable of providing at least 100 linear feet per minute of capture velocity measured at the point where the curing agent and resin contact during mixing. Exposure of skin and eyes to epoxy resin components shall be avoided by wearing appropriate chemically resistant gloves, apron, safety goggles, and face shields meeting or exceeding the requirements of ANSI Z87. Individuals who have a history of sensitivity to epoxy resin systems shall be medically evaluated before any exposure can occur. Individuals who are medically evaluated as exhibiting a sensitivity to epoxy resins shall not conduct work tasks or otherwise be exposed to such chemicals.

Individuals who develop a sensitivity shall be immediately removed from further exposure and medically evaluated. A combination unit, comprised of an eyewash and deluge shower, within close proximity to the epoxy resin mixing operation shall be provided in accordance with ANSI Z358.1, paragraph (9).

E. Paint Application:

i. Ventilation: When using solvent-based paint in confined spaces, ventilation shall be provided to exchange air in the space at a minimum rate of 5,000 cubic feet per minute per spray gun in operation. It may be necessary to install both a mechanical supply and exhaust ventilation system to effect adequate air changes within the confined space. All air-moving devices shall be located and affixed to an opening of the confined space in a manner that assures that the airflow is not restricted or short circuited and is supplied in the proper direction. Means of egress shall not be blocked. Ventilation shall be continued after completion of painting and through the drying phase of the operation. If the ventilation system fails or the concentration of volatiles exceeds 10 percent of the LEL (except in the zone immediately adjacent to the spray nozzle), painting shall be stopped and spaces evacuated until such time that adequate ventilation is provided. An audible alarm that signals system failure shall be an integral part of the ventilation system.

The effectiveness of the ventilation shall be checked by using ventilation smoke tubes and making frequent oxygen and combustible gas readings during painting operations. Exhaust ducts shall discharge clear of the working areas and away from possible sources of ignition.

ii. Explosion Proof Equipment: Electrical wiring, lights, and other equipment located in the paint spraying area shall be of the explosion proof type designed for operation in Class I, Division 1, Group D, hazardous locations as required by the NFPA 70. Electrical wiring, motors, and other equipment, outside of but within 20 feet of any spraying area, shall not spark and shall conform to the provisions for Class I, Division 2, Group D, hazardous locations. Electric motors used to drive exhaust fans shall not be placed inside spraying areas or ducts. Fan blades and portable air ducts shall be constructed of nonferrous materials.

Motors and associated control equipment shall be properly maintained and grounded. The metallic parts of air-moving devices, spray guns, connecting tubing, and duct work shall be electrically bonded and the bonded assembly shall be grounded.

iii. Further Precautions:

- Workers shall wear nonsparking safety shoes.

- Solvent drums taken into the spraying area shall be placed on nonferrous surfaces and shall be grounded.

- Metallic bonding shall be maintained between containers and drums when materials are being transferred.

- Insulation on all power and lighting cables shall be inspected to ensure that the insulation is in excellent working condition and is free of all cracks and worn spots.

- Cables shall be further inspected to ensure that no connections are within 50 feet of the operation, that lines are not overloaded, and that they are suspended with sufficient slack to prevent undue stress or chafing.

iv. Ignition Sources: Ignition sources, to include lighted cigarettes, cigars, pipes, matches, or cigarette lighters shall be prohibited in area of solvent cleaning, paint storage, paint mixing, or paint application.

v. Health Protection:

- Respirators: During all spray painting operations, spray painters shall use approved SCBA or SAR (air line) respirators, unless valid air sampling has demonstrated contaminant levels to be consistently within concentrations that are compatible with air-purifying respirator Assigned Protection Factor (APF). Persons with facial hair that interferes with the sealing surface of the facepiece to faceseal or interferes with respirator valve function shall not be allowed to perform work requiring respiratory protection. Air-purifying chemical cartridge/canister half- or full-facepiece respirators that have a particulate prefilter and are suitable for the specific type(s) of gas/vapor and particulate contaminant(s) may be used for nonconfined space painting, mixing, and cleaning (using solvents). These respirators may be used provided the measured or anticipated concentration of the contaminant(s) in the breathing zone of the exposed worker does not exceed the APF for the respirator and the gas/vapor has good warning properties or the respirator assembly is equipped with a NIOSH-approved end of service life indicator for the gas(es)/vapor anticipated or encountered. Where paint contains toxic elements such as lead, cadmium, chromium, or other toxic particulates that may become airborne during painting in nonconfined spaces, air-purifying half-and full-facepiece respirators or powered air-purifying respirators equipped with appropriate gas vapor cartridges, in combination with a high-efficiency filter, or an appropriate canister incorporating a high-efficiency filter, shall be used.

- Protective Clothing and Equipment: All workers shall wear safety shoes or boots, appropriate gloves to protect against the chemical to be encountered, and breathable, protective, full-body covering during spray-painting applications. Where necessary for emergencies, protective equipment such as life lines, body harnesses, or other means of personnel removal shall be used during confined-space work.

4.4.7 MEDICAL STATUS

Prior to the start of work and annually thereafter, all Contractor employees working with or around paint systems, thinners, blast media, those required to wear respiratory protective equipment, and those exposed to high noise levels shall be medically evaluated for the particular type of exposure they may encounter.

The evaluation shall include:

A. Audiometric testing and evaluation of employees that are to work in the noise environments.

B. Vision screening (employees who use full-facepiece respirators shall not wear contact lenses).

C. Medical evaluation shall include, but shall not be limited to, the following:

(i) Medical history including, but not limited to, alcohol use, with emphasis on liver, kidney, and pulmonary systems, and sensitivity to chemicals to be used on the job.

(ii) General physical examination with emphasis on liver, kidney, and pulmonary system.

(iii) Determination of the employee's physical and psychological ability to wear respiratory protective equipment and to perform job-related tasks.

(iv) Determination of baseline values of biological indices for later comparison to changes associated with exposure to paint systems and thinners or blast media, which include: liver function tests to include SGOT, SGPT, GGPT, alkaline phosphates, bilirubin, complete urinalysis, EKG (employees over age 40), blood urea nitrogen (bun), serum creatinine, pulmonary function test, FVC, and FEV, chest x-ray (if medically indicated), blood lead (for individuals where it is known there will be an exposure to materials containing lead), other criteria that may be deemed necessary by the Contractor's physician, and Physician's statements for individual employees that medical status would permit specific task performance.

(v) For lead-based paint removal, the medical requirements of 29 CFR 1926.62 shall also be included.

4.4.8 CHANGE IN MEDICAL STATUS

Any employee whose medical status has changed negatively due to work related chemical and/or physical agent exposure while working with or around paint systems and thinners, blast media, or other chemicals shall be evaluated by a physician, and the Contractor shall obtain a physician’s statement as described in paragraph MEDICAL STATUS prior to allowing the employee to return to those work tasks. The Contractor shall notify the Contracting Officer in writing of any negative changes in employee medical status and the results of the physician’s reevaluation statement.

4.4.9 PAINT PACKAGING, DELIVERY, AND STORAGE

Paints shall be processed and packaged to ensure that within a period of one year from date of manufacture, they will not gel, liver, or thicken deleteriously, or form gas in the closed container. Paints, unless otherwise specified or permitted, shall be packaged in standard containers not larger than 5 gallons, with removable friction or lug-type covers. Containers for vinyl-type paints shall be lined with a coating resistant to solvents in the formulations and capable of effectively isolating the paint from contact with the metal container. Each container of paint or separately packaged component thereof shall be labeled to indicate the purchaser's order number, date of manufacture, manufacturer's batch number, quantity, color, component identification and designated name, and formula or specification number of the paint together with special labeling instructions, when specified. Paint shall be delivered to the job in unbroken containers. Paints that can be harmed by exposure to cold weather shall be stored in ventilated, heated shelters. All paints shall be stored under cover from the elements and in locations free from sparks and flames.

4.4.10 SPECIAL INGREDIENTS FOR SPECIAL PAINT FORMULAS

The following ingredient materials and thinners apply only to those paints whose formulas are shown in Section 3.4 in detail.

A. Pigments and Suspending Agents:

i. Carbon Black: Carbon black shall conform to ASTM D 561, Type I or II.

ii. Zinc Dust: Zinc dust pigment shall conform to ASTM D 520, Type II.

iii. Iron Oxide: Iron oxide, (Dry) synthetic (red),…