am3.pdf

AMENDMENT NO. 0003 Rehabilitation and Painting Tainter Gates W912BV-09-R-1010 Fall River Dam, Kansas

AMENDMENT OF SOLICITATION

1. CONTRACT ID

CODE

2. AMENDMENT/MODIFICATION NO.

3. EFFECTIVE

DATE

4 May 2009

4. REQUISITION/PURCHASE REQ. NO.

N/A

5. PROJECT NO. (if applicable) N/A

6. ISSUED BY CODE 7. ADMINISTERED BY (if other than Item 6)

CODE

DISTRICT ENGINEER

TULSA DISTRICT, CORPS OF ENGINEERS

1645 SOUTH 101ST EAST AVENUE

TULSA, OK 74128-4609

N/A

9A. AMENDMENT OF SOLICITATION NO.

W912BV-09-R-1010

9B. DATED (SEE ITEM 11)

23 March 2009

10A. MODIFICATION OF CONTRACT/ORDER NO.

N/A.

8. NAME AND ADDRESS OF CONTRACTOR (No., street, county, State and ZIP Code)

CODE FACILITY CODE

10B. DATED (SEE ITEM 11)

11. THIS ITEM ONLY APPLIES TO AMENDMENTS OF SOLICITATIONS

The above numbered solicitation is amended as set forth in Item 14. The hour and date specified for receipt of Offers is extended, is not extended.

The Proposal Due Date is hereby changed to 18 May 2009, 4:00 p.m. local time

Offers must acknowledge receipt of this amendment prior to the hour and date specified in the solicitation or as amended, by one of the following methods:

(a) By completing items 8 and 15, and returning __1____ copies of the amendment; (b) By acknowledging receipt of this amendment on each copy of the offer submitted;

or (c) By separate letter or telegram which includes a reference to the solicitation and amendment numbers. FAILURE OF YOUR ACKNOWLEDGEMENT TO BE RECEIVED AT THE PLACE DESIGNATED FOR THE RECEIPT OF OFFERS PRIOR TO THE HOUR AND DATE SPECIFIED MAY RESULT IN REJECTION OF YOUR OFFER. If by virtue of this amendment your desire to change an offer already submitted, such change may be made by telegram or letter, provided each telegram or letter makes reference to the solicitation and this amendment, and is received prior to the opening hour and date specified.

12. ACCOUNTING AND APPROPRIATION DATA (If required) N/A

N/A 13. THIS ITEM ONLY APPLIES TO MODIFICATION OF CONTRACTS/ORDERS.

IT MODIFIES THE CONTRACT/ORDER NO. AS DESCRIBED IN ITEM 14.

CHECK ONE

A. THIS CHANGE ORDER IS ISSUED PURSUANT TO: (Specify authority) THE CHANGES SET FORTH IN ITEM 14 ARE MADE IN THE CONTRACT

ORDER NO. IN ITEM 10A.

B. THE ABOVE NUMBERED CONTRACT/ORDER IS MODIFIED TO REFLECT THE ADMINISTRATIVE CHANGES (such as changes in paying office, appropriation date, etc) SET FORTH IN ITEM 14, PURSUANT TO THE AUTHORITY OF FAR 43.103(b).

C. THIS SUPPLEMENTAL AGREEMENT IS ENTERED INTO PURSUANT TO AUTHORITY OF:

D. OTHER (Specify type of modification and authority)

E. IMPORTANT: Contractor is not, is required to sign this document and return _________ copies to the issuing office.

13. DESCRIPTION OF AMENDMENT/MODIFICATION (Organized by UCF section headings, including solicitation/contract subject matter where feasible.)

The proposal documents are revised as follows:

INITIAL TASK ORDER

Remove in its entirety Initial Task Order, Paint Tainter Gate #1, dated April 2009, Replace with new Initial Task Order, Rehabilitation and Painting Tainter Gates, dated May 2009, attached hereto.

NOTE: IN THIS AMENDMENT “SOLICITATION NO.”, “OFFER”, AND “OFFEROR” MEAN “INVITATION NO.”, “BID”, AND “BIDDER”, RESPECTIVELY Except as provided herein, all terms and conditions of the document referenced in item 9A or 10A, as heretofore changed, remains unchanged and in full force and effect.

15A. NAME AND TITLE OF SIGNER (Type or print)

16A. NAME AND TITLE OF CONTRACTING OFFICER (Type or print)

15B. CONTRACTOR/OFFEROR

(Signature of person authorized to sign)

15C. DATE SIGNED 16B. UNITED STATES OF AMERICA

N/A

(Signature of Contracting Officer)

16C. DATE SIGNED

NSN 7540-01-162-8070 30-105-02 STANDARD FORM 30 (REV. 10-8)

PREVIOUS EDITION UNUSABLE Prescribed by GSA

PAINT MATOC

INITIAL TASK ORDER

REHABILITATION AND PAINTING

TAINTER GATES

Fall River Dam, Kansas

This action is being procured as part of the American Recovery and Re-Investment Act

(ARRA) of 2009

May 2009

REHABILITATION AND PAINTING TAINTER GATES

Fall River, Kansas

TABLE OF CONTENTS

Fall River Dam, Kansas

SECTION TITLE

00100 SOLICITATION, OFFER AND AWARD (BIDDING SCHEDULE)

00800 SPECIAL CONTRACT REQUIREMENTS

01 00 00 SCOPE OF WORK

01 27 00 MEASUREMENT AND PAYMENT

35 01 41 TAINTER GATE ROLLER CHAINS

OTHER DOCUMENTS

1. Sections of latest District Inspection Report, including TAINTER GATE

CRITICAL LOCATIONS, PICTURES AND RECOMMENDATIONS.

2. FALL RIVER 2009 SEASONAL POOL PLAN

3. EVALUATION, LINK-BELT CRANE (JUNE 2002)

4. PLAN - RECOMMENDED CRANE PLACEMENT

5. SHOP DRAWINGS - CHAIN AND HOIST EQUIPMENT

PROPOSAL SCHEDULE

FALL RIVER DAM, KANSAS

Item Unit No. Description Quantity Unit Price Amount

1. Sandblast and Paint Upstream SUM Job XXXX _____

Side of Tainter Gates

2. Sandblast and Paint Downstream SUM Job XXXX _____ Side of Tainter Gates

3. Remove and Replace Side Seal SUM Job XXXX _____ Assemblies on Tainter Gates

4. Rehabilitate Babbitt and Repair SUM Job XXXX _____ Bottom of Tainter Gates

5. Replace Hoist Chains on Tainter SUM Job XXXX _____ Gates and Provide Two Spare Chains

6. Commercial Blast & Paint Hoist SUM Job XXXX _____ Machinery, Machinery Decks, and Spillway Catwalks

7. Replace Secondary Bull Gear and SUM Job XXXX _____ Pinion on Tainter Gate #3, and Repair Chipped Teeth

TOTAL $________

NOTES

1. All costs for items of work not listed separately in the Bidding Schedule or specifically mentioned to be included in a particular item price shall be included in the listed item price most closely associated with the work involved.

2. This solicitation requires submission of a proposal on all items. Failure to do so will result in the proposal being rejected without further consideration.

THE FOLLOWING PARAGRAPHS TO BE INCLUDED IN SECTION 00800 AS A PART OF THIS

TASK ORDER

52.0000-4020 TIME EXTENSIONS FOR UNUSUALLY SEVERE WEATHER (OCT 1989)

(ER 415-1-15)

1. This provision specifies the procedure for determination of time extensions for unusually severe weather in accordance with the contract clause entitled "Default: (Fixed Price Construction)". In order for the Contracting Officer to award a time extension under this clause, the following conditions must be satisfied:

a. The weather experienced at the project site during the contract period must be found to be unusually severe, that is, more severe than the adverse weather anticipated for the project location during any given month.

b. The unusually severe weather must actually cause a delay to the completion of the project. The delay must be beyond the control and without the fault or negligence of the contractor.

2. The following schedule of monthly anticipated adverse weather delays is based on National Oceanic and Atmospheric Administration (NOAA) or similar data for the project location and will constitute the base line for monthly weather time evaluations. The contractor's progress schedule must reflect these anticipated adverse weather delays in all weather dependent activities.

MONTHLY ANTICIPATED ADVERSE WEATHER DELAY

WORK DAYS BASED ON (5) DAY WORK WEEK

JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC

5 4 4 5 6 5 4 3 4 4 3 3

3. Upon acknowledgment of the Notice to Proceed (NTP) and continuing throughout the contract, the contractor will record on the daily CQC report, the occurrence of adverse weather and resultant impact to normally scheduled work. Actual adverse weather delay days must prevent work on critical activities for 50 percent or more of the contractor's scheduled work day.

The number of actual adverse weather delay days shall include days impacted by actual adverse weather (even if adverse weather occurred in previous month), be calculated chronologically from the first to the last day of each month, and be recorded as full days. If the number of actual adverse weather delay days exceeds the number of days anticipated in paragraph 2, above, the contracting officer will convert any qualifying delays to calendar days, giving full consideration for equivalent fair weather work days, and issue a modification in accordance with the contract clause entitled "Default (Fixed Price Construction)".

52.211-10 COMMENCEMENT, EXECUTION, AND COMPLETION OF WORK (APR 1984)

The Contractor shall be required to (a) commence work under this contract within 10 calendar days after the date the Contractor receives the notice to proceed, (b) prosecute the work diligently, and (c) complete the work:

Base bid - 290 calendar days.

52.211-12 LIQUIDATED DAMAGES--CONSTRUCTION (SEP 2000)

(a) If the Contractor fails to complete the work within the time specified in the contract, the Contractor shall pay liquidated damages to the Government in the amount of $242 for each calendar day of delay until the work is completed or accepted.

(b) If the Government terminates the Contractor's right to proceed, liquidated damages will continue to accrue until the work is completed. These liquidated damages are in addition to excess costs of repurchase under the Termination clause.

(End of clause)

(END OF SECTION 00100)

SECTION 00800

SPECIAL CONTRACT REQUIREMENTS

PART 1 GENERAL

1.1 SUMMARY

Specification Section 00800 – SPECIAL CONTRACT REQUIREMENTS in the base MATOC contract shall be revised by replacing the same numbered base MATOC contract clauses with the contract clauses included or revised herein.

252.236-7001 CONTRACT DRAWINGS, MAPS, AND SPECIFICATIONS (AUG 2000)

Delete paragraph (e) and replace with the following:

(e) The work shall conform to the specifications and the following contract drawings. Except when identified as a new drawing, the following drawings are as-built drawings from previous construction contracts, are intended only to show the original construction, and are furnished for information only.

DRAWING NUMBER TITLE

COVER SHEET (NEW DRAWING)

C1 VICINITY/LOCATION MAPS AND DRAWING INDEX (NEW DRAWING)

C22 SPILLWAY AND NON-OVERFLOW SECTIONS, GENERAL PLAN

C23 SPILLWAY AND NON-OVERFLOW SECTIONS, GALLERIES

C40 TAINTER GATES GENERAL ARRANGEMENT

C41 TAINTER GATES SECTIONS & DETAILS

C42 TAINTER GATES SIDE SEAL & SILL BEAM

C43 TAINTER GATES TRUNNION ANCHORAGE

C44 OPERATING MACHINERY

PART 2 PRODUCTS (NOT USED)

PART 3 EXECUTION (NOT USED)

(END OF SECTION 00800)

SECTION 01 00 00

SCOPE OF WORK

1.1 GENERAL PROJECT DESCRIPTION

The contractor shall provide all materials, equipment, labor, instruments, tools, subcontractors, supervision, and management to rehabilitate and paint all eight tainter gates at Fall River Dam. Work shall include, but is not limited to: sandblast and paint tainter gates, replace existing side seals and rehabilitate babbitt on the weir sills, replace hoist chains, prepare and paint hoist machinery, machinery platforms and catwalks, and replace gear on Tainter Gate #3. The tainter gates are approximately 50 feet wide and 25 feet high. The entire gate including beams, girders, pockets behind cross braces, and strut arms shall be cleaned of all debris, including but not limited to: debris, sludge, water and biological formations. All drain holes shall be located and opened, open joints on the strut arm brace connections and cross plates shall be sealed, and gage mounts and entry points to the tie-back beam cavities on the upstream side shall be sealed. Blast and paint equipment, equipment platforms, and the access walkways. Remove the left secondary operating gear and pinion on Tainter Gate #3 and replace gears and assemblies with Government Furnished Equipment, and repair the chipped teeth on the replaced gear.

a. Upstream Surfaces of Tainter Gates: Clean all surfaces to SSPC SP5

(White Metal) and apply paint system 5-E-Z.

b. Downstream Surfaces of Tainter Gates: Clean all surfaces to SSPC SP5

(White Metal) and apply paint system 5-E-Z. Either pre-sandblast the corroded areas or sandblast to white metal and apply up to the first coat of paint in the 5-E-Z paint system on the gate. A combined inspection shall then be done with Corps and Contractor to verify areas that get epoxy. Inspect the gate for corrosion damage 1/8 inch or deeper. Document the number and size of corrosion damage pits or grooves and take photographs with a scale in the picture of corrosion damage areas. Repair all corrosion damage 1/8 inch or greater with weld build-up as specified. Fill all corrosion damage less than 1/8 inch deep with epoxy coating Thortex. Re-sandblast to white metal, prime with VZ 108d an area covering a minimum 1’ wider than the weld, and apply up to the first coat of paint the areas repaired with weld.

Sand smooth, clean with solvent, apply primer and apply up to the first coat of paint the areas filled with epoxy. Either pre-sandblasting or the re-sandblasting and applying up to the first coat in the repaired areas are to be included in the bid item for sandblasting and painting the downstream surface of Tainter Gate #1.

Areas that require weld build-up opposite the side that has been painted by the contractor shall be jointly inspected on the painted side after the weld is completed. If the paint has been damaged due to welding operations, the area on the painted side shall be repaired by a method to be approved by the Contracting Officer at no additional cost to the Government.

c. Trunnion Girders and Assemblies - Work shall include, but not necessarily be limited to, removing residual sealant, debris, laminated rust, and pack rust, unclogging drain holes, cleaning drain holes and pans of debris, blasting, painting, and greasing the trunnion assemblies. Painting work consists of blasting to white metal, priming, and painting each trunnion anchorage and assembly in its entirety with System No. 5-E-Z.

d. Tie Back Beams and Anchorages - Work shall include, but not necessarily be limited to, removing residual sealant, debris, laminated rust, and pack rust, and sealing gage mounts and entry points to the tie-back beam cavities on the upstream side with a one or two-component, elastomeric, polyurethane sealant or a single component urethane foam sealant. Painting work consists of blasting to white metal, priming, and painting each tie back beam and anchorage in its entirety with System No. 5-E-Z.

e. Provide and replace the side seal assemblies, including but not limited to seals, bolts, nuts, washers, screws, retainer and spacer bars, and appurtenant items, of the gates with new seals and adjust for proper fit to minimize water leaks when the gates are shut.

Repair babbitt on the weir sill to provide a smooth and level surface per the Babbitt Repair Procedure described in Section 05 50 03 of the base MATOC specifications. Ensure the gate bottom is straight and even to provide a flush watertight seal between babbitt and the gate.

f. Replace all existing hoist chains and provide two complete spare chains.

g. Hoist Machinery Platform - Work shall include, but not necessarily be limited to, cleaning, preparing for painting, and painting all of the hoist machinery for each of the nine platforms including the top surface of the beams supporting the platforms underneath. Paint shall be System No. 15.

h. Access Walkway – Work shall include, but not necessarily be limited to, cleaning, preparing for painting, and painting all of the catwalks for each of the eight gates. Paint shall be System No. 15.

i. Clean all Government property including the gates, weirs, and bridge of all blast media and debris resulting from the Contractor’s construction activities.

1.2 PROTECTION OF TRUNNION ASSEMBLY, HOIST EQUIPMENT, MACHINERY

Due to the enormous cost of possible repair, the importance of protecting this equipment and assemblies (bronze bushings, steel castings, trunnion pins, keys, keeper plates, motors, etc.) during blasting and painting cannot be over-emphasized. Proper protection shall rest solely on the Contractor.

Any damage, as with all damage to Government property, shall be repaired by the Contractor entirely at the Contractor’s expense. Protection methods shall be submitted to the Contracting Officer for approval before any work begins.

1.3 LEAD PAINT

The existing paint contains lead. Lead level is shown to be 12,800 mg/Kg.

Data was analyzed on February 5, 2009.

1.4 SITE VISIT

An authorized contractor representative in conjunction with the USACE Contracting Officer and/or technical representative(s) shall conduct a site visit at the proposed construction site. The purpose of the site visit will be to meet with project representative(s) and obtain a more detailed understanding of this Scope of Work. The site visit will also allow the contractor the opportunity to examine the project site conditions.

1.5 PRICE PROPOSAL

The price proposal for the task order shall follow the guidance in paragraph 1.1.3, Section 00050 of the basic MATOC contract. Proposals shall be submitted in accordance with the Bidding Schedule in Section 00100. The contractor shall use the information in this Scope of Work in conjunction with information obtained at the site visit as the basis of his proposal.

1.6 PRE-WORK CONFERENCE

The Contractor shall attend a pre-work conference with the Contracting Officer’s Representative prior to commencing work on the project.

1.7 WORK HOURS

Work hours shall be Monday through Friday, 7 a.m. to 6 p.m. unless otherwise requested in writing by the Contractor and approved in writing by the Contracting Officer. The Contractor shall not work on Federal holidays unless prior approval is granted in writing by the Contracting Officer.

Request and approval for working outside the designated work hours shall be on a case-by-case basis.

1.8 LIMITATION ON GATES OUT OF SERVICE

Only one tainter gate may be out of service at any time.

1.9 GOVERNMENT FURNISHED UTILITIES

480V/3 phase/30 amp electric service is available at each tainter gate operating machinery platform (Elevation 991.5). 120V/15 amp single-phase service is available at each pier. Non-potable (raw lake) water is available at the spillway. Electricity and non-potable water are available at no additional cost to the Contractor if proper energy conservation methods are implemented. The Contractor shall be responsible for conditioning the power as necessary and providing conductors, hoses, etc. from existing service locations.

1.10 RESERVOIR INFORMATION AND HISTORICAL DATA

The conservation pool elevation is 948.5 feet, and the top of the weir is at elevation 962.5 feet. Fall River Lake monthly charts of reservoir data since November 1994 may be viewed at http://www.swt-wc.usace.army.mil/FALL.lakepage.html. Any conclusions drawn by the Contractor from this data are done so at the Contractor’s risk.

1.11 WATER RELEASES THROUGH TAINTER AND SLUICE GATES

Water releases may affect the Contractor’s operations. Two types of water releases may occur: low flow releases and flood releases.

Low flow releases to maintain water quality for fish and wildlife habitat will be made from the outlet works year around as necessary to meet regulatory requirements. The Government will give 24 hours advance notice to the Contractor when water releases and/or gate changes are made for water quality purposes. Wind direction, gates currently being rehabilitated, and the volume of water to be released will be taken into consideration in an attempt to minimize impact on the Contractor’s work.

Flood releases will be made as required for flood damage reduction. In flood release emergencies, every effort will be made to give the Contractor 24 hours notification of gate changes. The Contractor shall constantly monitor weather conditions and forecasts and be prepared for potential emergency conditions. The Contractor shall be prepared to secure and protect current working areas and personnel from flood releases. The Contractor’s on-site superintendent will be notified of gate changes by the Government. Phone and/or voice mail notification will be made when Government personnel are unable to contact the superintendent in person.

PART 3 EXECUTION

3.1 TRUNNION ANCHORAGE AND TRUNNION ASSEMBLY WORK

3.1.1 Removal of Rust and Debris Between Anchor Beams and Concrete Piers

Before blasting, all loose laminated rust, pack rust, scaled rust, debris, and sealant shall be removed from the anchor beams. Removal shall extend 24” inside the face of the concrete piers. The Contractor’s method and equipment for removal shall be submitted to the Contracting Officer for approval. The Contractor shall provide 24 hours notice before any painting begins to allow the Government to inspect the anchor beams after blasting and before painting.

3.1.2 Blasting and Painting

The Contractor shall blast and paint each trunnion anchorage and assembly in accordance with the base MATOC specification Section 09 97 02 Painting of Hydraulic Steel and Cast Iron Structures, Including Removal of Lead Paint.

Paint for all structures shall be System No. 5-E-Z. Each subsequent coat of paint shall completely hide previous coat. Blasting and painting of the trunnion assemblies shall extend from the extreme downstream end of the trunnion assembly, along the tainter gate strut arms to a point 3 feet past the centerline of the trunnion pin. Using specialized equipment and/or nozzles, the Contractor shall blast and paint the anchor beams 24” inside the face of the concrete piers. Where the openings are too narrow to reach the full 24”, a lesser depth will be allowed upon approval of the Contracting Officer.

3.2 PAINTING OF HOIST MACHINERY

3.2.1 Cleaning and preparing of machinery

All of the exterior surfaces of the hoist machinery shall be commercial blasted to a surface preparation standard of SSPC-SP 6. Care shall be taken in covering and protecting all electrical and mechanical components not to be painted (i.e. electrical panels, switches, etc).

3.2.2 Painting machinery

All of the exterior surfaces of the hoist machinery shall be painted with system no. 15 as outlined in MATOC specification Section 09 97 02. The color shall be light gray or aluminum.

3.3 PAINTING OF HOIST PLATFORM BEAMS

3.3.1 Cleaning and preparing of beams

The top surfaces of all of the supporting beams underneath the platform shall be commercial blasted to a surface preparation standard of SSPC-SP 6.

3.3.2 Painting of beams

The top surfaces of all of the supporting beams underneath the platform shall be painted with system no. 15 as outlined in MATOC specification Section 09 97 02. The color shall be light gray or aluminum.

3.4 PAINTING OF ACCESS WALKWAYS

3.4.1 Cleaning and preparing of walkways

All of the steel components composing the catwalk shall be commercial blasted to a surface preparation standard of SSPC-SP 6. The entire catwalk for all eight tainter gates shall be prepared for painting.

3.4.2 Painting of walkways

The walkway shall be painted with system no. 15 as outlined in MATOC specification section 09 97 02. The color shall be light gray or aluminum.

3.5 GREASING TRUNNION ASSEMBLIES

The Contractor shall grease the trunnion assemblies. Grease shall be Texaco Starplex 2 or equal. The assembly shall be greased before Contractor is allowed to start work on the other trunnion anchorage. Trunnion assemblies should be greased during a full cycle of gate operation to ensure that the grease is evenly distributed.

3.6 PROTECTION OF GOVERNMENT PROPERTY

In addition to all requirements to protect Government property in the base MATOC specifications, Contract Clauses, and Special Contract Requirements, the Contractor shall take particular care to protect the tainter gate hoist operating machinery assemblies and trunnion assemblies, which are highly susceptible to damage by dust, blast media, and debris. The contractor shall not drill holes or otherwise alter or deface any existing structure including the bridge, trunnion anchorages, trunnion assemblies, tainter gates, piers, bullnoses, weirs, catwalks, or equipment decks unless requested in writing with proposed repair methods and approved in writing by the Contracting Officer. Scaffolding, work platforms, hoists, chain falls, or other equipment shall not be attached to catwalks or equipment decks unless requested in writing with attachment details and calculations showing the catwalks or equipment decks are capable of supporting the proposed loads and approved in writing by the Contracting Officer.

3.7 CRANE PLACEMENT AND BRIDGE LOADING

The Contractor shall furnish the crane necessary to perform the work. The bridge has been analyzed for the use of a Link-Belt HTC-8670LB crane. The results of the analysis are in the “Fall River Lake, Fall River, Kansas;

Spillway Bridge Evaluation, Link-Belt Crane” report dated June 2002. A copy of the report will be provided to the Contractor. The analysis specifies crane placement and load limits to safely set the bulkhead and for other operations. The HTC-8670LB can only be used in accordance with the directions specified in the report. If the contractor plans on using any other crane on the bridge, he must first analyze the bridge for that crane’s planned operation. The Contractor must submit to the Contracting Officer for approval, the analysis and an operation plan showing the size and type of crane, where and how it will be operated and how the outriggers will be placed. Depending upon the weight, boom, and placement of the outriggers, the bridge may not support some heavy crane operations. In addition, if the contractor plans on using a crane near the training walls of the spillway he must first analyze if the walls can withstand the crane loads and submit his analysis and operation plan for approval.

3.8 CLEAN UP

After completion of construction, the Contractor shall clean all Contractor-generated blast media and construction debris from all gates, weirs, bridge, catwalk, machinery, decks, and assemblies, and all other Government property.

The Contractor shall ensure that all drain holes are completely open.

3.9 SUBMITTALS

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

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

SD-01 Preconstruction Submittals

Detailed Work Plan; G

A detailed work plan shall be submitted. The plan shall include details for the following:

a. Sandblast, prepare for painting, and painting tainter gates,

b. Methods for removal, containment, and disposal of blast media and paint containing lead,

c. Babbitt repair,

d. Side seal replacement,

e. Hoist chain replacement,

f. Equipment, platform, and catwalk cleaning and painting

All submittals shall be in accordance with specification Section 01 33 00 SUBMITTAL PROCEDURES and Section 01 45 02 Quality Control System (QCS).

Items shall be submitted and numbered under the technical specification section to which the materials and equipment apply and these numbers shall properly interface with WinRMS and QCS.

(END OF SECTION 01 00 00)

SECTION 01 27 00

MEASUREMENT AND PAYMENT FOR INITIAL TASK ORDER

PAINT TAINTER GATE #1 AT

FALL RIVER DAM, KANSAS

Work referenced in the bid items is covered under the general MATOC technical provisions and the attached Tainter Gate Hoist Chain Replacement specification.

All costs for items of work, which are not specifically mentioned to be included in a particular unit price shall be included in the listed unit price item most closely associated with the work involved.

Payment for the items listed below shall constitute full compensation for furnishing all plant, labor, materials, and equipment, and performing any associated Contractor quality control, environmental protection, meeting safety requirements, tests and reports, and for performing all work required for which separate payment is not otherwise provided.

BID ITEM 1 SANDBLAST AND PAINT UPSTREAM SIDE OF TAINTER GATES

MEASUREMENT

No separate measurement will be made for the cleaning or painting of the upstream side of the tainter gates.

PAYMENT

Payment for removal of existing paint system, sandblasting and applying 4 coats of vinyl paint to the upstream surfaces of all eight tainter gates including repairing any corroded areas on the surfaces, will be made at the contract price for bid item, "Sandblast and paint upstream side of tainter gates". Price and payment shall constitute full compensation for materials, labor, plant, equipment and incidentals required for blasting, cleaning and painting the surfaces as specified.

BID ITEM 2 SANDBLAST AND PAINT DOWNSTREAM SIDE OF TAINTER GATES

No separate measurement will be made for the cleaning or painting of the downstream side of the tainter gates.

PAYMENT

Payment for removal of existing paint system, blast-cleaning and applying 4 coats of vinyl paint to the downstream surfaces of all eight tainter gates including gate ribs, girders, bracing, trunnion girders, tie-back beams, strut arms and thrust girders, and repairing any corroded areas on the surfaces will be made at the contract price for bid item, "Sandblast and paint downstream side of tainter gates". Price and payment shall constitute full compensation for materials, labor, plant, equipment and incidentals required for blasting, cleaning and painting the surfaces as specified.

Either pre-sandblasting or the re-sandblasting and applying up to the first coat in the repaired areas are to be included in the bid item for sandblasting and painting the downstream surfaces of the tainter gates.

BID ITEM 3 REMOVE AND REPLACE SIDE SEAL ASSEMBLIES ON TAINTER GATES

No separate measurement will be made for removing and replacing side seal assemblies on the tainter gates.

PAYMENT

Removing, preparing, furnishing, installing and adjusting of side seal assemblies and filler material, if required, will be made at the contract lump sum price for bid item "Remove and replace side seal assemblies on tainter gates". This work shall include removing and installing new rubber seals, neoprene gaskets, stainless steel bolts, nuts and washers, with plastic sleeves or other suitable material to isolate the bolting assembly from the gate metal, and replacing seals, bolts, nuts, washers, screws, retainer and spacer bars, and appurtenant items. Seal holes in the bottom corners of the gates with rubber wedges, Devcon’s Plastic Steel Liquid B, and roof cement or approved equal. This item shall include all material and hardware required for complete installation of side seal assemblies. Price and payment shall constitute full compensation for materials, labor, equipment and incidentals required to complete the work as specified and shown on the drawings.

BID ITEM 4 REHABILITATE BABBITT AND REPAIR BOTTOM OF TAINTER GATES

No separate measurement will be made for rehabilitating babbitt on the tainter gate sills and repairing the bottom of the tainter gates.

PAYMENT

Rehabilitation of the babbitt on all eight tainter gate sills will be made at the contract lump sum price for bid item "Rehabilitate babbitt and repair bottom of tainter gates". This work shall include rehabilitation of the babbitt on the gate sill and repair of the gate bottom to ensure the gate bottom is straight and even to provide a flush watertight seal between babbitt and the gate. Price and payment shall constitute full compensation for materials, labor, equipment and incidentals required to complete the work as specified and shown on the drawings.

BID ITEM 5 REPLACE HOIST CHAINS ON TAINTER GATES AND PROVIDE TWO SPARE

CHAINS

No separate measurement will be made for replacing hoist chains and providing two complete spare chains.

PAYMENT

Removal and replacement of the hoist chains on all eight tainter gates will be made at the contract lump sum price for bid item "Replace hoist chains on tainter gates and provide two spare chains". This work shall include removal and replacement of the hoist chains, adjusting and verifying operation. Price and payment shall constitute full compensation for materials, labor, equipment and incidentals required to complete the work as specified and shown on the drawings.

BID ITEM 6 – COMMERCIAL BLAST & PAINT HOIST MACHINERY, MACHINERY DECK, AND

SPILLWAY CATWALKS

MEASUREMENT

No separate measurement will be made for commercial blasting and painting of the hoist machinery, machinery deck, and spillway catwalks.

PAYMENT

Payment for cleaning, preparing for painting, and painting of all surfaces of the tainter gate hoist equipment, control panels, machinery bases, machinery decks, and the spillway catwalks will be made at the contract lump sum price for bid item "Commercial blast & paint hoist machinery, machinery deck, and spillway catwalks". This work shall include painting all machinery, platforms, and catwalks. Price and payment shall constitute full compensation for materials, labor, equipment and incidentals required to complete the work as specified and shown on the drawings.

BID ITEM 7 – REPLACE SECONDARY BULL GEAR AND PINION ON TAINTER GATE #3, AND

REPAIR CHIPPED TEETH

MEASUREMENT

No separate measurement will be made to replace the gear and pinion and repair chipped teeth.

PAYMENT

Payment to remove the existing gear and pinion, replace with government furnished property, clean, lubricate, operate, adjust, and repair the chipped teeth, will be made at the contract lump sum price for bid item "Replace secondary bull gear and pinion on tainter gate #3, and repair chipped teeth". Price and payment shall constitute full compensation for materials, labor, equipment and incidentals required to complete the work as specified and shown on the drawings.

PART 3 EXECUTION (NOT USED)

(END OF SECTION 01 27 00)

SECTION 35 01 41

TAINTER GATE HOIST CHAIN REPLACEMENT

03/09

1.1 SCOPE

This work consists of, but is not limited to, fabricating and delivery of roller chains for lifting tainter gates at Fall River Dam. The chain is a sprocket driven chain made up of links connected by pins. The work items shall consist of, but not necessarily be limited to, the following:

(1) fabrication of all components as shown and specified,

(2) assemble the chains in lengths as shown or specified,

(3) furnish spare chain parts as shown or specified,

(4) prepare the chains for shipping and deliver the chains to the designated site.

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

ASME INTERNATIONAL (ASME)

ASME B46.1(2002) Surface Texture (Surface Roughness, Waviness and Lay)

ASTM INTERNATIONAL (ASTM)

ASTM A 564/A 564M(2004) Standard Specification for Hot-Rolled and Cold- Finished Age-Hardening Stainless Steel Bars and Shapes

ASTM A 578/A578M(2007) Standard Specification for Straight-Beam Ultrasonic Examination of Rolled Steel Plates for Special Applications

ASTM A 666(2003) Standard Specification for Annealed or Cold-Worked Austenitic Stainless Steel Sheet, Strip, Plate and Flat Bar

ASTM B 505/B 505M(2005) Standard Practice for Ultrasonic Pulse-Echo Straight-Beam Examination by the Contact Method

ASTM E 114(2007) Standard Specification for Steel Bar, Carbon and Alloy, Cold-Finished

1.3 MEASUREMENT AND PAYMENT

Measurement and payment shall be in accordance with Section MEASUREMENT AND

PAYMENT.

1.4 SUBMITTALS

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

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. The following shall be submitted in accordance with Section 01300 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Ultrasonic Testing Agency; G

The Contractor shall submit for approval the name of the testing agency, names of individuals qualified and proposed to perform the ultrasonic examination of the chain components, and qualifications of those individuals (such as resumes including education, training, etc.).

Ultrasonic Testing Procedures; G

The Contractor shall submit ultrasonic testing procedures formulated by the NDT agency that includes description of the testing apparatus and governing ASTM specifications. This submittal shall contain information that demonstrates the defect threshold of 0.2 inch inclusions will be located and identified through the testing procedures.

Packaging

The contractor shall submit a detail showing construction of pallets for shipping chain. The submittal shall show the size and location of forklift slots in the pallets. Wrapping and securing the chains to the pallets shall be shown.

SD-02 Shop Drawings

Component Shop Drawings; G

Shop drawings shall be complete in detail; indicate thickness, type, grade, class of metal, and dimensions; include catalog cuts and erection/installation details; and show fabrication details and installation in relation to the fabrication/construction.

SD-03 Product Data

Materials Data

The Contractor shall submit, as soon as issued, copies of all purchase and mill orders, shop orders for materials, and work orders. The Contractor shall submit a list designating the material to be used for each item. The Contractor shall submit mill certificates of the materials used for fabrication of the chain side bars, pins, rollers, and collars. The Contractor shall furnish, upon request, documentation that demonstrates any other materials used in the fabrication of the chain components are in accordance with the contract requirements. Mill test documentation shall contain the name and address of the testing agency. A material data sheet shall be submitted for anti-seize compound used for protection of work.

SD-06 Test Reports

Ultrasonic Test Reports

Testing reports shall include reportable indications, geometry of indications, location of indications, test parameters, and date of testing.

The size, shape, and location of indications shall be characterized using sketches. The test report shall include all relevant information as required by ASTM E114.

SD-07 Test Reports

Retaining Rings

Submit retaining ring manufacturer's catalog and engineering data to demonstrate that it meets the specified criteria for composition and strength properties. Submit manufacturer's data including ring dimensions, installation instructions, and recommended ring groove dimensions.

1.5 QUALITY CONTROL/QUALITY ASSURANCE FOR ROLLER CHAIN ASSEMBLIES

1.5.1 Quality Control

The Contractor is responsible for quality control. The Contractor shall implement and maintain an inspection log for verification of dimensional tolerances. The inspection log shall be made available immediately upon request by the Contracting Officer prior to acceptance of the contract work.

Non-destructive testing shall be completed as described. Costs for replacement of rejected parts shall be borne by the Contractor.

1.5.1.1 NDT Agency Requirements

The ultrasonic examination shall be conducted by a testing agency adequately equipped and competent to perform such services or by the Contractor using suitable equipment and qualified personnel. In either case, written approval of the examination procedures will be required and the examination tests shall be made in the presence of the Contracting Officer's representative. Persons performing the ultrasonic examination shall be qualified for the specific procedure used in accordance with the current edition of ASNT SNT-TC-IA. Only individuals qualified for NDT Level II may perform this ultrasonic examination.

1.5.1.2 Non-Destructive Testing (NDT) for Flaws

Five percent (5%) of the total supplied quantity of sidebars, long pins, and short pins shall be ultrasonically scanned for internal defects. Lots from which examined specimen parts are selected shall consist of at least 25% of the total quantity of parts to be furnished. A lot shall be the completed components of a given type available at the inspection site. Parts to be examined shall be selected at random by the Contracting Officer. The Contractor shall notify the Government one week prior to when the lots are available for specimen selection. If a significant flaw (such as discontinuities, voids, or delamination) is detected with certainty, the component will be subject to rejection.

1.5.1.3 Non-Destructive Testing (NDT) for Flaws in Sidebars

Sidebars shall be tested in the machined and hardened state. Sidebars shall be ultrasonically examined in accordance with ASTM A578/A578M or as approved. Specimens with inclusion (defect) size greater than 0.20 inch in any direction shall be rejected.

1.5.1.4 Non-Destructive Testing (NDT) for Flaws in Pins

Pins tested shall have ends finished to 125 micro-inches or smoother and cross-holes not drilled, to allow axial direction ultrasound scans. Pins shall be ultrasonically examined in accordance with ASTM E114 or as approved. Specimens with inclusion (defect) size greater than 0.20 inch in any direction shall be rejected.

1.5.2 Quality Assurance

At the Government discretion, testing to supplement the Contractor Quality Control may be conducted. The Contractor shall notify the Government when the work is ready for inspection and shall assist in obtaining the necessary samples and inspections as given in the contract clause "Inspection of Supplies." Test specimens will be selected by random sampling.

Dimensional testing and hardness testing of the chain components shall be performed at the Contractor's fabrication site. More than one testing date may be required. The following testing measurements will be made by a representative of the Contracting Officer in order to verify that the parameters are within required tolerances. Components will be tested at a minimum frequency for the first manufacturing cycle as given in Table 1.

TABLE 1. TESTING REQUIRED

ITEM MEASURED PARAMETERS1 NUMBER OF

SAMPLES TESTED

Short Pin2 OD, BHN, FINISH 46

Long Pin2 OD, BHN, FINISH 16

Spacer Sleeve3 ID, OD, ID FINISH 68

End Roller3 ID, OD, ID FINISH 34

Side Bar4 ID, Pitch, BHN, ID FINISH 112

Link Plate4 ID, Pitch, BHN, ID FINISH 4

Bottom Links4 ID, Pitch, BHN, ID FINISH 4

Spacer5 ID, Width, BHN 34

Retaining Ring5 ID, Width, BHN 34

NOTES:

1. OD = Outside Diameter, ID = Inside Diameter, BHN = Brinell Hardness Number, FINISH = Surface Finish

2. Take three diameter readings and three hardness readings for each selected pin. Measure the diameter and width of the retaining ring grooves at each end. In addition, measure the diameters to the ends of the long pins. Inspect the finish of the bearing surfaces.

3. Measure inside and outside diameter of each selected sleeve and roller.

Inspect the finishes of both the inside and outside surfaces.

4. Measure inside diameters of both bores, three measurements per bore.

Inspect the finish of both bores. Measure pitch tolerance derived from sidebar inside diameter edge to edge measurements. Take three hardness readings per selected sidebar.

5. Measure inside diameter, outside diameter, and width; one measurement of each parameter.

1.5.2.1 Acceptance

All readings taken from the sample are required to be within the required tolerances. Each component that fails the tolerance test will make the entire quantity subject to rejection. Failure of any part to pass the contract requirements will be cause for rejection of the entire quantity until action taken by the Contractor to correct defects and prevent recurrence has been approved by the Contracting Officer. Retesting will be subject to the same random sampling as the original testing.

1.5.2.2 Gages

Gages shall be made available at the Contractor's fabrication site, by the Contractor, to the Government for use in checking critical dimensions. Gages shall be vernier, micrometer, or snap type. Gages are required to measure the following:

(1) Side-bar, inside diameter of bore (ID).

(2) Pin diameter.

(3) Side bar pitch (gage to measure pitch with minimum/maximum tolerance of bore and link pitch).

PART 2 PRODUCTS

2.1 ROLLER PINS

Short pins and long pins shall be fabricated from ASTM A564/A564M Type XM- 25, Condition H1050 stainless steel. This material shall be certified by the steel manufacturer to provide at least 115000 psi minimum yield strength as defined by ASTM A564/A564M. Heat treatment shall be done by the steel manufacturer or in strict adherence to the manufacturer's heat treatment instructions.

2.2 SIDEBARS, SPACER SLEEVES AND END ROLLERS

Sidebars, link plates, bottom links, spacer sleeves and end rollers shall be fabricated from heat treated ASTM B505/B505M aluminum bronze conforming to UNS No. C95500 HT. This material shall be certified by the aluminum bronze manufacturer to provide 62000 psi minimum yield strength as defined by ASTM B505/B505M. Heat treatment shall be done by the aluminum bronze manufacturer or in strict adherence to the manufacturer's heat treatment instructions.

2.3 SPACERS

The spacers shall be fabricated from ASTM A666 Type 302 stainless steel, 1/4 hard.

2.4 RETAINING RINGS

Retaining rings shall be Smalley WST-350 and WST-175 fabricated from ASTM A666 Type 302 stainless steel.

PART 3 EXECUTION

3.1 WORKMANSHIP

Workmanship shall be of the highest grade and in accordance with the best modern practices to conform with the contract requirements.

3.1.1 Manufacturing Process

The contract drawings and specifications only indicate dimensional and material characteristics of the chain components and finished assembly. The Contractor shall be responsible for the proper selection of manufacturing methods and assembly. The Contractor shall notify the Contracting Officer of conflicts within 30 calendar days after receipt of contract notice to proceed. The Contractor must receive written resolution before proceeding with the contract work.

3.2 FABRICATION

3.2.1 General

Unless approved otherwise, all like components shall be the product of one manufacturer. Flame cutting of material shall be stated on the shop drawings submitted. Shearing shall be accurately done and all portions of the work shall be neatly finished. Corners shall be square and true unless otherwise required.

3.2.2 Chain Sidebars

Chain sidebars shall be cut from mill stock plate or bar stock. Chain sidebars may be cut by mechanically guided or hand guided torches provided an accurate profile with a smooth surface free from cracks and notches is obtained. Cuts shall be ground or machined to sound metal, to the finished required dimensions. Top and bottom surfaces that control the plate thickness shall be machined or surface ground true over approximately 75 percent of the surface area and all subsequent machining operations shall be referenced from these surfaces.

3.3 PINNED CONNECTIONS

3.3.1 Chain Pin and Roller Connections

Holes shall be accurately located, cylindrical, and perpendicular to the chain pin and/or chain roller. Countersinking shall be true and square with the hole. Holes shall be larger than the diameter of the roller pins by the tolerances shown. The holes shall be drilled full size or smaller than the diameter of the roller pin and then reamed to full size unless otherwise approved.

3.4 MACHINE WORK

3.4.1 General

Unless otherwise required, all tolerance allowances, and gages for metal fits between plain, non-threaded and cylindrical parts shall conform to ANSI B46.1. Tolerances for machine-finished surfaces designated by non-decimal dimensions shall be within 1/64 inch unless required otherwise.

3.4.1.1 Lathe Work

Lathe centers on all pins are permissible provided they do not exceed 3/8 inch diameter or depth.

3.4.2 Finished Surfaces

3.4.2.1 Required Surface Finish

Required surface finish. Values of roughness height where required are arithmetical average deviations expressed in micro-inches. Required roughness is the maximum value and any lesser value will be satisfactory.

Compliance with required surface finish shall be determined by sense of feel and by visual inspection of the work compared to roughness comparison specimens in accordance with ANSI B46.1. Flaws such as scratches, ridges, holes, peaks, cracks, plating defects, or checks that could make the part unsuitable, as determined by the Contracting Officer, for the intended use will be cause for rejection.

3.4.2.2 Non-specified Surface Finish

The type of finish shall be that which is most suitable for the particular surface and shall provide the class of fit required. The Contractor shall finish the mating pin and bore surfaces as indicated on the drawings.

3.5 CLEANING

After fabrication and prior to assembly, oil, paint, and other foreign substances shall be removed from surfaces.

3.6 ASSEMBLY

Pipe wrenches, cold chisels, or other tools likely to cause damage to the surfaces of chain pins, rollers, sleeves, or other parts shall not be used for the work of assembling and tightening parts.

3.7 PREPARATION FOR SHIPPING

3.7.1 Marking and Labeling

All chain shall be labeled indicating the gate number. After assembly of complete chain and before separation for shipping, all chain shall be match marked at the separation points to ensure proper field assembly at their respective sites. The separation point of each chain shall be at the midpoint of the chain as shown. Match marks shall consist of clear, easily identified symbols. Labels and match marks shall be located in such a way as not to be hidden from view, and not to deteriorate due to exposure to the atmosphere, moisture, or weather.

3.7.2 Protection of Finished Work

All machined surfaces and parts to be assembled shall be thoroughly cleaned.

Protective coatings, packing compounds, dirt, grit, and other foreign matter shall be removed. All finished surfaces shall be protected by suitable means. All pins and bores shall be lubricated with an anti-seize compound at assembly. The anti-seize compound shall contain copper, graphite and other metallic additives in a bearing lubricant. Spare chains shall be oiled and wrapped with moisture resistant paper or protected by other approved methods.

3.7.3 Packaging Requirements

Each chain shall be split into two equal segments, each about 25 feet long.

Each 25 foot segment shall be folded onto a pallet about 14 feet long. Each chain shall be packaged on a separate pallet with both 25 foot segments.

Pallets shall be accessible with forklifts and suitable for stacking.

3.7.4 Storage

Chain, including spare parts, shall be stored off the ground and shall be protected from the elements.

(END OF SECTION 35 01 41)

October 2008October 2008

FALL RIVERFALL RIVER

TAINTER GATETAINTER GATE

STRUCTURAL STRUCTURAL

INSPECTION REPORTINSPECTION REPORT

TABLE…