W912DW19R0016_Amendment_0001.pdf

AMENDMENT OF SOLICITATION/MODIFICATION OF CONTRACT

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)

30-105-04EXCEPTION TO SF 30

APPROVED BY OIRM 11-84

STANDARD FORM 30 (Rev. 10-83) Prescribed by GSA

FAR (48 CFR) 53.243

Amendment 0001

(Please see continuation sheet)

1. CONTRACT ID CODE PAGE OF PAGES

1 2

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

16C. DATE SIGNED

BY 31-May-2019

16B. UNITED STATES OF AMERICA15C. DATE SIGNED15B. CONTRACTOR/OFFEROR

(Signature of Contracting Officer)(Signature of person authorized to sign)

8. NAME AND ADDRESS OF CONTRACTOR (No., Street, County, State and Zip Code) X W912DW19R0016

X 9B. DATED (SEE ITEM 11)

08-May-2019

10B. DATED (SEE ITEM 13)

9A. AMENDMENT OF SOLICITATION NO.

11. THIS ITEM ONLY APPLIES TO AMENDMENTS OF SOLICITATIONS

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

Offer 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 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 ACKNOWLEDGMENT 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 you 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)

13. THIS ITEM APPLIES ONLY TO MODIFICATIONS OF CONTRACTS/ORDERS.

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

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.

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

10A. MOD. OF CONTRACT/ORDER NO.

2. AMENDMENT/MODIFICATION NO. 5. PROJECT NO.(If applicable)

6. ISSUED BY

3. EFFECTIVE DATE

31-May-2019

CODE

USA ENGINEER DISTRICT, SEATTLE

ATTN: CENWS-CT

4735 EAST MARGINAL WAY SOUTH, BLDG. 1202

SEATTLE WA 98134-2388

W912DW 7. ADMINISTERED BY (If other than item 6)

4. REQUISITION/PURCHASE REQ. NO.

CODE

See Item 6

FACILITY CODECODE

EMAIL:TEL:

W912DW19R0016

SECTION SF 30 BLOCK 14 CONTINUATION PAGE

SUMMARY OF CHANGES

SECTION SF 30 - BLOCK 14 CONTINUATION PAGE

The following have been added by full text:

AMENDMENT 0001

1. This amendment provides for the following changes:

a. Section 05 59 13.01 26 – FABRICATION OF HYDRAULIC STEEL STRUCTURES 03/17 is revised

b. Drawings S-501, S-508, and S-509 are revised.

2. Attached are currently available answers to bidder inquiries.

3. The bid submittal time and date of 10 June 2019 at 1:00 PM PT is NOT CHANGED.

4. The attached revised sections are to be replaced in their entirety. All portions of the revised sections shall apply whether or not changes have been indicated.

5. NOTICE: Bidders must acknowledge receipt of this amendment by number and date on offer.

Attch:

Section 05 59 13.01 26 (revised) Drawings S-501, S-508, and S-509 (revised) Answers to bidder inqueries

(End of Summary of Changes)

SECTION 05 59 13.01 26

FABRICATION OF HYDRAULIC STEEL STRUCTURES

03/17

PART 1 GENERAL

1.1 GENERAL INFORMATION

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

a. One emergency sluice gate.

One emergency sluice gate is required to dewater a sluiceway. An emergency sluice gate consists of one section.

1.2 REFERENCES

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

AMERICAN ASSOCIATION OF STATE HIGHWAY AND TRANSPORTATION OFFICIALS

(AASHTO)

AASHTO HB-17 (2002; Errata 2003; Errata 2005, 17th Edition) Standard Specifications for Highway Bridges

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

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

AISC 325 (2011) Steel Construction Manual

AISC 326 (2009) Detailing for Steel Construction

AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING (ASNT)

ANSI/ASNT CP-189 (2016) ASNT Standard for Qualification and Certification of Nondestructive Testing Personnel (ANSI/ASNT CP-105-2006)

ASME INTERNATIONAL (ASME)

ASME B27.7 (1977; R 2010) General Purpose Tapered and Reduced Cross Section Retaining Rings, Metric

ASME B4.1 (1967; R 2009) Preferred Limits and Fits for Cylindrical Parts

ASTM INTERNATIONAL (ASTM)

ASTM A276/A276M (2015) Standard Specification for Stainless Steel Bars and Shapes

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

ASTM A354 (2011) Standard Specification for Quenched and Tempered Alloy Steel Bolts, Studs, and Other Externally Threaded Fasteners

ASTM A36/A36M (2008) Standard Specification for Carbon Structural Steel

ASTM A380/A380M (2013) Standard Practice for Cleaning, Descaling, and Passivation of Stainless Steel Parts, Equipment, and Systems

ASTM A435/A435M (1990; R 2012) Standard Specification for Straight-Beam Ultrasonic Examination of Steel Plates

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

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

ASTM A564/A564M (2013) Standard Specification for Hot-Rolled and Cold-Finished Age-Hardening Stainless Steel Bars and Shapes

ASTM A572/A572M (2012) Standard Specification for High-Strength Low-Alloy Columbium-Vanadium Structural Steel

ASTM A693 Standard Specification for Precipitation-Hardening Stainless and Heat-Resisting Steel Plate,Sheet, and Strip

ASTM A709/A709M (2011) Standard Specification for Structural Steel for Bridges

ASTM B22/B22M (2014) Standard Specification for Bronze Castings for Bridges and Turntables

ASTM D4020 (2011) Ultra-High-Molecular-Weight Polyethylene Molding and Extrusion Materials

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

ASTM E709 (2015) Standard Guide for Magnetic Particle Examination

ASTM F436 (2011) Hardened Steel Washers

AMERICAN WELDING SOCIETY (AWS)

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

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

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

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

RESEARCH COUNCIL ON STRUCTURAL CONNECTIONS (RCSC)

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

SOCIETY OF AUTOMOTIVE ENGINEERS INTERNATIONAL (SAE)

SAE AS8943 (2010) Bearings, Sleeve, Plain and Flanged, Self - Lubricating -65 to +250

DEG F

U.S. ARMY CORPS OF ENGINEERS (USACE)

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

1.3 SUBMITTALS

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

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

SD-01 Prefabrication and Assembly Submittals

Work Plan; G HDC

Field Verification of Control Dimensions; G HDC

Measuring Plan; G HDC

Quality Control Plan (QCP); G HDC

Material Tracking Log Template; G HDC

Weld Tracking Log Template; G HDC

Nonconformance Report Form Template; G HDC

NDT Written Practice; G HDC

NDT Equipment Calibration Records; G HDC

Witness Points; G HDC

Welding Procedure Specifications (WPS); G HDC

Fracture Control Plan (FCP); G HDC

Welding Repairs - Non-Fracture Critical Members; G HDC

Welding Repairs - Fracture Critical Members; G HDC

Heat Straightening Procedure; G HDC

WPS Schedule; G HDC

Random Testing; G HDC

Emergency Sluice Gate Handling Plan; G HDC

Stress Relief Heat Treatment Plan; G HDC

Procedure Qualification Records (PQR); G HDC

Filler Metal Product Data Sheets (PDS); G HDC

SD-02 Shop Drawings

Shop Drawings; G HDC

Delivery/Shipping Plan; G

Assembly and Fabrication Sequencing Plan; G HDC

Bolt Tensioning Sequence; G HDC

Bolt Inspection and Testing Log; G HDC

SD-03 Product Data

Materials Disposition Record; G HDC

Bolt Isolation; G HDC

Antigalling Compound; G HDC

Fluoropolymer Coating; G HDC

SD-06 Test Reports

Certified Test Reports; G

Weld Tracking Log; G HDC

Nonconformance Report; G HDC

Fabrication Quality Control Reports

Shop Dimensional Conformance Test; G HDC

At-Site Dimensional Conformance Test; G HDC

Mock Up Testing; G HDC

Functionality Test; G

Control Dimensions; G HDC

Painting Verification; G

Fabrication Record; G HDC

BALLAST UPPER ASSEMBLY INSTALLATION TEST; G HDC

SD-07 Certificates

Qualification of Welders and Welding Operators; G HDC

Inspector Qualifications; G HDC

Qualification of Structural Steel Fabricator; G HDC

1.4 DEFINITIONS

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

1.1.3 refers to the District engineer of record in lieu of the state bridge engineer as specified in Clause 1.1.3 of AWS D1.5M/D1.5.

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

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

d. Ancillary Items are as defined in AWS D1.5M/D1.5 Clause 1.3.7.

There are no ancillary items on the emergency sluice gate.

1.5 WORK PLAN

Submit a detailed Work Plan for fabrication, including descriptions of shop facilities, equipment, number of personnel, and related information prior to the Pre-Fabrication Conference. Update the Work Plan as conditions warrant. Provide procedures which ensure safe conduct of the work, careful removal and disposition of materials, protection of property that is to remain undisturbed, and coordination with other work in progress. Include in the procedures a detailed description of the methods and equipment to be used for each operation, and the sequence of operations in accordance with EM 385-1-1 for all onsite work. Include the recommended measuring system for ensuring dimensional tolerances in the Work Plan. Include detailed distortion control methods and procedures in the Work Plan.

1.5.1 Assembly and Fabrication Sequencing Plan

Provide drawings and detailed descriptions of the fabrication sequence of all components and subassemblies. Provide drawings and detailed descriptions of the assembly of components into the final structure.

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

1.5.2 Field Verification of Control Dimensions

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

1.6 PRE-FABRICATION CONFERENCE

Following approval of Contractor prepared shop drawings, preconstruction submittals, and prior to any fabrication, schedule and hold a Prefabrication Conference as soon as possible after Notice to Proceed.

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

1.7 QUALITY ASSURANCE

1.7.1 Quality Control Plan

Before the start of work, the fabricator is to supply a Quality Control Plan (QCP) to the Contracting Officer (CO) and Engineer for approval.

Ensure the QCP describes the methods, equipment, and procedures utilized to ensure quality control. The Engineer will use the AASHTO/NSBA, "Steel Bridge Fabrication QC/QA Guide Specification," as the basis for approving the QCP. The QCP will clearly address differences with these Specifications. These Specifications will govern between any discrepancies.

a. Submit a Material Tracking Log Template prior to fabrication.

Identify how all material will be tracked in the fabrication shop from receiving through complete assembly in the material tracking log template. Stamp each component with low-stress stamping to include the project number, part number, and additional required information to permit tracking of material.Assign trace numbers to each heat number.

Include trace number for each piece on shop drawing bill of materials with reference to its location on the structure. Reference each piece listed in material tracking log back to its location in the as-built drawings. Use material travelers to conform with the material tracking log and quality control plan. Provide structural material fabricated and assembled meeting the requirements of AASHTO/NSBA Steel Bridge Collaboration "Steel Bridge Fabrication Guide Specification" and AWS welding codes, except as modified in this document.

b. Submit Nonconformance Report Form Template a minimum of 30 days prior to the commencement of fabrication. Use the Nonconformance Report Template during fabrication to record and submit all Nonconformance's.

c. Submit for approval a Weld Tracking Log Template, a minimum of 30 days prior to commencement of fabrication, to identify all necessary components to be addressed in the tracking of all welds for the structures in question.

1.7.2 NDT Written Practice and NDT Equipment Calibration Records

Submit the NDT written practice including testing procedures for prototype complex geometries submitted a minimum of 30 days prior to commencement of fabrication. Establish in the written practice the minimum requirements for education, training, experience, examination and certification of personnel responsible for conducting nondestructive testing. It applies to all persons conducting nondestructive tests that are required to be certified to the provisions of ANSI/ASNT CP-189. Additionally the methods of nondestructive testing are to be outlined and described in the written practice and explanation as to how they will be used in accordance with the applicable codes, standards and specifications. In addition to the written practice, submit NDT Equipment Calibration Records for all NDT equipment used by both the fabricator and any subcontractors performing NDE. NDT calibrations required on a basis less than bimonthly will be submitted with test results. Bimonthly or greater calibration requirements will be submitted prior to testing.

1.7.3 Inspection Witness Points

a. Establish Witness Points for the Initial QA Inspection, Intermediate

QA Inspections, and Final Inspection as follows and prepare a detailed schedule showing the progression of work and completion of components with the Witness Points identified. Start the Initial QA Inspection after the Government has determined that there is substantial completion of components that comprise a reasonable sampling of each significant FCM and non-FCM details. The extent of completion and details and the date of the Initial QA Inspection will be determined at the Prefabrication Conference by the Government after discussion with the Contractor.

b. Update the inspection witness point schedule weekly and provided by e-mail to the CO. Give the CO two weeks minimum notice prior to the predetermined date for the Initial QA Inspection, including adjustments for changes in schedule. Conduct Intermediate QA Inspections on an as needed basis and at the discretion of the Government. Provide unpainted components for each QA NDT and Visual Inspection. At these stages of construction, give the Contracting Officer ten working days to inspect the structure. After the CO and the Engineer of Record have inspected the structure, make any changes required to the structure as directed by the CO before proceeding with any additional welding.

Proceed with the construction until the next witness point is reached, unless it is waived in writing by the CO. Each structure fabricated is subject to a Final Fabrication Inspection prior to painting. Conduct a Final Fabrication Inspection after each structure is completed.

Schedule and coordinate with the CO and the Engineer of Record the Final Fabrication Inspections of each structures. Give the CO a minimum notice of two weeks prior to the Final Fabrication Inspection.

1.8 CONTRACTOR QUALIFICATIONS

1.8.1 Qualification of Welders and Welding Operators

Submit Welder Qualification records for each welder, welding operator and tack welder to the Government for approval prior to commencing fabrication. All qualifications are to be current and the submitted records approved prior to commencing any work and be kept current for the duration of the Contract. State in the welder qualification record the type of welding and positions for which the welder, welding operator, or tacker is qualified, the code and procedure under which the individual is qualified, the date qualified, and the name of the firm and person certifying the qualification tests. Include welder continuity documents for all welders, welding operators, or tackers. Provide qualification records in accordance with AWS D1.5M/D1.5. Submit welder and welding operator qualification test records on forms similar or equivalent to the sample forms in AWS D1.5M/D1.5. Limit welders, welding operators, and tack welders to welding procedures for which they are qualified. Prepare, weld, and test all test welds in accordance with the requirements of AWS D1.5M/D1.5. Approve all welder qualifications by a CWI.

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

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

1.8.2 Inspector Qualifications

a. Quality control personnel can be assigned to no more than one task, provided they are qualified and able to fully perform the duties of each position. Individual(s) responsible for quality assurance/quality control may not serve as or report to production management. If the ability of QC is in doubt, the Government reserves the right to have QC personnel removed from the project.

b. All welding inspectors are required to be currently certified in accordance with these specifications and AWS QC1 as a Certified Welding Inspector (CWI) or Senior Certified Welding Inspector (SCWI).

Non-certified inspectors and Certified Associate Welding Inspectors (CAWI) are not qualified to be used for inspection under these specifications. Designate an individual inspector as the "lead" inspector to be the primary point of contact for quality control of welding and fabrication. This individual will be responsible for all quality control functions. Submit copies of certification documentation as provided by AWS. Qualifications for the lead inspector are to conform to one of the following:

(1) Currently certified as an AWS SCWI.

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

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

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

1.8.3 Qualification of Structural Steel Fabricator

The fabricating plant and fabricator is required to be certified under the AISC (American Institute of Steel Construction) Quality Certification Program with one of the following certifications; Major Bridge Fabrication (CBR), Certified Bridge Fabricator - Intermediate (IBR), Certified Bridge Fabricator - Advanced (ABR), or Certified Hydraulic Fabricator (HYD). In addition, the fabricator is required to be certified with Fracture Critical endorsement (F) and possess five years documented experience on projects of similar scope. Submit copies of the AISC certificate(s) indicating that the fabrication plant meets the specified structural steelwork category and documented experience. The rubber seals are excluded from the AISC fabricator certification requirements. Similar scope consists of having fabricated structures with the following minimum requirements:

a. Weight of 25-Tons or greater.

b. Member thicknesses of 1-inch or greater.

c. Geometry of structure 20-ft by 10-ft or greater.

d. Minimum tolerances of +/- 1/8-inch out of parallel over at least

20-ft.

e. Adequate crane capacity capable of picking and maneuvering the structures within fabrication building. Maneuvering the emergency sluice gate includes any rotating about any axis of the structure that may be required for fabrication and weld distortion control.

1.9 WELDING PROCEDURE SPECIFICATIONS (WPS)

Submit a Welding Procedure Specification (WPS) for each weld, which account for all welding on the structure, including prequalified welds, prior to commencing fabrication. Submit WPS's and Procedure Qualification Records (PQR) to the Government Representative/CO for approval before fabrication is commenced. Approved WPS are required prior to commencing fabrication.

Approve all WPS's and PQR's submitted for Government approval by an approved CWI. Submit the WPS and PQR with the shop drawings and reference WPS on the shop drawings. Individually identify and reference Welding Procedure Specifications on the shop drawings.

1.9.1 WPS Schedule

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

1.9.2 WPS Requirements

Prepare and qualify each WPS in accordance with the applicable provisions of AWS D1.5M/D1.5. In case of conflict between this specification and AWS D1.5M/D1.5 as applicable, this specification governs. A WPS is always required, even if the procedure is considered prequalified in accordance with AWS D1.5M/D1.5. Qualify all non-prequalified WPS by testing in the applicable process and position to be utilized. Qualify all combinations of required base metal by testing. Perform all tests in Figure 5.1 of AWS D1.5M/D1.5 regardless of differing base metals. Clearly identify each procedure as being either prequalified or qualified by tests. Individually identify Welding Procedure Specifications. Include in the Welding Procedure Specifications at a minimum the following; Indicate whether WPS is prequalified or qualified by testing, WPS ID#, Revision #, Date, Created by, Company Name, Supporting PQR#, Joint Design information (to include dimensional tolerances), Base Metal information, Shielding information, Preheat information, Type of operation, Position, Electrical Characteristics, Technique, PWHT, Joint Sketch including all code required essential variables, and labeling whether WPS is for FCM. Include filler metal data sheets with WPS and PQR. Submit all WPS with attached PQR and supporting test documentation on forms similar or equivalent to the sample forms in AWS D1.5M/D1.5.

1.9.3 WPS Documentation

All Government approved WPS are to receive a Government approval stamp and copies of the stamped WPS will be the only WPS allowed for use on this project. The Government approval stamp will include date approved, Contract number, project name, and initials of approver. Provide copies of approved WPS, including approval stamps, at all work stations where welding is occurring so that the welder, QC staff and Government QA staff have access to the WPS.

1.9.4 Government Witness of WPS Qualification

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

1.10 SHOP DRAWINGS

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

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

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

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

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

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

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

g. Show all anode attachments and installation details on the shop drawings.

1.11 DELIVERY AND STORAGE

Notify the CO at least 28 days in advance of delivery of the structures.

Store material above ground on platforms, skids, or other supports.

Protect material from dirt, oil, and other foreign matter. Protect material so that water is not permitted to collect and pool. Employ handling methods that do not result in damage to components during fabrication, assembly, loading, shipment, and unloading of components.

Replace damaged material with new material or repair using a procedure approved by the Engineer. Protect completed assemblies/structures from the environment. Shipping of the structures is to be at the Contractor's expense. Deliver all structures to Libby Dam per Sections 01 10 10.00 25 Contractor's Operations And Requirements and 01 11 00.00 25 Summary Of Work. Coordinate through the Seattle District CO for deliveries. Arrange the structures on the delivery vehicles such that no damage occurs during shipping. Direct all slings and lifting lugs up. Submit Delivery/Shipping Plan drawings providing descriptions of methods of delivering the completed structural units, including details for support during shipment to prevent distortion or other damages, and orientation and location of the structures on the delivery vehicles prior to shipment for Government approval.

1.12 EMERGENCY SLUICE GATE HANDLING

Take care while lifting the emergency sluice gate assembly from horizontal position to vertical position. Submit a Emergency Sluice Gate Handling Plan for approval. Include details, diagrams and/or drawings that identify the plan for lifting the emergency sluice gate from a horizontal to a vertical position. Include the locations, method of lift and all attachments to the emergency sluice gate in the emergency sluice gate handling plan.

Government Cranes are only equipped to handle emergency sluice gates in the vertical position and will be operated by Government Crane operators.

Contractor to deliver the emergency sluice gate in the upright position dogged in such a manner that the existing crane and lifting beam can reach and handle the emergency sluice gate.

PART 2 PRODUCTS

2.1 FRACTURE CRITICAL MEMBERS (FCM)

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

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

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

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

d. 12.7 Welding Procedure Specifications (WPS). Ensure all procedures, including repair welds, are prequalified or qualified by test as required and documented in the WPS and Procedure guidelines of

AWS D1.5M/D1.5.

e. 12.8 Certification and Qualification. Utilize welders and welding operators which meet the applicable requirements of AWS D1.5M/D1.5.

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

g. 12.13 Tack Welds and Temporary Welds. Locate all welds within the joint and meet the requirements of AWS D1.5M/D1.5, Table 12.2.

Temporary welds on FCM are not permitted. Any and all temporary welding required for the fabrication or assembly of welded components (i.e. lifting aides, assembly jigs etc.) shall be submitted for Engineer approval prior to use.

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

i. 12.16 Weld Inspection. Document the Quality Control inspection program in the FCP. Do not perform NDT examination until welds have been visually accepted by an approved CWI. Qualify all inspectors and NDT technicians as required. Test all butt joints with UT and RT.

Encoded PAUT can be used as an alternate to RT. All indications found by encoded PAUT are to be confirmed by conventional UT and meet UT acceptance criteria. Inspection procedures and documentation are as specified in the applicable sections of AWS D1.5M/D1.5. Strictly adhere to cooling times.

j. 12.17 Repair Welding. Repair welds are classified as "critical repairs" or "non-critical repairs" for all repair welding. Follow the minimum provisions, unless specified otherwise, for repair procedures.

Qualify and approve repair procedures which are subject to the same QA/QC inspection requirements as other welds. Minimum preheat for repair welding is as defined in AWS D1.5M/D1.5 Clause 12.17.6. All weld repairs to fracture critical members are considered critical welds in accordance with AWS D1.5M/D1.5 Clause 12.17.3 and are to be approved by the engineer of record.

2.2 NON-FRACTURE CRITICAL MEMBERS

All items not labeled as Fracture Critical are Non-Fracture Critical Members. Provide ASTM A709/A709M, grade as specified or shown on the drawings, using killed fine-grain mill practice, unless otherwise shown or specified. Mill repairs of base metal are prohibited. Meet toughness requirements of ASTM A709/A709M, Table 8, for Zone 2, unless otherwise indicated or specified. Meet the requirements of Section 10 of ASTM A709/A709M for all materials used for the construction of non-fracture critical components and include mill certification showing that the material meets the necessary toughness requirements. Meet all requirements of AWS D1.5M/D1.5 for welding non-fracture critical members.

2.3 FABRICATION

2.3.1 Structural Fabrication

Material must be straight before being laid off or worked. If necessary, straighten by methods that will not impair the metal. Sharp kinks or bends are cause for rejection of the material. Material with welds will not be accepted unless the welding is specified or indicated on the drawings or otherwise approved. Do not commence welding until welding procedures, inspectors, nondestructive testing personnel, welders, welding operators, and tackers have been qualified and approved. Make bends by approved dies, press brakes or bending rolls. Where heating is required, take precautions to avoid overheating the metal and allow to slowly cool in still air in a manner that will not impair the original properties of the metal. Proposed flame cutting of material other than structural steel is subject to approval. Indicate proposed flame cutting on shop drawings. Provide neatly finished work with accurate shearing for all portions of the work.

Provide square and true corners unless otherwise shown. Provide filleted re-entrant cuts with a minimum radius of 1 inch in accordance with AWS D1.5M/D1.5 Clause 3.2.4 unless otherwise indicated or approved.

Provide finished members free of twists, bends and open joints. Cut steel and fabricate steel plates and splice plates for major structural components so the primary direction of rolling is parallel to the direction of the main tensile or compressive stresses. For CJP butt joint splices which will be ground flush, establish the center line of the weld on the components before welding by placing four low-stress stamp punch marks.

Place low-stress stamp punch marks 1-ft back from the center line of the weld, on each side of the weld, and 1-in from the edge of the plate, at each end of the plate.

a. Dimensional Tolerances for Structural Work.

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

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

b. Structural Steel Fabrication. Structural steel may be cut by mechanically guided or hand-guided torches, provided an accurate profile with a surface that is smooth and free from cracks and notches is obtained. Prepare surfaces and edges in accordance with

AWS D1.5M/D1.5, Clause 3.2. Chip, grind or machine hand-guided cuts to sound metal.

2.3.2 Heat Straightening

Straighten material without shearing, fracturing, stressing, or damaging the bolts, welds, or base metal. Use heat straightening methods approved by the Engineer. Replace material damaged during straightening operations with new material at no additional cost to the Government. Do not heat the metal unless allowed by the Engineer of Record. If allowed and before performing any straightening operations, submit a Heat Straightening Procedure to the engineer for review and approval for any application where heat may be applied to correct or remedy dimensions. Follow the FHWA publication "GUIDE FOR HEAT-STRAIGHTENING OF DAMAGED STEEL BRIDGE MEMBERS" for the Heat Straightening Plan. Do not heat metal to temperatures greater than 1200F. The use of cutting heads for heating and straightening will not be permitted. After heating and straightening, allow the metal to slowly cool in still air to ambient before inspecting for evidence of fracture or other damage. If the Engineer determines it is not possible to straighten a member as part of an assembly, remove the bent material from the assembly, straighten, and re-assemble or replace the component as required by the Engineer.

2.3.3 Materials Disposition Record

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

2.3.3.1 Material Identification

Provide all fracture critical members and skin plates with identification numbers placed on each individual piece of material that are referenced to the corresponding heat number. Use low-stress die stamps for the identification coding of material. Stamp each component with low-stress stamping of the associated heat number. Place low-stress stamping in same location for similar components and located in an area that is visible after assembly. Use material travelers to conform with the material tracking log and quality control plan.

2.3.3.2 Material Test Reports

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

Submit reports of tests, inspections, and verifications of all materials used under this Contract approved by the Government before incorporation into the structure. All steel used in this Contract is required to be tested by the steel mill to ensure that it meets the required standards.

2.3.4 Welded Connections

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

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

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

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

d. Weld Tracking Log. A weld-tracking log will be developed and maintained by the Contractor as described herein. Provide a log capable of individually identifying and tracking every weld on the project. Follow the numbering scheme shown on the shop drawings for member identification. At a minimum, include the following in the log;

the member to be welded, member type (FCM and Non-FCM), type of weld including temporary and tack welds which are not fully consumed, welding position, applicable WPS reference, AWS joint preparation designation, name or stamping designation of welder, welding operator or tacker, date and time of completion of welding and/or tacking (weld time required to designate required hold time prior to NDT), name and date of CWI visual inspection, NDT testing performed, including the type of inspection, date(s) of inspection, inspector name, and the acceptance criteria used, description of defects found and reason for non-compliance, corrective action taken, or whether the weld is acceptable. Match weld identification between the shop drawing and weld tracking log. Continually maintain the weld tracking log. Ensure the weld tracking log, including draft copies of NDT testing, is available on the shop floor during any inspection. Provide a bound, completed log for each structure included in the Fabrication Record upon completion of the fabrication of each structure.

e. Welding Technique.

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

12.6.7.4. The combination of differing filler metals and

processes in the same joint or weld is not permitted.

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

Perform preheat for fracture critical welds as defined in Table

12.3 and in accordance with the PQR/WPS. Slowly and uniformly heat the weldments to be preheated by approved means to the prescribed temperature, held at that temperature until the welding is completed and then permitted to cool slowly in still air as required and in accordance with the approved WPS in order to prevent cracking or distortion. Preheating by use of oxygen cutting equipment will be restricted to the use of "rosebud" heads designed for heating. The use of cutting heads for preheating is not permitted.

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

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

AWS D1.5M/D1.5.

(2) Tack and Temporary Welds. Make tack and temporary welds required for fabrication and erection in accordance with AWS D1.5M/D1.5 under the controlled conditions prescribed herein for permanent work. Tack welds that are to be incorporated into the permanent work are subject to the same quality requirements as the permanent welds. Clean and fuse such tack welds thoroughly with the permanent welds. Multiple-pass tack welds are required to have cascaded ends. Remove defective tack welds before permanent welding. Use low-hydrogen welding electrodes and by welders qualified for permanent work as specified elsewhere in these specifications for all welds. Preheat as required by AWS D1.5M/D1.5 for permanent tack welds. Preheat must not produce moisture in the weld joint. In making temporary welds, do not strike arcs outside weld locations. Make all tack welds which are incorporated into the final weldment a maximum of 1/8 inch with a minimum length of 1 inch long spaced at a maximum of 6 inch on center. Remove each temporary weld as required by AWS D1.5M/D1.5, Clause 3.3.8. Grind out all arc strikes struck outside the weld zone, and inspect by MT in accordance with AWS D1.5M/D1.5.

(3) Weld Access Holes. Provide weld access holes as shown on the shop drawings. If the oversite of intersecting out-of-plane members is encountered, the fabricator is required to notify the CO and engineer for the approval of weld access hole additions in such locations. Payment for the addition of weld access holes not shown on plans will be the Contractor's responsibility.

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