01 11 00.01 28 R0003.pdf

AFD Powerhouse Bridge Crane Rehab 23011 Oldtown, ID W912DW24R0019

SECTION TABLE OF CONTENTS

DIVISION 01 - GENERAL REQUIREMENTS

SECTION 01 11 00.01 28

CONCEPTUAL DESIGN INFORMATION

02/24

PART 1 GENERAL

1.1 REFERENCES

1.2 SCOPE OF SERVICE

1.3 QUALITY CONTROL

1.4 SAFETY

1.5 HAZARDOUS ENERGY CONTROL PROGRAM (HECP)

1.6 OPERATION AND MAINTENANCE MANUALS

1.7 DESCRIPTION OF WORK

1.7.1 Area Description

1.7.2 Principal Work Items

1.8 SUBMITTALS

1.9 DEFINITIONS

1.10 PRE-FABRICATION REQUIREMENTS

1.10.1 Verification of Existing Conditions

1.10.2 FPS Installer Qualification Requirements

1.10.3 FPS Designer (Qualified Person) Qualification Requirements

1.10.4 Weld Inspector Qualification Requirements

1.10.5 Active Fall Protection System (FPS) Design Requirements

1.10.6 Qualification of Welders and Welding Operators

1.10.7 Welding Procedure Specifications (WPS)

PART 2 PRODUCTS

2.1 MATERIALS AND EQUIPMENT

2.2 CONTRACTOR-PROVIDED FPS EQUIPMENT ITEMS

2.3 GOVERNMENT-PROVIDED PERSONAL FALL PROTECTION EQUIPMENT

2.4 MATERIAL

2.4.1 Structural Steel

2.4.2 FPS Material

2.4.3 Grout Material

2.5 FABRICATION

2.5.1 General

2.5.2 Dimensional Tolerances

2.5.3 Structural Steel Fabrication

2.6 FPS DESIGN PACKAGE SUBMITTALS

2.6.1 30 Percent FPS Design Package

2.6.2 100 Percent FPS Design Package

2.7 OPERATION AND MAINTENANCE MANUAL FPS USER GUIDE

PART 3 EXECUTION

3.1 EXISTING FPS REMOVAL

3.2 FPS CONCRETE DESIGN STRENGTH AND MATERIAL PROPERTIES FOR

CONSTRUCTION

3.3 PROPOSED FPS DESIGN

SECTION 01 11 00.01 28 Page 1 R0003

3.4 CONCRETE REINFORCEMENT STEEL

3.5 WELDING PROCESS, TECHNIQUE AND WORKMANSHIP

3.5.1 Welding Process

3.5.2 Welding Technique

3.5.3 Workmanship

3.6 CERTIFIED TEST REPORTS

3.6.1 Nondestructive Testing

3.6.2 Inspection of Structural Steel Welding

3.6.2.1 Visual Examination

3.6.2.2 Nondestructive Examination

3.6.2.3 Supplemental Examination

3.6.3 Structural Steel Welding Repairs

3.7 PROTECTION OF EXISTING STRUCTURES AND UTILITIES

3.8 ON-SITE FPS TRAINING

-- End of Section Table of Contents --

SECTION 01 11 00.01 28 Page 2

SECTION 01 11 00.01 28

CONCEPTUAL DESIGN INFORMATION

02/24

PART 1 GENERAL

1.1 REFERENCES

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

AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING (ASNT)

ASNT SNT-TC-1A (2020) Recommended Practice for Personnel Qualification and Certification in Nondestructive Testing

AMERICAN SOCIETY OF SAFETY PROFESSIONALS (ASSP)

ASSP Z359 (2013) Fall Protection Code

ASSP Z359.0 (2018) Definitions and Nomenclature Used for Fall Protection and Fall Arrest

ASSP Z359.1 (2020) The Fall Protection Code

ASSP Z359.2 (2017) Minimum Requirements for a Comprehensive Managed Fall Protection Program

ASSP Z359.6 (2016) Specifications and Design Requirements for Active Fall Protection Systems

ASSP Z490.1 (2016) Criteria for Accepted Practices in Safety, Health, and Environmental Training

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2020; Errata 1 2021) Structural Welding Code - Steel

AWS QC1 (2016) Specification for AWS Certification of Welding Inspectors

ASTM INTERNATIONAL (ASTM)

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

ASTM A53/A53M (2022) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

ASTM A325 (2014) Standard Specification for

SECTION 01 11 00.01 28 Page 3

Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength

ASTM A500/A500M (2021a) Standard Specification for Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and Shapes

ASTM A514/A514M (2018) Standard Specification for High-Yield-Strength, Quenched and Tempered Alloy Steel Plate, Suitable for Welding

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

ASTM A992/A992M (2020) Standard Specification for Structural Steel Shapes

ASTM C1107/C1107M (2020) Standard Specification for Packaged Dry, Hydraulic-Cement Grout (Nonshrink)

ASTM E165/E165M (2018) Standard Practice for Liquid Penetrant Examination for General Industry

ASTM E709 (2021) Standard Guide for Magnetic Particle Testing

ASTM F436 (2011) Hardened Steel Washers

U.S. ARMY CORPS OF ENGINEERS (USACE)

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

1.2 SCOPE OF SERVICE

The Contractor shall provide a detailed design for the Powerhouse Bridge Crane personal fall protection.. The system shall be designed with an emphasis on ease of operation, reliability and safety.

The Contractor shall field verify the condition and dimensions of the existing structure and components that will affect the contractors design to the extent possible.

The Design Builder shall provide the Government with the following integrated Design-Build (D-B) services:

Development:

Final site layout.

Design:

Detailed Design of components and supporting equipment consistent with the Design Criteria Package.

Construction:

Construction of the components and supporting equipment as appropriate.

Completion of installation and start-up of all required equipment.

SECTION 01 11 00.01 28 Page 4

In providing these services, the Design Builder shall at all times comply with the following:

Design criteria and performance standards outlined in the contract.

Design review/approval processes as detailed in the RFP.

Government and industry construction standards.

1.3 QUALITY CONTROL

Contractor Quality Control requirements during design and construction are defined in Section 01 45 00.00 10 QUALITY CONTROL.

1.4 SAFETY

Contractor shall design the system and develop the procedures for installation, operation and removal of the system to conform to the requirements of Section 01 35 26 GOVERNMENTAL SAFETY REQUIREMENTS.

1.5 HAZARDOUS ENERGY CONTROL PROGRAM (HECP)

Design the system to accomodate the HECP requirements specified in Section 01 35 26 GOVERNMENTAL SAFETY REQUIREMENTS, CENWS-OD A HECP Local Supplement, and HECP NWS 11519 Revision 2.

1.6 OPERATION AND MAINTENANCE MANUALS

Provide Operation and Maintenance Manuals as required in Section 01 78 00

CLOSEOUT SUBMITTALS.

1.7 DESCRIPTION OF WORK

Operations and Maintenance activities require Users to travel or perform work activities for the full length of the Powerhouse while on top of the downstream and upstream bridge crane corbels as well as the bridge crane trolley rail girders. The crane power bus is located on top of the upstream crane corbel adjacent to the crane rail. The upstream crane corbel is not accessible without a safe clearance lockout/tagout of the crane power bus in place. The Contractor is required to design, install, and train Users on how to operate/maintain the installed active fall protection system (FPS). The Contractor is also required to remove the existing FPS. The Contractor is responsible for measuring the bridge crane corbel and bridge crane trolley fall clearances as necessary to facilitate the FPS design. The Contractor shall not use the existing Powerhouse bridge crane upstream and downstream horizontal life lines or bridge crane trolley horizontal life lines as fall protection.

1.7.1 Area Description

The FPS contract installation portion of work shall be completed at the Albeni Falls Dam Powerhouse.

1.7.2 Principal Work Items

The principal work items to be accomplished by the Contractor are:

a. Removal of the existing (2) 300' upstream and , downstream, and

(2) 47' North and South trolley rail access horizontal lifeline (HLL)

SECTION 01 11 00.01 28 Page 5 and attached HLL appurtenances.

b. Engineer-design of the FPS.

c. Permanent FPS installation of the engineered FPS design.

d. Preparation of FPS User Guide.

e. On-site FPS operation, inspection and maintenance training.

1.8 SUBMITTALS

Government approval is required for submittals with a "G" classification. Submittals not having a "G" classification are for information only. When used, a code following the "G" classification 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 Preconstruction Submittals

Welding Procedure Specifications (Wps); G

Installer Qualifications; G

Designer And Installer's Qualifications; G

Concrete Quality Control Program; G

SD-06 Test Reports

Certified Test Reports;

SD-07 Certificates

Welder's Qualifications; G

Certified Welding Inspector; G

SD-11 Closeout Submittals

Operation And Maintenance Manual; G

1.9 DEFINITIONS

Refer to ASSP Z359.0 and EM 385-1-1 for the definitions and nomenclature associated with the design and installation of the active fall protection system (FPS).

Fall Hazard. For the bridge crane FPS there are two hazards which is falling off of the corbel or the bridge crane trolley girders.

Fall Protection System (FPS). Any secondary system that prevents Users from falling or, if a fall occurs, arrests the fall.

Horizontal Lifeline (HLL). A component of a horizontal lifeline subsystem, consisting of a flexible line with connectors or other coupling means at

SECTION 01 11 00.01 28 Page 6 both ends for securing it horizontally between two anchorages or anchorage connectors. Intermediate anchorages are typically used on long HLL systems to reduce sag.

Overhead Fall Arrest. Fall arrest protection provided to the User by attaching to anchorage located over his or her head while standing on the upstream or downstream powerhouse bridge crane corbel or bridge crane trolley girders.

Qualified Person. A person with the knowledge, training and experience in the fall protection and rescue field who is capable of designing, analyzing, evaluating and specifying fall protection and rescue systems to the extent required by this Section.

Mainline Buss. Main line contact conductors are required to transmit electrical power to the bridge crane. The conductor rails are mounted on the upstream crane corbel adjacent to the crane rail.

User. A person who performs rail inspection activities as defined in this Section while protected by the bridge crane personal FPS.

1.10 PRE-FABRICATION REQUIREMENTS

1.10.1 Verification of Existing Conditions

It is recommended that Contractors submitting bids to complete the goods and services specified in this Section attend the Government site visit prior to bid submission. Access to the bridge crane corbels or bridge crane trolley girders will be limited to the access points for each corbel where fall protection is not required. Walking along the corbels or bridge crane trolley girders will not be allowed. The awarded Contractor's Qualified Person shall complete a site visit to the Albeni Falls Dam Powerhouse to verify the existing site conditions. The Qualified Person shall verify all existing dimensions, member sizes, and conditions prior to commencing any work, including fall clearances. All dimensions of existing construction shown on the drawings are intended as guidelines only and shall be field verified by the Qualified Person. The Contractor shall notify the Contracting Officer Representative (COR) of any discrepancies prior to construction. The Qualified Person shall complete the site visit prior to developing the 30 Percent Design Submittal.

a. Coordinate site visits for verification of existing conditions with the COR. Provide a minimum of 5 working days advance notice prior to the requested date and time.

1.10.2 FPS Installer Qualification Requirements

The FPS installer shall have installed a minimum of two (2) permanent horizontal lifeline fall arrest systems within the last five (5) years.

The Contractor shall employ personnel experienced in using ground penetration radar (GPSR) in locating steel reinforcement in mass concrete.

Submit a FPSinstaller qualifications Report for Government review.

Include the following minimum information in the submittals:

a. Project name

b. Project location

c. Project FPS designer name

d. FPS installation date

e. FPS description and salient features

f. Installed FPS contact information including telephone and address

SECTION 01 11 00.01 28 Page 7

g. Experience description of the personnel performing the steel reinforcement locating

1.10.3 FPS Designer (Qualified Person) Qualification Requirements

The FPS shall be designed by a Qualified Person as defined in ASSE/SAFE Z359.0 and meet the following additional requirements. Submit a FPS designer and installer's qualifications Report. Include the following minimum information in the submittals:

a. Qualified Person name

b. State of Professional Engineering or Structural Engineering licensure

c. State license number

d. Number of years FPS design experience

e. Description including the salient features of the FPS projects the Qualified Person has designed or participated in design

The Qualified Person shall be a licensed professional engineer or structural engineer registered in the United States. The Qualified Person shall affix his or her professional seal to the FPS plans, specifications and calculations.

The Qualified Person shall have a minimum of three years' experience in the design of active fall protection systems in accordance with ASSP Z359.1 and ASSP Z359.6 standards.

1.10.4 Weld Inspector Qualification Requirements

All inspectors, performing structural steel inspection in accordance with this Section, shall be qualified and certified in conformance with AWS QC1.

Provide an AWS Certified Welding Inspector (CWI) as the primary point of contact for quality control of welding. When several CWI and NDT technicians are working, one primary individual shall be designated as having primary responsibility for all quality control. Non-certified inspectors and certified associate weld inspectors (CAWI) shall not be used for inspection under this Section. All personnel who perform NDT shall be qualified in accordance with ASNT SNT-TC-1A NDT Level II. NDT shall be performed by Level II technicians or by Level I technicians only when working under the direct supervision of personnel possessing Level II ASNT NDT certification in accordance with AWS D1.1/D1.1M . Submit a certified welding inspectorCertified Welding Inspector (CWI) Qualifications certificate for Government review.

1.10.5 Active Fall Protection System (FPS) Design Requirements

In addition to the standards requirements specified in this Section the following additional requirements shall be incorporated into the FPS design. These requirements are applicable for the entire corbel length and the entire bridge crane trolley rail girder length at the Albeni Falls Dam powerhouse.

a) FPS Design Requirements. The FPS shall be designed to provide the User fall protection while the User is performing work activities on top of the upstream and downstream corbel and on top of the bridge crane trolley rail girders. The User shall be capable of physically touching the crane rail and crane rail attachments while performing the work activities. The User shall also be capable of touching all "top" of the corbel and girder horizontal and walking surfaces while

SECTION 01 11 00.01 28 Page 8 performing those work activities.

b) The FPS shall conform to ASSE/SAFE Z359.6 & Z359.1 and EM 385-1-1 standards

c) The FPS shall be designed to simultaneously support a maximum of four (4) Users while on top of either the upstream or downstream corbel and North or South bridge crane trolley rail girder for assisted rescue. Assisted rescue on the upstream corbel shall occur only when the mainline buss is de-energized. Other than during assisted rescue, a maximum of three (3) Users are permitted simultaneously on each FPS while conducting activities.

d) The FPS shall be designed such that movement/operation of the bridge crane is not impeded in any manner. The clearance between the bridge crane and adjacent objects shall be field verified by the Qualified Person.

e) The FPS (including travel restraint) shall be designed for fall arrest loads.

f) The FPS shall consist of compatible components as defined by

ASSE/SAFE Z359.1.

g) The User shall have the ability to connect to the FPS at the corbel entrance, disconnect from the FPS upon boarding the bridge crane, move the bridge crane to a new location and reattach to the FPS at the new location. This requirement is necessary to prevent the User from becoming "stranded" after he or she moves the bridge crane and requires reconnection to the FPS at the new location. The user shall also have the ability to connect to the bridge crane trolley girder FPS from the bridge crane trolley without exposing the user to a fall hazard before connecting to the FPS.

h) The FPS shall be designed such that the User can travel the entire length of the upstream and downstream corbel or bridge crane trolley girders without the need to use a dual-legged lanyard to maintain 100 percent FPS connection.

i) The FPS shall be designed such that the User can travel from the corbel entrance to either end of the powerhouse upstream bridge crane corbel without having to use a dual-legged lanyard to maintain 100 percent FPS connection.

j) The FPS shall be designed such that installation, inspection, maintenance and repair of the FPS can be accomplished from the bridge crane or the corbel.

k) The FPS shall be capable of inspection by a competent person not affiliated with the FPS Installer or FPS manufacturer. The FPS shall also be capable of recertification by a Government designated qualified person that is not affiliated with the FPS installer or FPS manufacturer. The Contractor shall provide the competent and qualified person training necessary to fulfill the applicable Z359 Standard(s) FPS inspection and recertification requirements. This training shall be part of the on-site FPS training.

l) The FPS shall contain personal rescue devices. The personal

SECTION 01 11 00.01 28 Page 9 rescue devices shall be a Latchways Personal Rescue Device integrated harness or a personal rescue device that can be attached to an existing harness or an equivalent device that permits the lowering of a User after a fall arrest fall. The personal rescue device shall have the following salient features.

1) A brake mechanism and spool with a cord of sufficient length to lower the User to Elevation 2060' after falling off of the 2,105' bridge crane corbel and 2,114' elevation bridge crane trolley girder.

2) A parachute type 'rip cord' or pull strap that releases the descending system.

3) A secondary release mechanism or a method that permits third party descent should the User not be capable of self-rescue after a fall.

4) The User can be lowered without having to transfer FPS connection.

5) Manufacturer recommended maintenance and inspection can be completed by a Competent Person.

6) A User weight that includes a range between 130 and 310 pounds.

7) The descent rope shall be either UHMWPE or Aramid synthetic material.

8) Meet applicable EM 385-1-1 and ASSP Z359.1 requirements

9) Worn as part of either a standard harness or attached to an existing harness.

1.10.6 Qualification of Welders and Welding Operators

The Contractor shall certify the qualification of welders and welding operators and tack welders who will perform structural steel welding have been qualified for the particular type of work to be done in accordance with the requirements of AWS D1.1/D1.1M Section 4, prior to commencing fabrication. The Contractor shall submit welder's qualifications Records (WQR) for all welders who perform FPS weld fabrication.

a. List the qualified welders by name and specify the code and procedures under which qualified and the date of qualification within the certification. Prior qualification will be accepted if welders have performed satisfactory work under the code for which qualified within the preceding three months. Welders are required to repeat the qualifying tests when their work indicates a reasonable doubt as to proficiency. Those passing the requalification tests will be recertified. Those not passing will be disqualified until passing.

Contractor incurs all expenses in connection with qualification and requalification.

b. Welding will be subjected to inspection to determine conformance with the requirements of AWS D1.1/D1.1M , the approved welding procedures and provisions stated in this Section.

1.10.7 Welding Procedure Specifications (WPS)

Only pre-qualified weld procedures shall be used to fabricate the FPS.

Prequalify welding procedures for structural steel in accordance with

SECTION 01 11 00.01 28 Page 10

AWS D1.1/D1.1M , Section 4. Submit only the applicable Weld Procedure Specifications (WPS) prior to fabrication. The WPS submittals shall NOT contain WPS that are not applicable to the FPS work. Approval of any WPS will not relieve the Contractor of responsibility for producing a finished FPS meeting all requirements of this Section. Each WPS shall be clearly identified as being prequalified. The WPS shall show types and locations of welds designated for nondestructive testing.

PART 2 PRODUCTS

2.1 MATERIALS AND EQUIPMENT

Provide materials and equipment incorporated into the work pursuant to Contract Clause 52.236-5 MATERIAL AND WORKMANSHIP (incorporated by reference).

2.2 CONTRACTOR-PROVIDED FPS EQUIPMENT ITEMS

The Contractor shall provide the following number of permanent FPS equipment items to the Government as part of this contract. All FPS equipment items provided by the Contractor for use on the FPS shall be approved for use by the Qualified Person and meet the requirements of

ASSP Z359.1 .

The design shall utilize commercially Off the Shelf Components with minimal modification as much as is feasible.

a. Eight (8) self-retracting lifelines (SRL) or lanyards suitable for attachment to the bridge crane corbel or bridge crane trolley girders FPS. All components shall work with the whole of the corbel or bridge crane trolley girders FPS.

b. Three (3) lanyards suitable for attachment to the travel restraint line.

c. Nine (9) steel auto locking karabiners capable of withstanding 5,000 pounds and proof tested to at least 3,600 pounds. All karabiners shall incorporate a captive eye to prevent cross gate loading of the hardware and suitable for connection to the SRLs.

d. Nine (9) overhead shuttles suitable for connection to the FPS.

The overhead shuttles shall be capable of attachment or removal from the wire rope through a double locking mechanism. The mechanism shall be capable of being engaged by hand without the aid of tools.

e. Two (2) Personal Rescue Devices.

f. FPS Placard and FPS Sign.

1. FPS Placard. The Contractor shall provide two (2) FPS placards one at the upstream crane corbel access and the other one at downstream crane corbel access. The placard shall be placed on the wall, approximately 5 feet above the floor and is readable while standing on the corbel access floor. The FPS placard shall meet the following requirements:

a. Series 316 steel conforming to ASTM A276 material

b. States the User allowable weight range

SECTION 01 11 00.01 28 Page 11

c. States the FPS manufacturer and FPS Installer

d. States the FPS installation date

e. States the number of Users permitted on the FPS for the assisted rescue operation

f. Top of placard states in capital letters "REFER TO THE FPS USER

GUIDE PRIOR TO USE"

g. All placard lettering shall be laser etched.

2. FPS Sign. The Contractor shall provide two (2) warning signs. Install one sign on the upstream crane corbel access and the other one at downstream crane corbel access, such that they can be read while standing on the corbel access platform. The FPS sign shall meet the following requirements:

a. Series 316 steel conforming to ASTM A276 material

b. Sign states in all capital letters "WARNING: FALL PROTECTION

REQUIRED BEYOND THIS POINT. THE USER SHALL FOLLOW THE FPS USER GUIDE

REQUIREMENTS.

c. The message lettering shall be one-half inch height minimum and laser etched

2.3 GOVERNMENT-PROVIDED PERSONAL FALL PROTECTION EQUIPMENT

It is the responsibility of the Government to provide the ASSP Z359.1 approved fall protection harnesses for Government use on the Contractor-designed FPS. The Government-provided fall protection harnesses are for Government personnel use only. The Contractor is responsible for providing the personal fall protection equipment necessary to complete the requirements of this contract.

2.4 MATERIAL

All manufactured assemblies shall be compatible to the extent that special modification or conversion is not necessary for the configuration conditions present. Modification of system components without written approval from the Qualified Person is prohibited. The Contractor shall provide the Government documentation of modifications.

a. HLL Terminations. Stainless steel swaged terminations shall be used to attach HLL to end anchors. Cable clamps are prohibited.

b. HLL Connectors. The HLL connectors shall be stainless steel providing secure attachment and detachment to the HLL at any location.

c. HLL. Continuous stainless steel cable as tested by the fall protection device manufacturer.

d. Intermediate HLL Supports. The intermediate HLL supports shall be stainless steel and allow pass-through of the HLL connectors.

e. Tension Indicators. Stainless steel allowing the User to determine whether the correct HLL tension is present.

SECTION 01 11 00.01 28 Page 12

2.4.1 Structural Steel

The structural steel material necessary for fabrication and installation of the FPS shall meet the following requirements.

a. Steel Plates, Rods and Other Shapes. ASTM A36/A36MASTM A36/A36M, yield strength 36 ksi. Dual certification to Grade 50 ksi yield strength material is permitted.

b. Structural Bolts. ASTM A325

c. Structural Nuts. ASTM A563, heavy hex

d. Washers. ASTM F436

e. Wide Flange Shapes. ASTM A992/A992M , yield strength 50 ksi.

f. Pipe. ASTM A53/A53M, Grade B, yield strength 35 ksi.

g. Hollow Steel Shapes. ASTM A500/A500M Grade B

2.4.2 FPS Material

The fall protection system (FPS) components shall meet the following requirements.

a. Overhead Shuttle. Primary components of the overhead shuttle shall be 304 or 316 stainless steel.

b. Concrete Anchors. All concrete anchors shall be of the undercut type and of 316 stainless steel material.

c. Cable Connection Hardware Terminations. The cable hardware including tensioner and shock absorbing connectors shall be 316L stainless steel.

d. Cable Terminations. The cable terminations shall be 316L stainless steel swaged fittings. Cable clamps are prohibited.

e. Tension Indicators. The tension indicators shall allow the User to determine whether the necessary tension is present in the line.

f. Wire Rope. The wire rope shall be constructed of 316 stainless steel. Wire rope splicing is prohibited.

2.4.3 Grout Material

The grout shall be a commercially available prepackaged material. The use of metallic iron in the grout will not be acceptable. Prepackaged non-shrink grout shall be either a gas-liberating or expansive-cement type of material needing only the addition of water and consisting of a commercial formulation suitable for the application proposed and meeting the requirements of ASTM C1107/C1107M and having a minimum 4,000 psi compressive strength.

SECTION 01 11 00.01 28 Page 13

2.5 FABRICATION

2.5.1 General

Material shall be straight before being laid off or worked. Perform straightening, if necessary, by methods that will not impair the metal.

Sharp kinks or bends will be cause for rejection of the material. Material with welds will not be accepted except where welding is definitely specified, indicated or otherwise approved. Make bends using approved dies, press brakes or bending rolls. Where heating is required, take precautions to avoid overheating the metal and allow it to cool in a manner that will not impair the original properties of the metal. Proposed flame cutting of material, other than structural steel, will be subject to approval and shall be indicated on detail drawings. Shearing shall be accurate and all portions of the work neatly finished. Splices shall occur only where shown or approved. Corners shall be square and true unless otherwise shown. Re-entrant cuts shall be filleted to a minimum radius of ¾ inch unless otherwise approved. Provide finished members free of twists, bend and open joints. Bolts, nuts and screws shall be tight.

2.5.2 Dimensional Tolerances

The dimensional tolerances specified by the FPS manufacturer shall be complied with. Measure dimensions using a calibrated steel tape of approximately the same temperature as the material being measured. The overall dimensions of an assembled unit shall be within the tolerances indicated on the drawings or as specified in the particular section of these specifications for the item of work. Where tolerances are not specified in other sections of these specifications or shown, an allowable variation of 1/32 inch is permissible in the overall length of component members with both ends milled; component members without milled ends shall not deviate from the dimensions shown by more than 1/16 inch for members 30 feet or less in length, and by more than 1/8 inch for members over 30 feet in length.

2.5.3 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 D1.1/D1.1M , Subsection 3.2. Where structural steel is not to be welded, chipping or grinding will not be required except as necessary to remove slag and sharp edges of mechanically guided or hand-guided cuts not exposed to view. Chip, grind or machine to sound metal hand-guided cuts which are to be exposed or visible.

2.6 FPS DESIGN PACKAGE SUBMITTALS

The Contractor shall submit FPS Design Package (30 percent and 100 percent each) for Government review and approval as described below in this section's paragraphs. The shop drawings prepared by the Contractor for this Section shall comply with requirements of 01 33 00 SUBMITTAL PROCEDURES. The FPS Design Package hardcopy shall be provided in a comb binder. The FPS Design Package Plans and Specifications shall be signed, stamped and dated by the Qualified Person. Deliverables NOT ready for release for construction, shall be identified as "preliminary" or other appropriate designation. The Qualified Person shall also be responsible for maintaining the integrity of the design and for compliance with the contract requirements through construction and documentation of the

SECTION 01 11 00.01 28 Page 14 as-built condition. Activities include but not limited to the following:

1) Coordination, review and approval of extensions of design, material, equipment and other construction submittals

2) Review and approval or disapproval of requested deviations to the accepted design or to the contract

3) Coordination with the Government of the above activities

4) Other typical professional designer responsibilities

2.6.1 30 Percent FPS Design Package

The Contractor shall prepare and submit the Fall Protection System 30 Percent Design Package for Government review and approval. The submittals shall be provided in Adobe software format that is searchable and consisting of bookmarks. The 30 Percent FPS Design Package submittal shall contain the following minimum items:

a. Drawing(s) showing where the proposed FPS will be installed relative to the existing features.

b. Written FPS User instructions. The design package shall provide User instructions.

c. FPS manufacturer's standard catalog data. The FPS items for installation shall be identified in adequate detail to demonstrate compliance with contract requirements.

d. FPS manufacture recommended installation instructions and procedures.

e. Written FPS design loadings citing the applicable ASSP Z359 loading criteria including the maximum permissible Users that can be present on the FPS.

f. Written User instructions for connection and disconnection to the FPS upon exiting/entering the bridge crane trolley girder or bridge crane corbel.

g. The drawings shall state the minimum required FPS fall clearance along all HLLs, when three (3) Users are supported by the FPS. This can be accomplished by using drawing dimension lines or similar to identify the locations the specified fall clearances are applicable to.

h. The Qualified Person shall stamp, sign and date each design drawing and specifications.

2.6.2 100 Percent FPS Design Package

The Contractor shall prepare and submit the 100 Percent FPS Design Package for Government review and approval. The 100 Percent FPS Design Package shall be of sufficient detail to facilitate construction. The submittals shall be provided in Adobe software format that is searchable and consisting of bookmarks. Three (3) hard copies and one (1) software copy of the design packages shall be submitted to the Government. The 100 Percent FPS Design Package submittals shall contain the items sufficient to fulfill the requirements specified in this Section to include but not

SECTION 01 11 00.01 28 Page 15 limited to the following.

a. Qualified Person signed and stamped as-built FPS

b. FPS manufacturer's standard catalog data.

c. Welder Qualification Records

d. Weld Procedure Specifications

e. FPS design loading citing the maximum number of Users and the maximum User weight that can be present on the FPS. The User design weight shall be the mass of the heaviest worker permitted on the FPS, including all tools and equipment, but not less than 310 pounds.

f. Draft FPS User Guide

2.7 OPERATION AND MAINTENANCE MANUAL FPS USER GUIDE

The FPS User Guide submittal shall be provided in hardcopy and software formats. Submittal format, and requirements shall be as specified for OPERATION AND MAINTENANCE MANUALS AND PARTS CATALOGS in Section 01 78 00 CLOSEOUT SUBMITTALS. The software copies of the User Guide shall be provided for Government review and final submittal with OCR text recognition and section bookmarks in Adobe Reader file format (Version 9 or later). Software and hardcopies of the FPS User Guides must contain the following items:

a. Name of project and Contract number on the covers and spines of hardcopies.

b. Name of project and Contract number on Title Page of the software copies.

c. Name and address of Contractor.

d. Date of submittal.

e. Table of Contents.

f. FPS designer and installer name and contact information.

g. User qualifications including medical and training requirements on the front page in bold font.

h. Personal equipment specification requirements for use with the

FPS.

i. Permanent FPS equipment specifications, intended use, maintenance and inspection requirements.

j. Qualification requirements for FPS inspection and FPS re-certification.

k. List of the equipment specified for use with the FPS including model and serial numbers. Include the current commercial sources for equipment and current pricing information.

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l. Written step by step FPS procedure for procedures for all activities.

m. FPS operation requirements and limitations.

n. Assisted rescue procedure considerations.

o. Manufacturer-provided FPS component operator's guides or manuals.

p. FPS warranty information.

PART 3 EXECUTION

3.1 EXISTING FPS REMOVAL

An existing FPS consists of (2) 300' upstream and downstream, and (2) 47' North and South trolley rail access horizontal lifelines (HLLs) and attached HLL appurtenances. The Contractor shall remove and dispose of the existing FPS in accordance with local and federal government requirements.

The FPS anchor bolts shall be cut flush with the wall and sharp edges ground smooth. The intermediate anchors shall be removed in a manner that will not damage the building. The Contractor shall not use any of the existing Powerhouse horizontal life lines as fall protection.

3.2 FPS CONCRETE DESIGN STRENGTH AND MATERIAL PROPERTIES FOR CONSTRUCTION

The concrete design strength for the FPS design shall be f'c = 3,000 psi.

The following concrete material properties are provided as an aid in determining the drilling requirements only. Concrete strength, f'c = +4,000 psi (not to be used for FPS design). The aggregate material is basalt (hard to very hard) with sizes up to six inches. The sand material is sharp and abrasive.

3.3 PROPOSED FPS DESIGN

The proposed FPS design would consist of four (4) horizontal lifelines (HLLs). (2) approximately 300' HLLs along the upstream and downstream corbel walls, and (2)approximately 50' North and South bridge crane trolley rail access HLLs used to traverse and work on all of the crane rails. The fall arrest lines would provide User fall arrest or fall restraint while working on the corbels and while working on the bridge crane trolley rails.

The Contractor is permitted to submit a FPS design other than the Government-proposed design. The FPS design submitted shall meet the requirements of this SECTION.

3.4 CONCRETE REINFORCEMENT STEEL

The Contractor shall determine the concrete reinforcement steel locations prior to drilling. The Contractor shall use Ground Penetration Radar (GPFR) to determine the steel reinforcement locations and depths. The Contractor shall submit for Government review and approval the concrete quality control program Steel Reinforcement Location Report. The steel reinforcement locations shall be marked on the concrete surface prior to drilling. The Contractor shall cease drilling immediately if steel reinforcement is hit during drilling and fill the open hole with

SECTION 01 11 00.01 28 Page 17 cementitious non-shrink grout to a level flush with the concrete surface.

The repair action shall be completed at no cost to the Government. The Contractor shall remove the steel reinforcement markings from the concrete after completing drilling operations.

3.5 WELDING PROCESS, TECHNIQUE AND WORKMANSHIP

3.5.1 Welding Process

Perform welding in conformance with the applicable provisions of AWS D1.1/D1.1M . Minimize residual stressed, distortion and shrinkage from welding. Field welding is prohibited.

3.5.2 Welding Technique

a. Filler Metal - The electrode, electrode-flux combination and grade of weld metal shall conform to the appropriate AWS specification for the base metal and welding process being used or be as shown where a specific choice of AWS specification allowable is required. 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 D1.1/D1.1M , Subsection 3.5 to maintain low moisture of low hydrogen electrodes.

b. Preheat and Interpass Temperature - Perform preheating as required by AWS D1.1/D1.1M , Subsection 3.5 or as otherwise specified except that the temperature of the base metal shall be at least 70 degrees F. Slowly and uniformly preheat the weldments 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.

3.5.3 Workmanship

Perform welding workmanship in accordance with AWS D1.1/D1.1M , Section 3 and other applicable requirements of this Section.

a. Preparation of Base Metal - Prior to welding inspect surfaces to be welded to ensure compliance with AWS D1.1/D1.1M , Subsection 3.2.

b. Temporary Welds - Make temporary welds, required for fabrication and erection, under the controlled conditions prescribed for permanent work. Make temporary welds using low-hydrogen welding electrodes and by welders qualified for permanent work as specified in this Section.

Conduct preheating for temporary welds as required by AWS D1.1/D1.1M for permanent welds except that the minimum temperature shall be 120 degrees F in any case. In making temporary welds, arcs shall not be struck in other than weld locations. Remove each temporary weld and grind flush with adjacent surfaces after serving its purpose.

c. Tack Welds - Subject tack welds that are to be incorporated into the permanent work to the same quality requirements as the permanent welds; clean and thoroughly fuse them with permanent welds. Perform preheating as specified above for temporary welds. Multiple-pass tack welds shall have cascaded ends. Remove defective tack welds before permanent welding.

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3.6 CERTIFIED TEST REPORTS

Submit Certified Test Reports prior to construction. Submit reports of tests, inspections, and verifications of all materials used in fabricating the FPS. All steel used in this contract shall be tested by an approved U.S. laboratory to ensure that it meets the required standards.

3.6.1 Nondestructive Testing

When doubt exists as to the soundness of any material part, such part may be subjected to any form of nondestructive testing determined by the COR.

This may include ultrasonic, magnetic particle, dye penetrant, x-ray, gamma ray or any other test that will thoroughly investigate the part in question. The cost of such investigation will be borne by the Government.

Any defects will be cause for rejection and rejected parts shall be replaced and retested by the same test method that located the defect at the Contractor's expense.

3.6.2 Inspection of Structural Steel Welding

Nondestructive examination of designated welds will be required.

Supplemental examination of any joint or coupon cut from any location in any joint may be required.

3.6.2.1 Visual Examination

For all visual examination of completed welds clean and carefully examine for insufficient throat or leg sizes, cracks, undercutting, overlap, excessive convexity or reinforcement and other surface defects to ensure compliance with the requirements of AWS D1.1/D1.1M , Section 6, subsection 6.9, Part C for statically loaded connections. All FPS weld connections shall be visually inspected.

3.6.2.2 Nondestructive Examination

Perform as designated or described in the sections of this Section, the nondestructive examination of shop welds covering the particular items of work.

a. Testing Agency - The nondestructive examination of welds and the evaluation of examination tests as to the acceptability of the welds shall be performed 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 is required and the examination tests shall be made in the presence of the COR. The evaluation of examination tests are subject to the approval and all records become the property of the Government.

b. Examination Procedures - Conform to the following requirements.

1. Ultrasonic Testing - Making, evaluating and reporting ultrasonic testing of welds shall conform to the requirements of AWS D1.1/D1.1M , Section 6, Part C for statically loaded connections. Provide ultrasonic equipment capable of making a permanent record of the test indications. Make a record of each weld tested.

2. Magnetic Particle Inspection - Magnetic particle inspection of welds shall conform to the applicable provisions of ASTM E709.

3. Dye Penetrant Inspection - Perform dye penetrant inspection of welds

SECTION 01 11 00.01 28 Page 19 conforming to the applicable provisions of ASTM E165/E165M ASTM E165.

c. Acceptability of Welds - - Welds will be unacceptable if shown to have defects prohibited by AWS D1.1/D1.1M , or possess any degree of incomplete fusion, inadequate penetration or undercutting.

d. Welds to be subject to nondestructive examination

1. Complete Joint Penetration (CJP) Weld Connections. 100 percent of CJP weld connections shall be examined.

2. Horizontal Lifeline (HLL) Termination Anchor Plate Weld Connections.

100 percent of the HLL termination anchor plate weld connections shall undergo nondestructive inspection.

3. Intermediate HLL Support Weld Connections. A minimum of 50 percent of the intermediate HLL support weld connections shall undergo nondestructive inspection.

3.6.2.3 Supplemental Examination

When the soundness of any weld is suspected of being deficient due to faulty welding or stresses that might occur during shipment or erection, the Government reserves the right to perform nondestructive supplemental examination before final acceptance. The cost of such inspection will be borne by the Government.

3.6.3 Structural Steel Welding Repairs

Repair defective welds in the structural steel in accordance with AWS D1.1/D1.1M , Subsection 3.7. Remove defective weld metal to sound metal by use of air carbon-arc or oxygen gouging. Do not use oxygen gouging on ASTM A514/A514M steel. Thoroughly clean surfaces before welding. Retest welds that have been repaired by the same methods used in the original inspection. Except for the repair of members cut to remove test coupons and found to have acceptable welds costs of repairs and retesting will be borne by the Contractor. Submit welding repair plans for steel, prior to making repairs.

3.7 PROTECTION OF EXISTING STRUCTURES AND UTILITIES

Take all necessary precautions to avoid damage to existing structures, their appurtenances, or utilities that may be affected by work activities.

Repair any damage resulting from the Contractor's operations at no expense to the Government. Coordinate with the COR to locate utilities prior to beginning construction. Do not disturb utilities encountered which were not previously shown or otherwise located without approval from the Contracting Officer Representative. Perform work without damage or contamination of adjacent areas. Where existing work is damaged or contaminated, restore work to its original conditions or better as determined by the COR.

3.8 ON-SITE FPS TRAINING

The Contractor shall provide two (2) on-site FPS User training sessions.

The training session shall be a minimum of two (2) hours in duration. The days available to conduct training sessions are Monday through Thursday, 0730 - 1700, excluding Federal Government holidays. Five (5) hardcopy FPS User Guides shall be provided during the training session. The training session shall not occur until the FPS has been installed and the FPS

SECTION 01 11 00.01 28 Page 20

User's Guide has been submitted for Government review. The training session shall consist of "hands-on" instruction of the procedures to follow when using the FPS including maintenance and inspection. The On-Site FPS Training content shall be documented in the FPS User Guide and conducted by either a competent person trainer or qualified person trainer in accordance with ASSP Z359.2 and ASSP Z490.1 . Upon successful completion of the FPS training, each student shall be provided a hardcopy certificate. The certificate shall document that the individual has received sufficient fall protection training to be an authorized person to use the Contractor installed FPS. The Contractor shall contact the COR to schedule the FPS training a minimum of 15 calendar days prior to the proposed training session date.

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