A.01.30TechnicalSpecAmendment2.pdf

Ice Harbor/Little Goose Spare Set Draft Tube Stoplogs W912EF-15-R-0046 Amend-0002

SECTION TABLE OF CONTENTS

DIVISION 05 - METALS

SECTION 05 59 13.00 28

FABRICATION OF HYDRAULIC STEEL STRUCTURES

PART 1 GENERAL

1.1 REFERENCES

1.2 SUBMITTALS

1.3 PRE-FABRICATION REQUIREMENTS

1.3.1 Qualification of Structural Steel Fabricator

1.3.2 Shop Drawings

1.3.3 Material Acceptance

1.3.4 Definition of Engineer

1.3.5 Qualification of Welders and Welding Operators

1.3.6 Weld Tracking Log Template

1.3.7 Weld Tracking Log

1.3.8 Welding Procedure Specifications (WPS)

1.3.9 Fracture Critical Members (FCM)

1.3.10 Structural Fabrication Quality Control Plan

1.3.11 Distortion Control Plan

1.3.12 Nonconformance Report

1.3.13 NDT Written Practice

1.3.14 Pre-Fabrication Conference

1.4 DELIVERY, STORAGE, AND HANDLING

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Metals

2.1.1.1 Structural Steel

2.1.1.2 Seal Retainer Bars

2.1.1.3 Bearing and Guide Plates and Bars

2.1.1.4 Aligning & Lifting Pins

2.1.1.5 Cap Screws, Nuts and Washers

2.1.1.6 Springs

2.1.2 Electrical Isolation Material

2.1.3 Rubber Seals

PART 3 EXECUTION

3.1 FABRICATION

3.1.1 Structural Fabrication

3.1.2 Materials Disposition Record

3.1.3 Welded Connections

3.1.4 Bolted Connections

3.1.5 Miscellaneous Provisions

3.1.6 Shop Assembly

3.1.7 Seals

3.2 CERTIFIED TEST REPORTS

3.2.1 General

SECTION 05 59 13.00 28

3.2.2 Nondestructive Testing

3.2.3 Inspection of Structural Steel Welding

3.2.4 Welds to be Subject to Nondestructive Examination

3.2.5 Test Coupons

3.2.6 Supplemental Examination

3.2.7 Structural Steel Welding Repairs

3.3 BOLTED ASSEMBLIES

3.3.1 Assembly and Cleaning

3.3.2 Alignment and Setting

3.4 PROTECTION OF FINISHED WORK

3.5 ALIGNMENT TEST

3.6 PAINTING

3.7 HSS IDENTIFIER

3.8 WEIGHT OF STOPLOGS

3.9 STOPLOG FABRICATION REPORT

-- End of Section Table of Contents --

SECTION 05 59 13.00 28

G4EDHCMP

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FABRICATION OF HYDRAULIC STEEL STRUCTURES

PART 1 GENERAL

1.1 REFERENCES

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

AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING (ASNT)

ANSI/ASNT CP-189 (2011) ASNT Standard for Qualification and Certification of Nondestructive Testing Personnel (ANSI/ASNT CP-105-2006)

AMERICAN WELDING SOCIETY (AWS)

AWS D1.5M/D1.5 (2010) Bridge Welding Code

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

ASTM INTERNATIONAL (ASTM)

ASTM A194/A194M (2014a) Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High-Pressure or High-Temperature Service, or Both

ASTM A325 (2010) Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength

ASTM A563 (2007a) Standard Specification for Carbon and Alloy Steel Nuts

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

ASTM E165 (2009) Standard Test Method for Liquid Penetrant Examination

ASTM E709 (2008) Standard Guide for Magnetic Particle Examination

ASTM F436 (2011) Hardened Steel Washers

ASTM D1264 (2012) Standard Test Method for Determining the Water Washout Characteristics of Lubricating Grease

ASTM A789/A789M (2013a) Standard Specification for

Seamless and Welded Ferritic/Austenitic Stainless Steel Tubing for General Service

ASTM D 2240 (2005; R 2010) Standard Test Method for Rubber Property - Durometer Hardness

ASTM D 572 (2004; R 2009) Rubber Deterioration by Heat and Oxygen

ASTM D 573 (2004) Standard Test Method for Rubber - Deterioration in an Air Oven

ASTM D 471 (2006e1) Standard Test Method for Rubber Property - Effect of Liquids

ASTM D 412 (2006ae2) Standard Test Methods for Vulcanized Rubber and Thermoplastic Elastomers - Tension

ASTM D 395 (2003; R 2008) Standard Test Methods for Rubber Property - Compression Set

ASTM A564/A564M (2004; R 2009) Standard Specification for Hot-Rolled and Cold-Finished Age-Hardening Stainless Steel Bars and Shapes

ASTM A 689 (1997; R 2002) Carbon and Alloy Steel Bars for Springs

1.2 SUBMITTALS

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

submittals having an "I" designation are for information only. When used, a designation following the "G" or "I" designation identifies the office that will review the submittal for the Government. The following shall be submitted in accordance with SECTION 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Welding Procedure Specifications (WPS); G, C Weld Tracking Log Template; G, C Fracture Control Plan (FCP); I, ST Distortion Control Plan; I, ST Structural Fabrication Quality Control Plan; G, ST NDT Written Practice; I, ST

SD-02 Shop Drawings

Shop Drawings; G, ST Welding Repairs - Fracture Critical Members; G, C Nonconformance Report; G, ST Delivery/Shipping Plan; G, ST

SD-03 Product Data

Materials Disposition Record; I, C Rubber Seals; I, ST Anti-Seize Product Technical Data Sheet; I, ST

SD-05 Design Data

Weight of Stoplogs; I, ST

SD-06 Test Reports

Certified Test Reports; I, ST Weld Tracking Log; I, C NDT Equipment Calibration Records; I, C

SD-07 Certificates

Qualification of Welders and Welding Operators; G, C Inspector Qualifications; G, C Qualification of Structural Steel Fabricator; G, ST

SD-09 Manufacturer's Field Reports

Alignment Test; I, ST Stoplog Fabrication Report; G, ST

1.3 PRE-FABRICATION REQUIREMENTS

1.3.1 Qualification of Structural Steel Fabricator

a. The fabricator shall be certified under the AISC Bridge QMS Certification program. Certification must be in one of the following categories:

1. Certified Bridge Fabricator - Intermediate (IBR) with Fracture Critical Endorsement.

2. Certified Bridge Fabricator - Advanced (ABR) with Fracture Critical Endorsement.

b. Certifications were formerly listed under the AISC quality certification program, Category III, Major steel bridges with Fracture Critical Rating. Certifications under the former AISC Certification Program that are still current will be acceptable.

c. The fabricator shall be certified on or before the date of award and the certification shall remain current for the duration of the contract. Initial certification of the plant after date of award will not be acceptable. If renewal of the certification is necessary before the required contract completion date, the fabricator will be required to complete the certification renewal process. Submit copies of the AISC certificate indicating that the fabrication plant meets the specified AISC category requirements. If a renewal of the certification is required after the date of Award, submit a copy of the renewed certification.

1.3.2 Shop Drawings

Contractor shall submit detailed shop drawings showing individual stoplog fabrication details and assembly view. Shop drawings for the stoplogs shall include fabrication and assembly details and type, grade and class of material as appropriate. All applicable welding procedure numbers shall be listed in the tails of the weld symbols on drawings. Provide assembly drawings indicating the sequence of fabrication and provide details for connecting the adjoining fabricated components in the shop. Elements of fabricated items inadvertently omitted on contract drawings shall be detailed by the fabricator and indicated on the shop drawings.

1.3.3 Material Acceptance

Material with welds will not be accepted unless the welding is specified or indicated on the drawings or otherwise approved. Welding shall not be started until welding procedures, inspectors, nondestructive testing personnel, welders, welding operators, and tackers have been qualified and approved. Each Contractor performing welding shall maintain records of the test results obtained in welding procedure, and welder, welding operator, and tacker performance qualifications.

1.3.4 Definition of Engineer

As it is used in these specifications, "The Engineer" refers to the government engineer of record. The AWS D1.5M/D1.5 definition of "The Engineer" as specified in AWS D1.5M/D1.5 section 1.1.3 shall refer to the government engineer of record in lieu of the state bridge engineer.

1.3.5 Qualification of Welders and Welding Operators

Welding operators, welders, and tack welders shall be qualified for the particular type of work to be done. Qualification shall be in accordance with AWS D1.5M/D1.5. Welders and welding operators shall conform to all qualification requirements established by AWS D1.5M/D1.5 Clauses 5 and 12 where applicable. The qualifications shall be submitted on Form N-5, Annex N of AWS D1.5M/D1.5. The welder or welding operator shall be required to repeat the qualifying tests when, in the opinion of the COR, their work indicates a reasonable doubt as to their proficiency. Certification shall be submitted for those passing the test and upon approval, they shall be considered qualified. Those not passing shall be disqualified until passing. All expenses in connection with qualification or requalification shall be borne by the Contractor. A Government representative is required to be present during welder requalification.

1.3.6 Weld Tracking Log Template

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. A weld-tracking log will be developed and maintained as described in the following paragraphs.

1.3.7 Weld Tracking Log

Submit a log capable of individually identifying and tracking every weld on the project. Member identification shall follow the numbering scheme shown on the shop drawings. The log shall include the member to be welded, member type (FCM and Non-FCM), type of weld including temporary and tack welds, 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, 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. Weld identification on the shop drawing shall match weld tracking log identification. Completed tracking logs shall be bound together for each structure and shall be submitted to the Contracting Officer immediately upon completion of the fabrication of each structure. Draft copies of NDT testing shall be furnished to the Contracting Officer upon request and shall be available on the shop floor during any inspection.

1.3.8 Welding Procedure Specifications (WPS)

Submit a Welding Procedure Specification (WPS) with PQR and supporting test documentation on forms similar or equivalent to the sample forms in AWS D1.5M/D1.5, Annex III, for each weld, including prequalified welds, in accordance with paragraph Welded Connections approved before fabrication is commenced. Approved WPS's are required prior to commencing fabrication.

Approve all WPS's and PQR's submitted for Government approval by an approved CWI. Welding Procedure Specifications shall be individually identified and shall be referenced on the shop drawings. In case of conflict between this specification and AWS D1.5M/D1.5 as applicable, this specification governs.

1.3.9 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. Submit a Fracture Control Plan (FCP) for welding on all Fracture Critical Members (FCM) in accordance with AWS D1.5M/D1.5, Section 12. Welding Procedures, qualifications, and certifications shall be submitted showing compliance with FCP requirements. All materials to be welded shall be 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. Toughness shall meet the requirements of ASTM A709/A709M, Table 9, for Zone 2, unless otherwise indicated or specified. All materials used for the fabrication of fracture critical components shall meet the requirements of section 10 of ASTM A709/A709M and shall include mill certification showing that the material meets the necessary toughness requirements. Welding for fracture critical members shall meet all requirements of AWS D1.5M/D1.5 Section 12, including:

a. 12.5 Welding Processes. All procedures shall be qualified as required.

b. 12.6 Consumable Requirements. All welding consumables shall be heat or lot-tested by the manufacturer to determine conformance with the requirements of the Fracture Control Plan (FCP) per section 12 of AWS D1.5M/D1.5. Exceptions are not allowed. Toughness test results shall meet the values specified in Table 12.1 of AWS D1.5M/D1.5.

c. 12.7 Welding Procedure Specifications (WPS). All procedures, including repair welds, shall be prequalified or qualified by test as required and documented in the WPS and Procedure guidelines of AWS D1.5M/D1.5.

d. 12.8 Certification and Qualification. Welders and welding operators shall meet the applicable requirements of AWS D1.5M/D1.5.

Qualification of Welders and Welding Operators shall be submitted for approval.

e. Material handling and preparation, including thermal cutting, preparation of base metal, and straightening, curving, cambering shall meet the applicable requirements.

f. 12.13 Tack Welds and Temporary Welds. All welds shall be located within the joint and shall meet the requirements of AWS D1.5M/D1.5, Table 12.2. Temporary welds on FCM are not permitted.

g. Welding processes, including preheat, interpass temperatures, and postweld thermal treatment shall meet the applicable requirements.

h. 12.16 Weld Inspection. The Quality Control inspection program shall be documented in the FCP. All inspectors and NDT technicians shall be qualified as required and specified herein. Submit Inspector Qualifications for approval. All butt joints shall be tested with UT and RT. Inspection procedures and documentation are as specified in the applicable sections of AWS D1.5M/D1.5. Cooling times must be strictly adhered to.

i. 12.17 Repair Welding. Repair welds must be classified as "critical repairs" or "non-critical repairs" for all repair welding. Repair procedures shall follow the minimum provisions unless specified otherwise. Repair procedures must be qualified and approved and subject to the same QA/QC inspection requirements as other welds.

Minimum preheat for repair welding shall be as defined in AWS D1.5M/D1.5 section 12.17.6. All weld repairs to fracture critical members shall be considered critical welds in accordance with AWS D1.5M/D1.5 Section

12.17.3 and shall be approved by the engineer of record.

1.3.10 Structural Fabrication Quality Control Plan

Before the start of work, the fabricator is to supply a Structural Fabrication Quality Control Plan (QCP) for approval. Ensure the QCP describes the methods, equipment, Non-Destructive Testing (NDT), and frequency of testing used. The Engineer will use the AASHTO/NSBA, "Steel Bridge Fabrication QC/QA Guide Specification" as the basis for approving the QCP. Quality control personnel can be assigned to more than one task, provided they are qualified and able to fully perform the duties of each position. Individual(s) responsible for quality assurance/quality control may not serve as or report to production management.

1.3.11 Distortion Control Plan

Submit a distortion control plan addressing means and methods used to prevent and control distortion during fabrication inclusive but not limited to: jigs, rotation of part, support of part during fabrication, temp control, backstepping, welding sequencing, methods used to verify dimensional conformity during fabrication.

1.3.12 Nonconformance Report

Properly document all nonconformance's using a Nonconformance Report form.

Submit Non Conformance Form Template prior to fabrication. The Non Conformance Report Template will be used during fabrication to record and submit all Nonconformance's. Submit a Nonconformance Report on the approved form to the Engineer documenting any deviation from the QCP, approved shop drawings, code, Work Plan and/or specifications. The Nonconformance Report Form shall include the following items: company name and address; report title; Nonconformance Report number; date ; company job number; piece mark;

owner of structure; contractor; owners project number; location ; a detailed description of the nonconformance; photo, sketch, or drawing;

proposed repair/disposition of the nonconformance; and the Quality Control Manager's signature and date.

1.3.13 NDT Written Practice

The NDT written practice shall establish the minimum requirements for education, training, experience, examination and certification of personnel responsible for conducting nondestructive tests while in the employment of the contracted company. 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 NDT.

1.3.14 Pre-Fabrication Conference

Following approval of Contractor prepared shop drawings and prior to any fabrication, schedule and hold a Prefabrication Conference as soon as possible after Notice of Award. The meeting will be held at least one (1) week prior to start of fabrication. The Project Manager shall lead the Pre-Fabrication Meeting. Include in the Prefabrication Conference, at a minimum, the Prime Contractor, Fabricator, the Fabricator's primary QC representative, representative from the third party testing lab if applicable, the COR, the GQAR, 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 PQR requirements and required witnessing of testing. 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.

1.4 DELIVERY, STORAGE, AND HANDLING

The structures shall be arranged on the delivery vehicles such that no damage occurs during shipping. The stoplogs shall be delivered in an up-right position so that the lifting lugs can be picked vertically using the project's gantry crane and draft tube stoplog lifting beam. The Government's gantry crane will be available to offload the stoplogs.

Submit a Delivery/Shipping Plan showing orientation and locations of structures on the delivery vehicles prior to shipment for Government approval. Submit 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 structure on transport equipment.

PART 2 PRODUCTS

2.1 MATERIALS

The Contractor shall implement a physical material tracking process suitable to ensure materials are identifiable at all times during the fabrication process (i.e. marking materials with project number, piece mark number, material type, etc.). Materials for fabrication of stoplogs shall conform to the requirements of the specification sections below:

2.1.1 Metals

Structural steel and other metal materials sections and standard articles shall be as shown and as specified herein.

2.1.1.1 Structural Steel

Structural steel plates and bars shall conform to ASTM A709/A709M, Grade

50. Structural wide flange, channel and angle shapes shall conform to ASTM A709/A709M, Grade 50.

2.1.1.2 Seal Retainer Bars

Retainer bars for rubber J-seals shall conform to ASTM A709/A709M.

2.1.1.3 Bearing and Guide Plates and Bars

Bearing and guide plates include, but are not limited to, end guide shoes, bearing guide shoes, guide shoes, alignment guides and crane guides.

Bearing and guide plates and bars shall be fabricated from structural steel conforming to ASTM A709/A709M.

2.1.1.4 Aligning & Lifting Pins

Aligning and lifting pins shall conform to ASTM A564/A564M, S17400, Type 630, Condition H900. Pins shall be machined to the sizes shown on the drawings.

2.1.1.5 Cap Screws, Nuts and Washers

Seal cap screws, nuts, washers, shall be 300 series stainless steel. Sizes are indicated on the drawings. Seal cap screws shall be conform to ASTM A789/A789M Group 1, 300 series. Nuts shall conform to ASTM A194/A194M UNS designation S21800 Grade 8S, which are referred to as nitronic 60 stainless steel nuts. The threads of fasteners used to secure the J-bulb seal between the back-up and bar clamp plates shall be coated with a non-curing calcium sulfonate based Marine Grade Anti-Seize material that meets the requirements of ASTM D1264 with a water washout of zero (0.0) percent. The anti-seizing material is intended to prevent galvanic corrosion. Submit the Anti-Seize Product Technical Data Sheet (or similar) specifying the product characteristics. The anti-seizing material shall be Loctite Marine Grade Anti-Seize, or an approved equal.

2.1.1.6 Springs

Springs shall conform to ASTM A 689 AISI 5150.

2.1.2 Electrical Isolation Material

Electrical isolation material to prevent dissimiliar metal corrosion between the lifting pin, and the lifting pin bracket, shall consist of a fiber reinforced laminated plastic composite formed by impregnating fabric with thermosetting resin. The composite shall incorporate solid lubricants to reduce the coefficient of friction and reduce wear. Material shall provide a compressive strength perpendicular to the laminate of approximately 35,000 psi and a tensile strength of approximately 10,000 psi. Water absorption shall be less than 0.1%. Isolation material shall provide for a sliding coefficient of friction of less than 0.1. Where fits are specified for fiber reinforced plastic (FRP) bearings, those fits shall be with the FRP material in the maximum material condition assuming full swell as a result of water absorption.

2.1.3 Rubber Seals

Submit manufacturer's descriptive data, catalog cuts and other information to fully describe the rubber seals proposed for use. Rubber seals shall be compounded of natural rubber, fully molded type only, synthetic polyisoprene, or a blend of both, and shall contain reinforcing carbon black, zinc oxide, accelerators, antioxidants, vulcanizing agents, and plasticizers. Physical characteristics of the seals shall meet the following requirements:

TEST METHOD

PHYSICAL TEST TEST VALUE SPECIFICATION

Tensile Strength 2,500 psi (min.) ASTM D 412

Elongation at Break 400% (min.) ASTM D 412

300% Modulus 900 psi (min.) ASTM D 412

Durometer Hardness 60 to 70 ASTM D 2240 (Shore Type A)

*Water Absorption 5% by weight (max.) ASTM D 471

Compression Set 30% (max.) ASTM D 395

Tensile Strength 80% of tensile ASTM D 572 (after aging 48 hrs) strength (min.) ASTM D 573

* The "Water Absorption" test shall be performed with distilled water. The washed specimen shall be blotted dry with filter paper or other absorbent material and suspended by means of small glass rods in the oven at a temperature of 70 degrees plus/minus 2 degrees C for 22 plus/minus 1/4 hour. The specimen shall be removed, allowed to cool to room temperature in air, and weighed. The weight shall be recorded to the nearest 1 mg as W1 (W1 is defined in ASTM D 471). The immersion temperature shall be 70 degrees plus/minus 1 degree C and the duration of immersion shall be 166 hours.

Strips and corner seals shall be molded, hot factory spliced in lengths suitable for obtaining the finish lengths shown. A two week period shall be allowed for seal shrinkage to occur prior to fabricating the seal assembly.

PART 3 EXECUTION

3.1 FABRICATION

3.1.1 Structural Fabrication

Material shall be straight before being laid off or worked. If straightening is necessary, fabricator shall submit a procedure for Government approval. The straightening shall be done by methods that will not impair the metal. Sharp kinks or bends shall be cause for rejection of the material. Material with welds will not be accepted except where welding is definitely specified, indicated or otherwise approved. Bends shall be made by approved dies, press brakes or bending rolls. Where heating is required, precautions shall be taken to avoid overheating the metal and it shall be allowed to cool in a manner that will not impair the original properties of the metal. Proposed flame cutting of material, other than structural steel, shall be subject to approval and shall be indicated on detail drawings. Shearing shall be accurate and all portions of the work shall be neatly finished. Corners shall be square and true unless otherwise shown. Re-entrant cuts shall be filleted round to a minimum radius of 1 inch in accordance with AWS D1.5M/D1.5 section 3.2.4 unless otherwise indicated or approved. Finished members shall be free of twists, bends and open joints.

a. Dimensional Tolerances for Structural Work.

(1) Dimensions shall be measured by an approved measuring system.

Submit the measuring system for approval with the work plan (i.e.

calibrated steel tape of approximately the same temperature as the material being measured). The overall dimensions of an assembled structural unit shall 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, 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 shall not deviate from the dimensions shown by not more than 1/16 inch for members 30 feet or less in length and by not 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 fabrication. All tolerances shall be measured with the gate in the vertical position.

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. Surfaces and edges shall be prepared in accordance with AWS D1.5M/D1.5, Subsection 3.2. Hand-guided cuts shall be chipped, ground or machined to sound metal.

3.1.2 Materials Disposition Record

Submit copies 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.

Where mill tests are required, purchase orders shall contain the test site address and the name of the testing agency. 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. Submit material records before the beginning of fabrication. Additional requirements for this submittal are listed below.

3.1.3 Welded Connections

a. Welding Procedure.

(1) Welding shall conform to the applicable provisions of AWS D1.5M/D1.5. Prior to the start of production welding, submit a complete schedule of welding procedures for a typical structure. The schedule shall conform to the requirements specified in the provisions of AWS D1.5M/D1.5. The schedule shall provide detailed procedure specifications and tables or diagrams showing the procedures to be used for each required joint.

(2) Submit a Welding Procedure Specification for each weld to be made. Submit Welding Procedure Specifications and Procedure Qualification Records (PQR) for approval before fabrication is commenced. All Welding Procedures Specifications approved by the Government will receive a Government approval stamp, copies of the "stamped WPS" shall be the only recognized version of that WPS approved for use. Approved WPS's bearing a government approval stamp shall be posted in work areas where welding is being performed, WPS's shall be readily available for reference at all times. Copies of the Welding Procedure specification and the results of the procedure qualification test for each type of welding which requires procedure qualification shall be submitted for approval. Submit the WPS and PQR with the shop drawings.

Each WPS shall be prepared and qualified in accordance with the applicable provisions of AWS D1.5M/D1.5. Welding procedures shall show types and locations of welds designated or specified to receive nondestructive examination and identify the weld as FCM when applicable. A WPS is always required, even if the procedure is considered prequalified in accordance with AWS D1.5M/D1.5.

Properly documented evidence of compliance with all requirements of these specifications for previous qualification tests shall establish the welding procedure as prequalified. Each procedure shall be clearly identified as being either prequalified or qualified by tests. If a PQR is performed, a representative of the Government shall witness the test plate welding and the specimen testing. Approval of any procedure, however, will not relieve the Contractor of the responsibility for producing a finished structure meeting all requirements of these specifications. Copies of the WPS shall be made available for reference to the welders, welding operators and tack welders. A CWI meeting the specified qualifications shall approve all WPS's and PQR's.

(3) Welding Procedure Specifications shall include 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. A WPS is required regardless if the procedure is considered prequalified or qualified through testing.

Filler metal data sheets shall be included with WPS and PQR. Weld repair procedures shall be included on each WPS. Welding Procedure Specifications will be approved by an individual who at a minimum is certified through the American Welding Society as a Certified Welding Inspector.

All Welding Procedure Specifications for new base metal to existing base metal is required to be qualified through testing.

b. Welder Performance Qualification of Welders and Welding Operators.

Welding operators, welders, and tack welders shall be qualified and requalified if necessary for the particular type of work to be done.

Qualification shall be in accordance with AWS D1.5M/D1.5. Before assigning any welder, welding operator, or tacker to work under this contract, submit the names of the welders, welding operators, and tackers to be employed, and certification that each individual is qualified as specified. The certification shall state 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. Copies of the Performance Qualification records shall be submitted to the Government Representative and approved before fabrication is commenced. Require the welder and welding operators to repeat the qualifying tests when, in the opinion of the Contracting Officer, the work indicates a reasonable doubt as to proficiency. In such cases, the welder shall be recertified, as above, after successfully passing the retest;

otherwise, he/she shall be disqualified until successfully passing a retest. A Government representative will be present for requalifying welder test when a reasonable doubt as to proficiency exists. The period of effectiveness for all welder and welding operator performance qualifications shall 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 shall be borne by the Contractor.

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

d. Welding Technique.

(1) 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 shall be as shown where a specific choice of AWS specification allowable is required. Weld metal toughness shall meet the requirements of AWS D1.5M/D1.5, Tables, 4.1, 4.2, or 12.1 as applicable. The AWS designation of the electrodes to be used shall be included in the schedule of welding procedures. Only low hydrogen electrodes shall be used for manual shielded metal-arc welding regardless of the thickness of the steel. A controlled temperature storage oven shall be used at the job site as prescribed by AWS D1.5M/D1.5, Subsection 12.6 to maintain low moisture of low hydrogen electrodes. Controlled temperature storage ovens shall be powered at all times. FCAW filler metal shall be subjected to the storage and handling requirements defined in AWS D1.5M/D1.5 section

12.6.7.4. Filler metals and processes shall not be combined in the same joint or weld.

(2) Preheat and Interpass Temperature - Preheating shall be performed as required by the applicable provisions of AWS D1.5M/D1.5 for all welds. Preheat for fracture critical welds shall be as defined in Table 12.3 and in accordance with the PQR/WPS. The weldments to be preheated shall be slowly and uniformly heated by approved means to the prescribed temperature, held at that temperature until the welding is completed and then permitted to cool slowly as required and in accordance with the approved WPS in order to prevent cracking or distortion. Preheating by use of oxygen cutting equipment, or heads designed for heating "rosebud", will be restricted. Furthermore, the use of cutting heads for preheating will not be allowed.

e. Workmanship. Workmanship for welding shall be in accordance with AWS D1.5M/D1.5, Section 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 sections of

AWS D1.5M/D1.5.

(2) Tack and Temporary Welds. Tack and temporary welds required for fabrication and erection shall be made in accordance with AWS D1.5M/D1.5 under the controlled conditions prescribed herein for permanent work. All tack and temporary welds that are not be be incorporated into permanent work shall be removed and ground flush with the existing base metal. Tack welds that are to be incorporated into the permanent work shall be subject to the same quality requirements as the permanent welds. Such tack welds shall be cleaned and fused thoroughly with the permanent welds.

Multiple-pass tack welds shall have cascaded ends. Defective tack welds shall be removed before permanent welding. All welds shall be made using low-hydrogen welding electrodes and by welders qualified for permanent work as specified elsewhere in these specifications. Preheat shall be as required by AWS D1.5M/D1.5 for permanent tack welds . All tack welds which will be incorporated into the final weldment shall be a maximum of 1/8 inch with a minimum length of 1 inch long spaced at a maximum of 6 inch on center. In making temporary welds, arc strikes shall not be struck in other than weld locations. Each temporary weld shall be removed as required by AWS D1.5M/D1.5, Subsection 3.3.8. All arc strikes struck outside the weld zone shall be ground out and inspected in accordance with AWS D1.5M/D1.5.

(3) Weld Access Holes. Weld access holes shall be provided as shown on the shop drawings. If the oversight of intersecting out-of-plane welds is encountered, the fabricator shall notify the Contracting Officer for the approval of weld access hole additions in such locations. Payment for the addition of weld access holes not shown on plans will be the Contractor's responsibility.

(4) Weld Removal. Unless otherwise indicated, all steel weld backing material shall be removed from welded joints prior to testing.

All weld backing material that cannot be removed shall be identified on the shop drawings.

(5) Weld Backing Material Other Than Steel. All weld backing material, other than steel, shall be qualified by testing and shall be included in submitted PQR/WPS. Variation from approved weld backing material will not be permitted and will require the development and testing of a new weld procedure which addresses the change in backing material.

3.1.4 Bolted Connections

All high strength connections shall be tightened to a tension not less than that given below for A325 Bolts. Tightening shall be done by turn-of-nut, direct tension indicator, calibrated wrench, or alternative design bolt methods.

5/8 inch 19 kips

3/4 inch 28 kips

7/8 inch 39 kips

1 inch 51 kips

1-1/8 inch 56 kips

1-1/4 inch 71 kips

1-3/8 inch 85 kips

1-1/2 inch 103 kips

All other connections shall be tightened to the snug-tight condition. The snug-tight condition is defined as the condition that exists when all of the plies in a connection have been pulled into firm contact by the bolts in the joint and all of the bolts in the joint have been tightened sufficiently to prevent the removal of the nuts without the use of a wrench. Perform snugging in a systematic manner starting at the most rigid part of the joint and working to the outside of the connection or the free edges. Use thin metal feeler gages, such as a machinists 6 inch metal rule, to ensure that gaps do not exist between the steel at the bolt holes. Install all bolts in a connection to a snug tight condition prior to pretensioning. Perform pretensioning in the same order as snug-tightening.

a. Bolts, Nuts, and Washers. Provide bolts, nuts and washers of the type specified or indicated. All nuts to be used with high strength bolts shall be ASTM A563. All nuts shall be equipped with washers. Where the use of high strength bolts is specified or indicated the materials, workmanship and installation shall conform to the applicable provisions of ASTM A325 and RCSC Specifications for Structural Joints Using ASTM A325 Bolts. Washers to be used with high strength bolts shall conform to ASTM F436.

b. Bolt Holes. Bolt holes shall be accurately located, smooth, perpendicular to the member and cylindrical.

(1) Holes for regular bolts shall be drilled or subdrilled and reamed in the shop and shall not be more than 1/16 inch larger than the diameter of the bolt.

(2) Holes for high strength fitted bolts shall be match-reamed or drilled. Remove burrs resulting from reaming. The threads of bolts shall be entirely outside of the holes. The body diameter of holes and bolts shall have tolerances as specified on the drawings.

(3) The provisions of AWS D1.5M/D1.5 Section 3.7.7 allowing misdrilled holes do not apply. All misdrilled holes shall be repaired as directed by the Engineer. Repair of mislocated or misdrilled holes shall be submitted for Government approval.

3.1.5 Miscellaneous Provisions

a. Weldments. Portions of the structure include thick weldments where locked in thermal stresses may make final dimensions unstable. The Contractor is required to sequence the work and thermally stress relieve subassemblies of thick weldments such that final machining achieves stable specified dimensions and tolerances.

b. Drain Holes. Locate drain holes as shown on the drawings, unless otherwise noted. Drain holes shall be drilled. Flame cutting of holes will not be permitted.

c. Seal Welds. Seal welds are required to maintain water tightness. All seal welds shall be shown and made as indicated on the shop drawings.

Seal welds, when called for on the drawings, shall be made the minimum size fillet weld as required in AWS D1.5M/D1.5. In addition, seal welds may require weld wrapping around reentrant corners that is specifically prohibited in AWS D1.5M/D1.5. All seal welds on fracture critical members shall be subjected to the minimum preheat requirements of AWS D1.5M/D1.5 Table 12.3 as applicable. All seal welds shall be subjected to the same testing requirements required for a fillet weld made to any fracture critical member according to AWS D1.5M/D1.5 Chapter 12.

3.1.6 Shop Assembly

Perform fabrication and assembly in an indoor, climate controlled shop.

Each item shall be closely checked to ensure that all necessary clearances have been provided and that binding does not occur in any moving part. All shop testing for assembly shall be witnessed by the Government Representative. Errors or defects disclosed shall be immediately remedied without cost to the Government.

3.1.7 Seals

Each stoplog shall be provided with rubber seals as specified and as shown on the contract drawings. The surfaces of finished splices shall be smooth and free of irregularities. Bolt holes in the rubber seals shall be match-drilled with the seal support and clamping bars, as applicable; to insure proper fit and spacing between holes of the completed seal assembly. Seal support and clamping bars shall conform to the configurations shown on the drawings and shall be machine finished. Torque clamping bars 40-45 foot-pounds as to prevent over tightening of seal. The seals and blocks shall be installed after painting has been completed.

3.2 CERTIFIED TEST REPORTS

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 shall be tested by an approved U.S. laboratory to ensure that it meets the required standards.

3.2.1 General

Have required material tests and analyses performed and certified by an approved laboratory, at the Contractor's expense, to demonstrate that materials are in conformity with the specifications. Tests, inspections, and verifications shall conform to the requirements of the particular sections of these specifications for the respective items of work unless otherwise specified or authorized. Tests shall be conducted in the presence of the Contracting Officer. Furnish specimens and samples for additional independent tests and analyses upon request by the Contracting Officer.

3.2.2 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 Contracting Officer. 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.

3.2.3 Inspection of Structural Steel Welding

Maintain an approved inspection system and perform required inspections per AWS D1.5M/D1.5. Welding shall be subject to inspection to determine conformance with the requirements of AWS D1.5M/D1.5 and the approved welding procedures and provisions stated in other sections of these specifications. All completed welds shall be cleaned and carefully visually examined 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 D1.5M/D1.5, subsection 6.26 and the additional requirements of chapter 12 for the Fracture Control Plan. In addition, the Government may choose to hire a third party inspector to perform verification of this work. The Government's third party inspection will occur at various times throughout the duration of fabrication. The Contractor will be advised that third party inspection shall be coordinated with the GQAR and the Contractor for all verification inspections selected by the Government.

a. Visual Examination - Prior to any welding, a certified weld inspector (CWI) supplied by the Contractor shall visually inspect and document on the weld tracking log the preparation of material for welding at each weld or joint in order to assure compliance with AWS D1.5M/D1.5 and approved WPS. An approved CWI will be present at all times during fabrication. The CWI shall also perform VT inspection on all completed welds throughout the welding process to assure compliance with AWS D1.5M/D1.5 and approved WPS. All completed welds shall be cleaned free of oxide, flux, scale, paint spatter, or other foreign matter before inspection.

b. Nondestructive Examination - The nondestructive examination of welds shall be performed as specified or described on the drawings or as listed in the following paragraphs.

(1) 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 Contracting Officer. The evaluation of examination tests shall be subject to the approval of, and all records shall become the property of, the Government. Certified Weld Inspectors (CWI) shall be qualified and certified in accordance with the provisions of AWS QC1 and shall be familiar with AWS D1.5M/D1.5 fracture critical member inspection as required in AWS D1.5M/D1.5 Section 12.16. 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 in accordance with AWS D1.5 section 6.1.2.2. The CWI who serves as the primary point of contact shall obtain the AWS D1.5 Bridge Code Endorsement and/or achieve certification as a AWS Senior Certified Welding Inspector (SCWI). Non-certified inspectors and certified associate welding inspectors (CAWI) shall not be used for inspection under these specifications. The laboratory and all personnel performing nondestructive testing shall be qualified as specified. Only individuals qualified for NDT Level II or Level III may perform nondestructive testing.

The Level III NDT inspector who supervises all NDT shall posses a currently valid American Society for Nondestructive Testing (ASNT) Level III certificate for each of the processes for which they are qualified. Copies of the certifications, including the ASNT certificate of Level III NDT Technician that certified the Level II Technicians shall be included in the submittals.

(2) Examination Procedure and Extent - All nondestructive testing shall comply with AWS D1.5M/D1.5, Section 6 or section 12, as applicable. Testing shall be required as defined in the following paragraph. If procedures cannot be completed in compliance with AWS D1.5M/D1.5 alternate testing procedures shall be developed and submitted for Government approval.

(3) Acceptability of Welds - Welds will be unacceptable if shown to have defects prohibited by AWS D1.5M/D1.5.

(4) Examination Procedures - Examination procedures shall conform to the following requirements:

(5) Ultrasonic Testing (UT) - Ultrasonic testing of welds shall conform to the provisions of AWS D1.5M/D1.5. The ultrasonic equipment shall be capable of making a permanent record of the test indications. A record shall be made of each weld tested.

Base metal shall be longitudinally scanned for laminations prior to shearwave examination. Longitudinal examinations conducted by the material producer are not considered acceptable for this testing. Sensitivity reference levels for shear wave examinations shall be established on an iiw type block utilizing the .060 sensitivity hole. Any alternative method shall be approved by the engineer. The contractor is required to remove the backing bar from a complete joint penetration weld when, in the opinion of the UT technician, the backing bar is preventing correct interpretation of the sound return.

(6) Radiographic Testing (RT) - Making, evaluating and reporting radiographic testing of welds shall conform to the applicable requirements of AWS D1.5M/D1.5. The fabricator shall ensure that radiographic film provided is developed with a film density from

2.5 to 3.5. The Government will retain ownership of the radiographic film provided by the fabricator. Only ASNT RT Level III's or individuals specifically certified in radiographic film interpretation are allowed to perform the interpretation and acceptance/rejection of…