16-B-0001_Amend-0003_SECTION_05_60_05.00_28.pdf

McNary N/L D/S Gate 2016 Interim Repairs W912EF-16-B-0001 Amend-0003

SECTION TABLE OF CONTENTS

DIVISION 05 - METALS

SECTION 05 60 05.00 28

NAVIGATION LOCK GATE REPAIRS

PART 1 GENERAL

1.1 REFERENCES

1.2 SUBMITTALS

1.3 DEFINITIONS

1.4 SYMBOLS

1.5 CARBON EQUIVALENCE TESTING

PART 2 PRODUCTS

2.1 WELD FILLER METAL

2.2 BARS AND PLATES

2.3 VINYL PAINT

2.3.1 Formula V-766e, Vinyl-Type Gray Impacted Immersion Coating

2.4 PAINT THINNER

2.4.1 Methyl Ethyl Ketone

PART 3 EXECUTION

3.1 DEWATER THE WORK AREA

3.2 STIFFENER PLATE REPAIR

3.3 QUOIN AND MITER BLOCK RESURFACING

3.3.1 QUANTITIES

3.3.2 WELD REQUIREMENTS

3.3.3 FINISH REQUIREMENTS

3.3.4 WELDING AND FINISHING PROCEDURE

3.3.5 GREASING

3.4 WELDING

3.4.1 Stiffener Plate Welding Operations

3.4.1.1 Qualification of Welders and Welding Operators

3.4.1.2 Workmanship Requirements

3.4.1.2.1 Stiffener Plate Welding Procedure

3.4.1.2.2 Welding Technique

3.4.1.2.3 Workmanship

3.5 Nondestructive Testing (NDT)

3.5.1 Visual Examination

3.5.1.1 Nondestructive Examination

3.6 Workmanship

3.7 LEAD PAINT REMOVAL

3.8 Additional Preparation for Repainting

3.9 CLEANING AND PREPARATION OF SURFACES TO BE PAINTED

3.10 PAINT APPLICATION

3.10.1 Method of Paint Application

3.11 PAINT SYSTEMS

ATTACHMENTS:

Carbon Equivalence Testing

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SECTION 05 60 05.00 28

SECTION 05 60 05.00 28

NAVIGATION LOCK GATE REPAIRS

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 TESTING AND MATERIALS (ASTM)

ASTM A 36/A 36M (2005) Standard Specification for Carbon Structural Steel

ASTM A 751 (1996) Test Methods, Practices, and Terminology for Chemical Analysis of Steel products.

ASTM E 165 (1995) Liquid Penetrant Examination Inspection Method

AMERICAN WELDING SOCIETY (AWS)

AWS A2.4 (1998) Standard Symbols for Welding, Brazing and Nondestructive Examination

AWS A3.0 (1994) Standard Welding Terms and Definitions

AWS D1.1/D1.1M (2010; Errata 2011) Structural Welding Code - Steel

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

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

ASTM INTERNATIONAL (ASTM)

ASTM A668/A668M (2013) Standard Specification for Steel Forgings, Carbon and Alloy, for General Industrial Use

ASTM D5864 (2011) Standard Test Method for Determining Aerobic Aquatic Biodegradation of Lubricants or Their Components

THE SOCIETY FOR PROTECTIVE COATINGS (SSPC)

SSPC SP 3 (1982; E 2004) Power Tool Cleaning

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

Qualification of Welders and Welding Operators ; G C

Stiffener Plate Welding Procedure ; G C

Quoin and Miter Welding Procedure ; G C

Quoin and Miter Finishing Procedure ; G ST

Pre-Weld ; I ST

SD-03 Product Data

Vinyl Paint ; I GE

Weld Filler Metal ; G ST

SD-06 Test Reports

Nondestructive Examination ; G ST

SD-07 Certificates

Test Result Certificate ; I ECC

SD-11 Closeout Submittals

Post-Weld ; I ST

1.3 DEFINITIONS

Definitions of welding terms shall be in accordance with AWS A3.0 .

1.4 SYMBOLS

Symbols shall be in accordance with AWS A2.4 , unless otherwise indicated.

1.5 CARBON EQUIVALENCE TESTING

Carbon Equivalence Testing was performed in 2014 in accordance with the requirements of AWS D1.5/D1.5M , Annex VIII, paragraph VIII6.1.1 to determine the carbon equivalence for the Fed Spec QQ-S-741D Type II steel on the downstream miter gate, as indicated. Chemical analysis of the Fed Spec QQ-S-741D Type II steel members was determined in accordance with methods specified in ASTM A 751 . The results of the testing are included at the end of this section. The carbon equivalence test results shall be used to determine welding conditions (principally preheat) necessary to prevent cold cracking and shall be incorporated into all welding procedure specifications.

PART 2 PRODUCTS

2.1 WELD FILLER METAL

The electrode, electrode-flux combination and grade of weld metal shall conform to the appropriate AWS specification for the base metal or metals and welding process being used. Only low hydrogen electrodes shall be used for shielded metal-arc welding. The AWS designation of the electrodes to be used shall be included in the schedule of welding procedure to be furnished. The filler metal shall meet the requirements of AWS D1.1/D1.1M or AWS D1.5/D1.5M . To maintain low moisture of low-hydrogen electrodes, a controlled temperature storage oven shall be used at the welding work area as prescribed by AWS D1.1/D1.1M or AWS D1.5/D1.5M .

2.2 BARS AND PLATES

All plate shall conform to ASTM A 36/A 36M .

2.3 VINYL PAINT

Use Corps of Engineers formulation vinyl paint V766e gray color that has been tested and approved by CERL lab. Submit paint certification. No substitutes will be allowed.

2.3.1 Formula V-766e, Vinyl-Type Gray Impacted Immersion Coating

INGREDIENTS PERCENT BY MASS

Vinyl Resin, Type 3 5.6 Vinyl Resin, Type 4 11.6 Titanium Dioxide and (for Gray) Carbon Black 13.0 Diisodecyl Phthalate 2.9 Methyl Isobutyl Ketone 32.0 Toluene 34.7 Ortho-Phosphoric Acid 0.2 100.0

2.4 PAINT THINNER

2.4.1 Methyl Ethyl Ketone

Methyl ethyl ketone (MEK) shall conform to ASTM D 740 .

PART 3 EXECUTION

3.1 DEWATER THE WORK AREA

The Government will set the downstream stoplogs and unwater the lock chamber so the Contractor can access the work area in the lock. The seals on the downstream stoplogs leak and water will run over the concrete gate sill in the work area. The Contractor shall install sandbags to contain the water leakage and either pump the water over the stoplogs into the river or channel the water over the concrete sill into the lock chamber upstream of the concrete sill. All equipment and pumps necessary to keep the work area dewatered shall be provided by the Contractor.

3.2 STIFFENER PLATE REPAIR

The Contractor shall install stiffener plates as shown in the contract drawings. Due to the limited accessibility to the backside of the stiffener plate, the Contractor may leave the backing bar in place. Since backing bar cannot be removed and the root pass cannot be backgouged and rewelded, the nondestructive testing may reveal weld irregularities within the root pass. Therefore, irregularities in the root pass will be acceptable and any irregularities outside of the root pass shall be subject to the acceptance criteria of AWS D1.5/D1.5M .

3.3 QUOIN AND MITER BLOCK RESURFACING

The seal contact blocks at the quoin ends of the gate leaves and the miter blocks at the center of the gate leaves do not bear on the adjacent contact blocks as they should. A contract to resurface portions of the quoin and miter blocks was performed in March 2015. The Contractor shall inspect and verify that previously resurfaced blocks are within the tolerances of this specification.

3.3.1 QUANTITIES

The wall and gate quoin blocks and the miter blocks shall be repaired by building up sufficient weld metal to provide a clean, smooth surface on each face with enough thickness to close the gap. For bidding purposes, it is estimated that 1/3rd of the total length shown on the contract drawings will require weld build-up. The worn areas are approximately 8 inches wide and the gap varies from zero to 0.150 inches , and is typically from 0.040 to 0.080 inches . The gate quoin blocks and miter blocks shall be resurfaced in the contact area, 4 inches wide at the center of the quoin and miter blocks. The full width of the blocks need not be resurfaced.

For bidding purposes, it is estimated that approximately 10% of the previously resurfaced blocks shown on the contract drawings require weld build-up.

3.3.2 WELD REQUIREMENTS

Surfaces to be welded shall be preheated in accordance with the Hydrogen Control Method of AWS D1.1/D1.1M Annex I. The base metal for the seal contact block and bearing plates is ASTM A235 Class G, an obsolete ASTM specification now covered by ASTM A668/A668M .

3.3.3 FINISH REQUIREMENTS

Filler metal shall be selected to achieve a Brinell hardness between 187 and 235. Finished surfaces shall have a roughness of 125 microinches or smoother.

a. At the quoins, no gap shall be larger than 0.030 inches after resurfacing when the gate is in the closed position.

b. At the miter, the Contractor shall use an 8 foot straight edge to verify that no gap is larger than 0.060 inches after resurfacing. The Contractor shall start from the top of the work area and place the straight edge so that it bears upon 4 feet of existing surface above the work areas. This forms a reference line to measure from. The Contractor shall work down the miter, while ensuring that the straight edge overlaps with the previous reference surface by one half its length. Additionally, the Contractor shall install a piano wire as an additional reference line to ensure that the reference line from surface does not diverge as it is projected down the miter.

3.3.4 WELDING AND FINISHING PROCEDURE

The Contractor shall submit a quoin and miter welding procedure and a quoin and miter finishing procedure for Government approval before commencing this portion of the work.

a. The approved quoin and miter welding procedure shall conform to the requirements of AWS D1.1/D1.1M . Properly documented evidence of compliance with all requirements of these specifications, for previous welding qualifications tests, will establish the joint welding procedure as pre-qualified and a re-qualification test will not be required. Each procedure shall be clearly identified as being either pre-qualified or qualified by tests.

b. The approved quoin and miter finishing procedure shall consist of a detailed description of the process to be used for resurfacing the quoin and miter, and shall identify the method to be used to ensure quality control.

c. Submit pre-weld finishing measurements and post-weld finishing measurements. Measurements shall be taken at 6 inch intervals over the work area.

3.3.5 GREASING

Upon completion and acceptance of the quoin and miter block resurfacing, the Contractor shall apply a coating of environmentally acceptable lubricant to the full height of all quoin and miter block surfaces. The Contractor shall inform the Contracting Officer Representative (COR) of how much lubricant is brought on site and shall turn the remaining lubricant over to the Government at contract completion. The lubricant shall have the following salient characteristics:

a. Must be biodegradable with a biodegradability of >60% ThOD per

ASTM D5864.

b. Bioaccumulation (Log Kow) shall be <3 or >7 and pass OECD 107 and

OCED 117

c. Produces no visual sheen as required in 58 FR 12507.

d. Shall pass the criteria in EPA 800-R-11-002.

3.4 WELDING

3.4.1 Stiffener Plate Welding Operations

All welding of stiffener plates is considered critical repair welding as specified in AWS D1.5/D1.5M , Section 12.17. Stiffener plate weld procedures shall be as indicated on the drawings and as specified herein.

3.4.1.1 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 D1.1/D1.1M or AWS D1.5/D1.5M Section 12. Welders and welding operators shall pass the qualification tests prescribed by AWS D1.1/D1.1M or AWS D1.5/D1.5M within 12 months prior to performing work on this contract. 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 re-qualification shall be borne by the Contractor. The Contractor is not required to be an AISC Category III Certified fabricator in accordance with AWS D1.5/D1.5M , Subsection 12.8

3.4.1.2 Workmanship Requirements

3.4.1.2.1 Stiffener Plate Welding Procedure

The approved weld procedure shall consist of detailed procedure specifications for each required joint to be welded with tables or diagrams showing the procedure to be used. Qualification of welding procedures for welding for all welding procedures shall conform to the requirements of AWS D1.5/D1.5M . Properly documented evidence of compliance with all requirements of these specifications for previous welding joint qualifications tests will establish the joint welding procedure as pre-qualified and a qualification test will not be required. Each procedure shall be clearly identified as being either pre-qualified or qualified by tests.

3.4.1.2.2 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 D1.1/D1.1M or AWS D1.5/D1.5M , 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 regardless of the thickness of the steel. A controlled temperature storage oven shall be used at the job site as prescribed by AWS D1.5/D1.5M , 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 D1.1/D1.1M or AWS D1.5/D1.5M 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 Hydrogen Control Method as outlined in the applicable provisions of AWS D1.1/D1.1M and AWS D1.5/D1.5M for all welds. 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.

3.4.1.2.3 Workmanship

(1) Preparation of Base Metal. Prior to welding, inspect surfaces to be welded to assure compliance with the applicable sections of AWS D1.1/D1.1M or AWS D1.5/D1.5M .

(2) Tack and Temporary Welds. Tack and temporary welds required for fabrication and erection shall be made in accordance with AWS D1.1/D1.1M or AWS D1.5/D1.5M 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 D1.1/D1.1M or AWS D1.5/D1.5M 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 D1.1/D1.1M or AWS D1.5/D1.5M , Subsection 3.3.8. All arc strikes struck outside the weld zone shall be ground out and inspected in accordance with AWS D1.5/D1.5M .

(3) Weld Backing 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.

(4) 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.

3.5 Nondestructive Testing (NDT)

3.5.1 Visual Examination

All visual examination of completed welds shall be cleaned and carefully 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 D1.1/D1.1M or AWS D1.5/D1.5M , Sections 3 and 9 and all other applicable sections of AWS D1.5/D1.5M .

3.5.1.1 Nondestructive Examination

The nondestructive examination (NDT) of field welds shall be performed as designated or described in the sections of these specifications covering the particular items of work. Test methods used may include ultrasonic, magnetic particle, or dye penetrant inspection. Defects identified will be used as the basis for making repairs, as directed by the COR.

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. Written approval of the examination procedures is required. The evaluation of examination tests shall be subject to the approval and all records shall become the property of the Government.

b. Examination Procedures - Examination procedures shall 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 or AWS D1.5/D1.5M , Section 6, Part C. The ultrasonic equipment shall be capable of making a permanent record of the test indications. The Certified inspector shall make a permanent record of the test indications.

(2) Dye Penetrant Inspection - Dye penetrant inspection of welds shall conform to the applicable provisions of ASTM E 165 .

c. Acceptability of Welds - Welds shall be unacceptable if shown to have defects prohibited by AWS D1.1/D1.1M or AWS D1.5/D1.5M , or possess any degree of incomplete fusion, inadequate penetration or undercutting.

d. Welds to be Subject to Nondestructive Examination

(1) All stiffener plate welds shall be tested in accordance with AWS D1.5/D1.5M , Subsection 12.16. 100 percent of all Complete Joint Penetration repair welds shall be subjected to ultrasonic testing and pass the acceptance criteria for compressive stress per AWS D1.5M/D1.5 Table 6.4 . The testing shall be done as early in the project as possible to ensure the quality of the procedure and process. Weld backing shall be removed from all repair welds prior to all NDT unless the weld backing member is permanent. The UT report for all repair welds shall include non-rejectable indications with defect severity ratings within 5 db of being rejectable and shall be fully recorded as to indication, rating, size, and location. In accordance with AWS D1.5/D1.5M Section 12.16.5.3, all discontinuities found by UT must be recorded if required by AWS D1.5/D1.5M Section 6.19.8. Please note the above specification regarding the root pass of the CJP weld.

(2) 100 percent of all quoin and miter block repair welds shall be subjected to dye penetrant testing. All testing shall be in accordance to AWS D1.1/D1.1M and shall meet the acceptance criteria for statically loaded nontubular connections.

3.6 Workmanship

Workmanship shall be of the highest grade and in accordance with the best modern practices to conform with the specifications for the item of work being furnished.

3.7 LEAD PAINT REMOVAL

The paint in the work area for the stiffener plate installation is assumed

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Line to be a vinyl red lead paint system. Remove the paint out to 6 inches from the area where the stiffener plates are to be installed onto the gate, to include heat-affected zones on all faces, by a chemical peel method designed for this application. Any Chemical product used shall be environmentally safe, biodegradable, non-flammable, contain no methylene chloride or caustic. While performing the chemical peeling place all of the waste into a contractor furnished hazourdous waste container as specified in SECTION 01 57 20.00 28 ENVIRONMENTAL PROTECTION. After all paint is removed with the chemical peeler, perform a RCRA 8 TCLIP test and submit the test result certificate to the project ECC. After the TCLP test is completed, turn over the chemical stripped paint in a hazourdous material container as specified to the project ECC. Once the chemical peeling is completed and all welding is completed and approved, prepare the surface using a power tool conforming to the requirements of SSPC SP 3 .

3.8 Additional Preparation for Repainting

Where existing vinyl paint has been removed, the edges of the remaining paint may be frayed or curled. Following power tool cleaning all edges of the remaining vinyl paint shall be feathered by rubbing with steel wool soaked in vinyl paint thinner. The prepared surfaces shall then be coated as specified.

3.9 CLEANING AND PREPARATION OF SURFACES TO BE PAINTED

Surfaces to be painted shall be cleaned before applying paint. Deposits of grease or oil shall be removed in accordance with SSPC SP 1 , prior to mechanical cleaning. Solvent cleaning shall be accomplished with mineral spirits or other low toxicity solvents having a flash point above 100 degrees F . Clean cloths and clean fluids shall be used to avoid leaving a thin film of greasy residue on the surfaces being cleaned. Items not to be prepared or coated shall be protected from damage by the surface preparation methods. Within 8 hours after cleaning, prior to the deposition of any detectable moisture, contaminants, or corrosion, all ferrous surfaces shall be cleaned of dust and by brush, vacuum cleaner, and/or blown down with clean, dry, compressed air, and given the first coat of paint.

3.10 PAINT APPLICATION

As soon as the repair and NDT of each area is satisfactorly completed and approved, the Contractor shall prepare the surface as specified above, and imediatley after this step apply the first coat of paint. The remaining coat of paint shall be applied as soon as possible following the guidelines specified. Cleaning and painting shall be so programmed that dust or other contaminants from the cleaning process do not fall on wet, newly painted surfaces, and surfaces not intended to be painted shall be suitably protected from the effects of cleaning and painting operations.

Paint damaged by grinding operations shall be repainted in the same manner as the areas to be painted in this contract.

3.10.1 Method of Paint Application

The Contractor may brush the paint on in 2 coats. The brush shall be no larger than 3/4 of an inch. Brush shall be a natural bristle with fine bristles. Paint shall be applied with as little pressure as possible.

Special attention shall be directed toward ensuring adequate coverage of edges, corners, crevices, pits, rivets, bolts, welds, and similar surface irregularities.

3.11 PAINT SYSTEMS

TOUCH-UP PAINITNG

All ferrous surfaces on the gate that have paint removed as the result of the repair and NDT of welds covered in this contract.

1st COAT 2nd COAT

Gray Vinyl Gray Vinyl V-766e V-766e