Amend-0002_SECTION_05_50_01.00_28.pdf

Ice Harbor Trolley and Fish Release Pipes W912EF-16-B-0016 Amend-0002

SECTION TABLE OF CONTENTS

DIVISION 05 - METALS

SECTION 05 50 01.00 28

METALWORK FABRICATION

PART 1 GENERAL

1.1 REFERENCES

1.2 SUBMITTALS

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 General

2.1.2 Trolley Pipe Structural Steel

2.1.3 Trolley Steel

2.1.4 Fish Release Pipe Structural Steel

2.1.5 Bolts, Nuts, and Washers

2.1.6 Concrete Anchors

2.1.6.1 Trolley Pipe Concrete Anchors

2.1.6.2 Fish Release Pipe Concrete Anchors

2.1.7 Ultra High Molecular Weight Polyethylene (UHMW or UHMW-PE)

2.1.8 Paint Materials

2.2 Fall Protection Anchors

2.3 Nonshrink Grout

PART 3 EXECUTION

3.1 STRUCTURAL FABRICATION

3.1.1 General

3.1.2 Dimensional Tolerances for Structural Work

3.1.3 Fabrication

3.2 WELDING

3.2.1 General

3.2.2 Filler Metal

3.2.3 Qualification of Welders and Welding Operators

3.2.4 Workmanship Requirements

3.2.4.1 Welding Procedure

3.2.4.2 Preheat and Interpass Temperature

3.2.4.3 Stress-Relief Heat Treatment

3.2.5 Inspection

3.2.5.1 Visual Examination

3.2.5.2 Nondestructive Examination

3.2.5.3 Supplemental Examination

3.2.6 Structural Steel Welding Repairs

3.3 BOLT HOLES

3.4 SHOP INSPECTION

3.4.1 INSPECTIONS AND TESTS

3.4.1.1 Fish Release Pipe Smoothness Inspection

3.4.1.1.1 Trolley Pipe Slide Test

3.5 PAINTING

3.6 APPLICATION TROLLEY PIPES

3.7 INSTALLATION OF TROLLEY PIPES AND FISH RELEASE PIPES

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G4EDDRJR

Line

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3.8 REBAR

3.9 BEARING SURFACES

3.10 FALL PROTECTION ANCHORS

-- End of Section Table of Contents --

SECTION 05 50 01.00 28

SECTION 05 50 01.00 28

METALWORK FABRICATION

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.

ASME INTERNATIONAL (ASME)

ASME B16.5 (2013) Pipe Flanges and Flanged Fittings:

NPS 1/2 Through NPS 24 Metric/Inch Standard

ASTM INTERNATIONAL (ASTM)

ASTM A36/A36M (2014) Standard Specification for Carbon Structural Steel

ASTM A53/A53M (2012) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

ASTM A105/A105M (2014) Standard Specification for Carbon Steel Forgings for Piping Applications

ASTM A193/A193M (2016) Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service and Other Special Purpose Applications

ASTM A240/A240M (2015b) Standard Specification for Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications

ASTM A276/A276M (2016) Standard Specification for Stainless Steel Bars and Shapes

ASTM A312/A312M (2016) Standard Specification for Seamless, Welded, and Heavily Cold Worked Austenitic Stainless Steel Pipes

ASTM A403/A403M (2015) Standard Specification for Wrought Austenitic Stainless Steel Piping Fittings

ASTM A500/A500M (2013) Standard Specification for Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and Shapes

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ASTM C1107/C1107M (2014a) Standard Specification for Packaged Dry, Hydraulic-Cement Grout (Nonshrink)

ASTM C1090/C1090M (2015) Standard Test Method for Measuring Changes in Height of Cylindrical Specimens of Hydraulic-Cement Grout

ASTM D6712 (2009) Standard Specification for Ultra-High-Molecular-Weight Polyethylene (UHMW-PE) Solid Plastic Shapes

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

ASTM E488/E488M (2015) Standard Test Methods for Strength of Anchors in Concrete and Masonry Elements

ASTM E709 (2015) Standard Guide for Magnetic Particle Examination

ASTM F593 (2013a) Stainless Steel Bolts, Hex Cap Screws, and Studs

ASTM F594 (2009; E 2011) Standard Specification for Stainless Steel Nuts

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1 (2000) Structural Welding Code - Steel

AWS D1.6 (2000) Structural Welding Code - Stainless Steel

CORPS OF ENGINEERS (COE)

COE CRD-C 621 (1988) Specifications for Non-Shrink Grout

EM 385-1-1 (2003) Safety and Health Requirements Manual

SOCIETY FOR PROTECTIVE COATINGS (SSPC)

SSPC SP 10/NACE No. 2 (2007) Near-White Blast Cleaning

1.2 SUBMITTALS

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

submittals having an "I" designation are for information only. 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 ; G, ST

SD-02 Shop Drawings

Shop Drawings Of Fall Protection Anchors ; G, ST

SD-03 Product Data

Concrete Anchors ; I, ST

Trolley Pipe Concrete Anchors ; G, ST

Fish Release Pipe Concrete Anchors ; G, ST

Ultra High Molecular Weight Polyethylene (UHMW or UHMW-PE) ; I, ST

Paint Materials ; I, ST

Fall Protection Anchors ; I, ST

Nonshrink Grout ; I, ST

Submit manufacturer's catalog cuts, descriptive data, and other information to fully describe the concrete anchors, UHMW-PE, paint materials, fall protection anchors, and nonshrink grout proposed for use.

SD-06 Test Reports

Nondestructive Examination ; G, ES

Trolley Pipe Slide Test ; I, ST

Fish Release Pipe Smoothness Inspection ; I, EA

SD-07 Certificates

Qualification Of Welders And Welding Operators ; G, C

Qualification Of Fall Protection Competent Person ; G, C

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 General

Materials and standard articles shall be furnished in accordance with the drawings and specifications. Where material requirements are not specified, materials furnished shall be suitable for the intended use and shall be subject to approval.

2.1.2 Trolley Pipe Structural Steel

Trolley pipes shall be ASTM A53/A53M, standard pipe, black.

Flanges shall comply with ASME B16.5 class 150 and ASTM A105/A105M .

Support HSS shall be ASTM A500/A500M , grade B.

Base plates shall be ASTM A36/A36M.

SECTION 05 50 01.00 28

2.1.3 Trolley Steel

Note: This section refers to the trolleys that slide up and down inside the trolley pipes.

All pipes shall be ASTM A312/A312M , type 304L or 316L, schedule 40.

All angles and rods shall be ASTM A276/A276M , type 304L or 316L.

2.1.4 Fish Release Pipe Structural Steel

Fish release pipes shall be ASTM A312/A312M , type 304L or 316L, extra-strong pipe.

Flanges shall comply with ASME B16.5 class 150 and ASTM A403/A403M type 304L or 316L.

Support pipes shall be ASTM A312/A312M , type 304L or 316L, standard pipe.

Base plates shall be ASTM A240/A240M , type 304L or 316L.

2.1.5 Bolts, Nuts, and Washers

Bolts shall be ASTM F593, type 304

Nuts shall be ASTM F594, type 304 self locking type.

Stainless Steel flat washers 300 series.

2.1.6 Concrete Anchors

Provide stainless steel undercut anchors with sizes and minimum concrete embedment specified on contract drawings. Design values shall be tested according to ASTM E488/E488M .

2.1.6.1 Trolley Pipe Concrete Anchors

Anchors shall be Williams S-9 part number S9T-05-S42 or S9T-05-S62, or equal as manufactured by Williams Form Engineering Corporation, 8165 Graphic Dr., Belmont, MI 49306. The concrete anchor salient physical, functional, or performance characteristics an equal item must meet to be acceptable are as follows:

a. Anchors shall be ASTM A193/A193M 304 B8 Class II or ASTM A193/A193M 316 B8M Class II.

b. Anchors shall be rated for a minimum 13.0 kips allowable tension load.

c. Anchors shall be rated for a minimum 4.23 kips allowable simple shear load.

2.1.6.2 Fish Release Pipe Concrete Anchors

Anchors shall be Williams S-9 part number S9T-06-S42 or S9T-06-S62, or equal as manufactured by Williams Form Engineering Corporation, 8165 Graphic Dr., Belmont, MI 49306. The concrete anchor salient physical, functional, or performance characteristics an equal item must meet to be acceptable are as follows:

a. Anchors shall be ASTM A193/A193M 304 B8 Class II or ASTM A193/A193M

SECTION 05 50 01.00 28

316 B8M Class II.

b. Anchors shall be rated for a minimum 19.3 kips allowable tension load.

c. Anchors shall be rated for a minimum 6.24 kips allowable simple shear load.

2.1.7 Ultra High Molecular Weight Polyethylene (UHMW or UHMW-PE)

Ultra High Molecular Weight Polyethylene(UHMW or UHMW-PE)shall conform to

ASTM D6712.

2.1.8 Paint Materials

The paint shall be either an epoxy paint or a single component, moisture cure urethane formulated for immersed service and capable of curing down to 20° F without the addition of additives for cold temperature curing such as:

(a) Field repairs shall be accomplished as recommended by the paint manufacturer.

(b) Color of top coat paint shall be haze gray or concrete gray.

2.2 Fall Protection Anchors

Design and provide single-point permanent fall protection anchors at the locations indicated on the drawings. Each anchor shall be capable of resisting a 5000 lb load and anchorage system suitable for installation on horizontal concrete decks. Anchors shall have a low profile to lessen trip hazards and be located to allow for safe installation of trolleys into trolley pipes. All fall protection anchors shall comply with EM 385-1-1 . Design shall be completed by a fall protection competent person. Qualification of Fall Protection Competent Person shall be submitted.

2.3 Nonshrink Grout

Nonshrink grout shall conform to ASTM C1107/C1107M or COE CRD-C 621 and shall be a commercial formulation recommended for the application underwater. The grout shall show positive expansion in accordance with

ASTM C1090/C1090M .

PART 3 EXECUTION

3.1 STRUCTURAL FABRICATION

3.1.1 General

Material shall be straight before being laid off or worked. If straightening is necessary it 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 on the drawings or otherwise approved. Bends shall be made by dies, press brakes or bending rolls normally used in this type of fabrication. 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 restore the original properties of

SECTION 05 50 01.00 28

the metal. Proposed flame cutting of material other than structural steel shall be subject to approval and shall be indicated on shop drawings.

Shearing shall be accurate and all portions of the work shall be neatly finished. Corners shall be square and true unless otherwise shown on the drawings. Finished members shall be free of twists, bends and open joints. All bolts, nuts and screws shall be tight.

3.1.2 Dimensional Tolerances for Structural Work

Dimensions shall be measured by a calibrated steel tape of approximately the same temperature as the material being measured at the time of measurement. The overall dimensions of an assembled structural 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 on the drawings an allowable 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 on the drawings 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.

3.1.3 Fabrication

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 to be welded shall be prepared in accordance with AWS D1.1 or AWS D1.6 . Where structural steel is not to be welded, all hand or mechanically guided cuts shall be chipped, ground or machined to sound metal. All exposed edges shall be ground to provide a radius, approximately 1/16, especially the edges of the trolley slot cut in the trolley pipes.

NOTE 1: It is critical that the trolley pipes have no obstructions that will prevent the trolley that has a 1-inch arm extending through the slot from moving down the track. The slot shall be straight and smooth and the width shall be checked the entire length after all welding is complete.

The interior of the steel pipes shall be smooth and free of all burrs, weld splatter, and any other obstructions that would interfere with movement of the trolley.

NOTE 2: It is critical that the fish release pipes have no obstructions that will prevent a 4-inch diameter flex hose or fish from moving down the pipe. The interior of the stainless steel pipes shall be smooth and free of all burrs, weld splatter, and any other obstructions that would interfere with movement of the flex hose or fish.

3.2 WELDING

3.2.1 General

Welding shall be by an electric arc welding process using a method which excludes the atmosphere from the molten metal. Welding shall conform to AWS D1.1 or AWS D1.6 for structural steel, as applicable.

3.2.2 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 or shall be as shown where a specific choice of AWS specification allowables is required. 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 or AWS D1.6 , as applicable.

3.2.3 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 or AWS D1.6 . Welders and welding operators shall pass the qualification tests prescribed by AWS D1.1 or AWS D1.6 within 12 months prior to performing work on this contract. The qualifications shall be submitted on Form N-4, Annex N of AWS D1.1 . The welder or welding operator shall be required to repeat the qualifying tests when 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.

3.2.4 Workmanship Requirements

3.2.4.1 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. The weld procedure shall be submitted on Form N-1, Annex N of AWS D1.1 or AWS D1.6 . Properly documented evidence of compliance with all requirements of these specifications for previous welding joint qualifications tests will establish the joint welding procedure as prequalified and a qualification test will not be required. Each procedure shall be clearly identified as being either prequalified or qualified by tests.

3.2.4.2 Preheat and Interpass Temperature

Preheating shall be performed as required by AWS D1.1 or AWS D1.6 or as otherwise specified. 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 in still air.

3.2.4.3 Stress-Relief Heat Treatment

If stress-relief heat treatment is needed it shall be done in accordance with the requirements of AWS D1.1 or AWS D1.6 .

3.2.5 Inspection

The Contractor shall maintain an approved inspection system and perform required inspections in accordance with Section SECTION 01 45 04.00 28 CONTRACTOR QUALITY CONTROL. Welding shall be subject to inspection to determine conformance with the requirements of AWS D1.1 or AWS D1.6 the approved welding procedures and provisions stated in other sections of these specifications. 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.

3.2.5.1 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 or AWS D1.6 .

3.2.5.2 Nondestructive Examination

The nondestructive examination of shop and field welds shall be performed as designated or described in the sections of these specifications 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. 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 or AWS D1.6 . The Certified inspector shall make a permanent record of the test indications.

(2) Radiographic Testing - Making, evaluating and reporting radiographic testing of welds shall conform to the requirements of AWS D1.1 or AWS D1.6 . The Contractor shall submit the film as part of the testing results.

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

(4) Dye Penetrant Inspection - Dye penetrant inspection of welds shall conform to the applicable provisions of ASTM E165.

c. Acceptability of Welds - Welds shall be unacceptable if shown to have defects prohibited by AWS D1.1 or AWS D1.6 , or possess any degree of incomplete fusion, inadequate penetration or undercutting.

d. Welds to be Subject to Nondestructive Examination

(1) One hundred (100) percent of completed welds shall be cleaned and visually inspected to ensure compliance with the requirements of AWS D1.1 or AWS D1.6

(2) One hundred (100) percent of full penetration welds shall be ultrasonically tested or Radiographic tested.

(3) One hundred (100) percent of all fillet and partial penetration welds shall be inspected by magnetic particle testing or liquid penetrant testing.

3.2.5.3 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 examinations before final acceptance. The cost of such inspection will be borne by the Government.

3.2.6 Structural Steel Welding Repairs

Defective welds in the structural steel welding repairs shall be repaired in accordance with AWS D1.1 or AWS D1.6 . Defective weld metal shall be removed to sound metal by use of air carbon-arc or oxygen gouging. The surfaces shall be thoroughly cleaned before welding. Welds that have been repaired shall be retested by the same methods used in the original inspection. All costs of repairs and retesting shall be borne by the Contractor.

3.3 BOLT HOLES

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

3.4 SHOP INSPECTION

Each structural unit shall be inspected prior to assembly to determine the correctness of the fabrication. Each unit inspected shall be closely checked to ensure that dimensions and tolerances are met.

3.4.1 INSPECTIONS AND TESTS

Inspections and tests shall be performed in accordance with this section and SECTION 01 45 04.00 28 to demonstrate that the fabrication and machine work are in conformity with the plans and specifications in addition to the applicable inspection requirements elsewhere specified. A detailed plan shall be prepared as part of the CQC Plan to record all measurements, and other details that indicate the plans and specifications are met.

These tests and inspections shall be performed and certified at the Contractor's expense and included in the daily CQC reports. Inspections and tests shall conform to the requirements of the particular sections of these specifications and plans for the respective items of work unless otherwise specified or authorized. The Government will notify the Contractor which inspections and tests shall be conducted in the presence of and witnessed by the Contracting Officer. The Government shall be notified at least 7 days in advance of the dates of the inspections and tests.

3.4.1.1 Fish Release Pipe Smoothness Inspection

Inspection shall be made of each fish release pipe to ensure required smoothness for safe fish passage has been obtained as described in paragraph 3.1.3 Fabrication. Inspection shall be conducted by Government Biologist in the presence of and witnessed by the Contracting Officer.

Records shall be kept of each inspection and included in the daily CQC report. Any failed inspection will be cause for rejection and rejected fish release pipe sections shall be repaired or replaced and re-inspected at the Contractor's expense.

3.4.1.1.1 Trolley Pipe Slide Test

Each trolley pipe shall be tested to ensure a trolley can slide easily without obstruction. Tests shall compose of an average worker successfully sliding a trolley, at a walking pace, through the entire assembled trolley pipe without needing to stop. Tests shall be conducted with the trolley pipes in a horizontal position that allows easy access for the worker conducting the test. Trolley pipes shall be tested in both directions to simulate the trolley being lowered down and raised back up.

Tests shall be conducted with the trolley pipes in their full assembled installation length. Tests shall take place after painting but prior to installation. Tests shall be conducted in the presence of and witnessed by the Contracting Officer. Records shall be kept of each test and included in the daily CQC report. Any failed test will be cause for rejection and rejected trolley pipe sections shall be repaired or replaced and re-inspected at the Contractor's expense.

3.5 PAINTING

Trolley pipes and all associated support steel shall be painted after fabrication.

NOTE: Ensure required tolerances for trolley slots are met post painting.

Electrical conduit shall be painted as described in paragraph 3.10 FALL

PROTECTION ANCHORS.

3.6 APPLICATION TROLLEY PIPES

All steel surfaces of trolley pipe assemblies including the interior of the steel pipes shall be blast cleaned to near-white blast cleaning grade, SSPC SP 10/NACE No. 2 . All weld splatter and burrs shall be removed. All corners and sharp edges of steel items shall be rounded before painting.

Apply two coats of epoxy paint to 5 mils DFT for each coat of urethane paint. Care shall be taken to insure proper and inform film thickness are obtained. Follow paint manufacturer's printed instructions for surface preparation for immersion service, mixing and thinning, application, extending pot life of opened cans, maximum film thickness per coat, and cleaning brushes and equipment when painting. Use manufacturer's recommended solvent and thinner.

CAUTION: Do not apply moisture cure urethane pain coasts thicker than the manufacturer's recommended film thickness.

3.7 INSTALLATION OF TROLLEY PIPES AND FISH RELEASE PIPES

Trolley pipes and fish release pipes shall be installed on the tailrace and south pumphouse piers at the locations and elevations shown on the drawings. Pipes shall be installed straight within 1/4 inch from top to bottom of pipes. The slots in the trolley pipes shall be in alignment at the butt joints between pipe sections. Reinforcing steel or tramp metal may be encountered when drilling holes for anchors. If steel is encountered the hole shall be relocated as needed. Installation work will be underwater so divers are required. Concrete anchors shall be installed in strict accordance with the manufacturer installation requirements.

3.8 REBAR

Holes drilled that encounter rebar shall be filled in if not used.

Underwater nonshrink grout shall be used to fill the unused holes.

3.9 BEARING SURFACES

Ensure that all bearing surfaces are level, flat, and free from irregularities within ± 1/16 inch. Correct bearing surface irregularities with underwater nonshrink grout.

3.10 FALL PROTECTION ANCHORS

Install the permanent fall protection anchors to the pump house deck in strict accordance with the manufacturer installation requirements.

Existing electrical conduit may not be modified or moved in anyway not described in the contract drawings. Electrical conduit shall be painted safety yellow in sections described in the contract drawings. Electrical conduit mounting unistrut may be relocated. Proposed mounting unistrut locations shall be per Government approval on case by case basis.

Existing life rings may be relocated per Government approval on a case by case basis. Submit shop drawings of fall protection anchors detailing anchor type and location, painting of the electrical conduit, and any proposed unistrut and life ring relocation.