TechSpecs-Amend-0004.pdf

Little Goose Adjustable Spillway Weir (ASW) W912EF-16-R-0001 Amend-0004

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 Final 3D CADD Structural Model

1.3.4 Material Acceptance

1.3.5 Definition of Engineer

1.3.6 Qualification of Welders and Welding Operators

1.3.7 Weld Tracking Log Template

1.3.8 Weld Tracking Log

1.3.9 Welding Procedure Specifications (WPS)

1.3.10 Fracture Critical Members (FCM)

1.3.11 Tension Members (TM)

1.4 DELIVERY, STORAGE, AND HANDLING

PART 2 PRODUCTS

2.1 METALS

2.1.1 Structural Steel

2.1.2 Structural Steel Plates Over 2 Inches Thick

2.1.3 Hollow Structural Sections

2.1.4 Seal Clamp Bars

2.1.5 Bearing Shoes

2.1.6 Aligning & Lifting Pins

2.1.7 Leaf Springs

2.2 HIGH STRENGTH BOLTS

2.2.1 Bolts

2.2.2 Nuts

2.2.3 Direct Tension Indicator Washers

2.2.4 Washers

2.3 CARBON STEEL BOLTS

2.4 STAINLESS STEEL BOLTS, CAP SCREWS, NUTS AND WASHERS

2.4.1 Cap screws and bolts

2.4.2 Nuts

2.5 RUBBER SEALS

2.6 RUBBER SEAL TEFLON COATING

2.7 ELASTOMERIC BEARING PADS

2.8 BEARING PAD ADHESIVE

2.9 UHMW-PE BEARING SHOES, PADS AND WEDGES

2.10 EPOXY ADHESIVE ANCHORS

2.10.1 Epoxy Adhesive

2.10.2 Internally Threaded Insert Anchors

2.10.3 Threaded Rod and Bolts

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2.10.4 Nuts and Washers

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

3.2.2 Nondestructive Testing

3.2.3 Inspection of Structural Carbon 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 IDENTIFIERS

3.8 LIFTING BEAMS

3.8.1 Initial Testing and Inspection

3.8.2 Rating Placard

3.8.3 Permanent Load Rating Identifier

3.9 STORAGE STANDS

3.9.1 Bearing Plates Attached to Base Plate

3.9.2 Test Fit

3.9.3 Labels

3.9.3.1 Stand Weight

3.9.4 Lanyards for Stoplog Wedges

3.10 STORAGE HANGERS FOR EXISTING SPILLWAY MAINTENANCE STOPLOGS

3.10.1 Load and Fit Test

3.10.2 Labels

3.10.3 Hanger Weight

3.11 WEIGHT OF ASW COMPONENTS

3.12 FABRICATION REPORTS

3.13 EPOXY ADHESIVE ANCHORS

-- End of Section Table of Contents --

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SECTION 05 59 13.00 28

FABRICATION OF HYDRAULIC STEEL STRUCTURES

PART 1 GENERAL

This specification includes fabrication of the following ASW components and accessories:

1. Hoist Assembly, including Machinery Bases

2. Wheel Tracks

3. Crest Assembly

4. Top Stoplog

5. Intermediate Stoplog

6. Base Stoplog

7. ASW Lifting Beam

8. Storage Stands for ASW Stoplogs

9. Storage Hangers for Existing Spillway Maintenance Stoplogs

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 ASSOCIATION OF STATE HIGHWAY AND TRANSPORTATION OFFICIALS

(AASHTO)

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

AMERICAN WELDING SOCIETY (AWS)

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

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

ASME INTERNATIONAL (ASME)

ASME B30.20 (2010) Below-the-Hooks Lifting Devices

ASTM INTERNATIONAL (ASTM)

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

ASTM A435/A435M 1990.12.28 (R 2012) Standard Specification for Straight-Beam Ultrasonic Examination of Steel Plates

ASTM A490 (2014a) Standard Specification for Structural Bolts, Alloy Steel, Heat

Treated, 150 ksi Minimum Tensile Strength

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

ASTM A709/A709M (2013a) Standard Specification for Structural Steel for Bridges

ASTM A770/A770M 2003.05.10 (R 2012) Standard Specification for Through-Thickness Tension Testing of Steel Plates for Special Applications

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 D 2240 (2004) Rubber Property - Durometer Hardness

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

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

ASTM D 471 (1998e1) Rubber Property - Effect of Liquids

ASTM D 412 (1998a; R 2002e1) Vulcanized Rubber and Thermoplastic Elastomers - Tension

ASTM D 395 (2003) Rubber Property - Compression Set

ASTM A 240/A 240M (2004ae1) Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels for General Applications

ASTM A 564/A 564M (2004) 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

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

ASTM A1085 (2013) Standard Specification for Cold-Formed Welded Carbon Steel Hollow Structural Sections (HSS)

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

ASTM F879 (2015.05.01) Standard Specification for Stainless Steel Socket Button and Flat Countersunk Head Cap Screws

ASTM F959 (2013) Compressible-Washer-Type Direct Tension Indicators for Use with Structural Fasteners

ASTM B695 (2004; R 2009) Standard Specification for Coatings of Zinc Mechanically Deposited on Iron and Steel

ASTM A194/A194M (2015) Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High-Pressure or High-Temperature Service, or Both

ASTM INTERNATIONAL (ASTM)

ASTM A307 (2014) Standard Specification for Carbon Steel Bolts and Studs, 60 000 PSI Tensile Strength

RESEARCH COUNCIL ON STRUCTURAL CONNECTIONS (RCSC)

RCSC S348 (2009) RCSC Specification for Structural Joints Using ASTM A325 or A490 Bolts

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, ST Weld Tracking Log Template ; G, ST Operational and Load Test ; G, ST

SD-02 Shop Drawings

Shop Drawings ; G, ST Final Shop Drawings ; G, ST Welding Repairs - Fracture Critical Members ; G, ST Delivery/Shipping Plan ; G, ST Alignment Test Procedure ; G, ST

SD-03 Product Data

Materials Disposition Record ; I, ST Rubber Seals ; I, ST Elastomeric Bearing Pads ; I, ST Bearing Pad Adhesive ; G, ST Epoxy Adhesive Anchors ; G, ST Direct Tension Indicator Washers

SD-05 Design Data

Weight of ASW Components ; I, ST Final 3D CADD Structural Model ; G, ST

SD-06 Test Reports

Certified Test Reports ; I, ST Weld Tracking Log ; I, ST Hoist Assembly Initial Operation and Load Test Report ; G, ST ASW Lifting Beam Initial Operation and Load Test Report ; G, ST

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 Report ; I, ST Fabrication Reports ; G, ST

1.3 PRE-FABRICATION REQUIREMENTS

1.3.1 Qualification of Structural Steel Fabricator

The fabricator shall be certified under any of the following categories of American Institute of Steel Construction (AISC) Quality Management Systems (QMS) Certification programs:

1) Intermediate Bridge

2) Advanced Bridge

The fabricator shall also have the following AISC endorsements:

1) Fracture Critical Endorsement

The fabricator shall be certified and endorsed on or before the date of award and the certifications and endorsements 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 certificates and endorsements indicating that the fabrication plant meets the specified AISC category requirements. If a renewal of the certification is required after the date of Notice to Proceed (NTP), submit a copy of the renewed certification.

1.3.2 Shop Drawings

Contractor shall submit detailed shop drawings showing individual ASW component fabrication details and assembly view. Shop drawings shall be submitted for review and acceptance prior to beginning fabrication. Shop drawings that are not acceptable shall be corrected and re-submitted.

Shop drawings for the ASW components shall include fabrication and assembly details and type, grade and class of material as appropriate.

Provide assembly drawings indicating the sequence of fabrication and provide details for connecting the adjoining fabricated components in the shop. Shop drawings shall include connection and mounting points where mechanical components connect to structural components. Elements of fabricated items inadvertently omitted on contract drawings shall be detailed by the fabricator and indicated on the shop drawings. At the completion of the contract, "as-built" Final Shop Drawings shall be submitted showing the actual, installed geometry.

1.3.3 Final 3D CADD Structural Model

At the completion of the contract an "as-built" 3D CADD Structural Model shall be submitted, showing the actual, installed geometry. The electronic file shall be submitted as a single ".dgn" file in Microstation version V8i 3D electronic file format and shall contain an assembly of each of the ASW structural components and existing structural features of the dam as listed below. This model shall be submitted and coordinated with the mechanical model such that the structural model shows the machinery and mounting points and the mechanical model shows the structural arrangement and clearances. Each element within the model shall be drawn as a solid with volumetric properties. Shell elements without volumetric properties will not be accepted. The file shall have a unique Microstation level and color assigned for each component as listed below:

1. Spillway Piers and Spillway Stoplog Slots

2. Spillway Deck with upstream Parapet Wall

3. Intake Gantry Crane Girder

4. Lifting Devices

5. Crest Assembly

6. Wheel Tracks

7. Hoist Assembly

8. Top Stoplog

9. Intermediate Stoplog

10. Base Stoplog

11. Storage Devices

1.3.4 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.

1.3.5 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.

1.3.6 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 pass the qualification tests prescribed by AWS D1.5M/D1.5 , within 12 months prior to performing work on this contract. 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.

1.3.7 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.

1.3.8 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 (KO) immediately upon completion of the fabrication of each structure. Draft copies of NDT testing shall be furnished to the KO upon request and shall be available on the shop floor during any inspection.

1.3.9 Welding Procedure Specifications (WPS)

Submit a Welding Procedure Specification (WPS) with Procedure Qualification Record (PQR) and supporting test documentation on forms similar or equivalent to the sample forms in AWS D1.5M/D1.5 , Annex N, for each weld, including prequalified welds, in accordance with paragraph Welded Connections approved before fabrication is commenced. 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 , this specification governs.

1.3.10 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 . All materials to be welded shall be ASTM A709/A709M Grade 50, 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 construction of fracture critical components shall meet the requirements of section 10.2 of ASTM A709/A709M for Fracture-Critical Tension Components 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 .

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

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.

1.3.11 Tension Members (TM)

Tension members (TM) are shown on the Contract Drawings and shall be ASTM A709/A709M Grade 50, 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 8, for Zone 2, unless otherwise indicated or specified. All materials used for the construction of tension members shall meet the requirements of section

10.1 of ASTM A709/A709M for Non-Fracture Critical Tension Components and shall include mill certification showing that the material meets the necessary toughness requirements.

1.4 DELIVERY, STORAGE, AND HANDLING

The ASW components shall be arranged on the delivery vehicles such that no damage occurs during shipping. All sling lifting lugs shall be directed up unless otherwise noted or approved by the COR . It is acceptable to ship the Crest Assembly, Base Stoplog, Intermediate Stoplog, Top Stoplog and Wheel Tracks in the horizontal position and to rotate these components from horizontal to vertical and vice versa. Submit a Delivery/Shipping Plan showing orientation and locations of ASW components on the delivery vehicles prior to shipment for Government approval. Submit drawings providing descriptions of methods of delivering the completed ASW components, including details for support during shipment to prevent distortion or other damages, and orientation and location of structures on transport equipment.

PART 2 PRODUCTS

2.1 METALS

Structural steel and other metal materials sections and standard articles shall be as specified herein. Metal for mechanical parts shall be as specified on the mechanical drawings and/or specifications.

2.1.1 Structural Steel

Structural steel plates, bars and shapes for structural components shall conform to ASTM A709/A709M , Grade 50, unless otherwise noted.

2.1.2 Structural Steel Plates Over 2 Inches Thick

Structural steel plates having a nominal thickness greater than 2 inches shall, in addition to all other applicable requirements of this specification, have less than 0.010 percent sulfur content, shall meet the acceptance criteria for through-thickness tension per ASTM A770/A770M , and shall be scanned and meet the acceptance criteria for lamination defects in accordance with ASTM A435/A435M before and after fabrication is complete.

2.1.3 Hollow Structural Sections

ASTM A1085 Grade A or ASTM A500/A500M Grade B. HSS that are welded to Tension Members (TM) or Fracture Critical Members shall be ASTM A1085 Grade A.

2.1.4 Seal Clamp Bars

Clamp bars for rubber J-bulb seals shall be 300 series stainless steel conforming to ASTM A 240/A 240M .

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2.1.5 Bearing Shoes

Bearing shoes shall be fabricated from structural steel conforming to ASTM A709/A709M , Grade 50.

2.1.6 Aligning & Lifting Pins

Aligning and lifting pins shall conform to ASTM A 564/A 564M , S17400, Type 630, Condition H900. Pins shall be machined to the sizes shown on the drawings. Provide two stainless steel nuts per pin (to prevent loosening) conforming to ASTM A194/A194M , Type UNS/AISI S21800 (brand name "Nitronic 60" or approved equal) . The first nut shall be installed snug tight to the structural plate, the second nut shall tightened against the first nut so that the aligning pin between the nuts is pretensioned to 50 percent of yield.

2.1.7 Leaf Springs

Leaf springs shall conform to ASTM A 689 AISI 5150.

2.2 HIGH STRENGTH BOLTS

2.2.1 Bolts

ASTM A325, Type 1 or ASTM A490, Type 1 or 2 as shown on Contract drawings.

2.2.2 Nuts

ASTM A563, Grade and Style as specified in the applicable ASTM bolt standard.

2.2.3 Direct Tension Indicator Washers

ASTM F959. Provide ASTM B695, Class 50, Type 1 galvanizing.

2.2.4 Washers

ASTM F436, plain carbon steel.

2.3 CARBON STEEL BOLTS

ASTM A307, unless otherwise specified .

2.4 STAINLESS STEEL BOLTS, CAP SCREWS, NUTS AND WASHERS

Bolts, cap screws, nuts, washers, and cap screws shall have the same or better corrosion resistance and strength for the application as AISI 300 series stainless steel. Sizes areindicated on the drawings.

2.4.1 Cap screws and bolts

Provide stainless steel socket cap screws and bolts conforming to ASTM F879.

Cap screws and bolts shall have hex socket heads. Slotted or other types of flat-head screws and bolts will not be allowed. Flat head cap screws and bolts shall be countersunk between 1/32 inch and 1/8 inch below the surface, unless otherwise noted. Bolts and cap screws that are tapped into structural members in lieu of nuts shall conform to ASTM A194/A194M , Type UNS/AISI S21800 (brand name "Nitronic 60" or approved equal)

2.4.2 Nuts

Provide stainless steel nuts conforming to ASTM A194/A194M , Type UNS/AISI S21800 (brand name "Nitronic 60" or approved equal) . Nuts shall be nylon insert lock nuts.

2.5 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, 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.

2.6 RUBBER SEAL TEFLON COATING

The vertical seals between the Wheel Track and Crest Assembly shall have a fluorocarbon film vulcanized and bonded to the sealing surface of the bulb.

The film shall be 0.060 inch thick Abrasion Resistant Fluorocarbon Film and shall have the following minimum physical properties:

Tensile strength 2,000 psi

Elongation 250 percent

2.7 ELASTOMERIC BEARING PADS

Bearing pads shall conform to AASHTO HB-17, Section 18, for Plain Elastomeric Pads, temperature Grade 3. Submit manufacturer's descriptive data, catalog cuts and other information to fully describe the bearing pads proposed for use. Bearing pads shall be of the size and shape shown on the contract drawings and shall be compounded of natural rubber, elastomers, or a blend of both. Bearing pads shall act as a seal between the ASW components and may contain synthetic fibers, reinforcing carbon black, zinc oxide, accelerators, antioxidants, vulcanizing agents, and plasticizers. Physical characteristics of the bearing pads shall meet the following requirements:

TEST METHOD

PHYSICAL TEST TEST VALUE SPECIFICATION

Tensile Strength 2,250 psi (min.) ASTM D 412

Durometer Hardness 70 +/-5 ASTM D 2240 (Shore Type A)

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

* 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.

2.8 BEARING PAD ADHESIVE

Bearing pads shall be bonded to the ASW components with a removable adhesive that will not cause the ASW paint system to deteriorate or fail.

The Contractor shall determine the adhesive to be used based on the bearing pad manufacturer and the ASW paint system manufacturer's recommendations.

2.9 UHMW-PE BEARING SHOES, PADS AND WEDGES

Ultra High Molecular Weight Polyethylene (UHMW-PE) material shall be a cross-linked polymer with a molecular weight equal to or greater than 4.5 million grams per mole, be formulated from 100% virgin material, and be resistant to damage from ultraviolet light (UV resistant).

2.10 EPOXY ADHESIVE ANCHORS

2.10.1 Epoxy Adhesive

Epoxy adhesive shall be Wej-It Inject-TITE AWF All-Weather Formula Epoxy

Acrylate, as manufactured by the Wej-it Division of Mechanical Plastics Corporation, 110 Richards Avenue, Norwalk, CT 06854, or equal with the following salient characteristics:

1. Suitable for installation in water filled holes.

2. Suitable for installation in temperatures as low as 0 degrees's Fahrenheit.

3. Minimum bond strength of 200 pounds per square inch with water saturated cracked concrete at 0-175 degrees Fahrenheit.

2.10.2 Internally Threaded Insert Anchors

Internally threaded insert anchors shall be Wej-It Power-Sert High Performance Anchors, as manufactured by the Wej-it Division of Mechanical Plastics Corporation, 110 Richards Avenue, Norwalk, CT 06854, or equal with the following salient characteristics:

1. Material shall be AISI 300 series stainless steel.

2. The strength of the insert body shall not control the strength of the final, installed anchor system under any combination of shear and tensile loads.

3. Insert threading shall be fully compatible with ASTM F593 bolts and threaded rod.

2.10.3 Threaded Rod and Bolts

Threaded rod and bolts shall be AISI 300 series stainless steel meeting the requirements of ASTM F593.

2.10.4 Nuts and Washers

Nuts and washers shall be provided per manufacturer's recommendations.

Stainless steel nuts shall conform to ASTM A194/A194M , Type UNS/AISI S21800. Washers shall be AISI 300 series stainless steel.

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, 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 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. Machined surfaces shall have a maximum surface roughness of 125 micro inches unless otherwise noted.

a. Dimensional Tolerances for Structural Work.

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(1) See sheet numbers SS502, SS503 and SY101 for assembly tolerances of ASW components. 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 construction.

b. Structural Carbon and Stainless 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. 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.

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 KO, 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. 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 for Welding of Carbon Steel - 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 filler metal toughness for carbon steel base metal 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 of carbon steel 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 except that the temperature of the base metal shall be at least 70 degrees F . Preheat for fracture critical welds shall be as defined in Table 12.3 of AWS D1.5M/D1.5 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.

e. Workmanship. Workmanship for welding shall be in accordance with AWS D1.5M/D1.5 , Section 3, 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. 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 of carbon steel shall be made using low-hydrogen welding electrodes.

All welds shall be made 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 except that the minimum temperature shall be 70 degrees F in any case, regardless of electrode used. 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, filled, 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. Weld access holes and sizes are shown on the contract drawings. If the oversite of intersecting out-of-plane welds is encountered, the fabricator shall notify the KO for the approval of weld access hole additions in such locations. Weld access holes will not be allowed in locations where it would compromise sealing between ASW components and/or between the ASW components and the spillway piers. The fabricator shall show any proposed changes to size and location of weld access holes on the shop drawings. Changes to weld access hole size and locations will not be allowed without Government approval.

(4) 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.

(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 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. Tightening shall be done by turn-of-nut, direct tension indicator, calibrated wrench, or alternative design bolt methods in conformance with RCSC S348. Bolt tension of all high strength bolts on the Hoist Assembly lifting legs shall be field-verified with a calibrated wrench prior to commissioning and after initial load testing.

Nominal Diameter A325 Bolts A490 Bolts

5/8 inch 19 kips 24 kips

3/4 inch 28 kips 35 kips

7/8 inch 39 kips 49 kips

1 inch 51 kips 64 kips

1-1/8 inch 56 kips 80 kips

1-1/4 inch 71 kips 102 kips

1-3/8 inch 85 kips 121 kips

1-1/2 inch 103 kips 148 kips

All other connections shall be tightened to the snug-tight condition. The snug-tight condition is defined as the tightness attained by either a few impacts of an impact wrench or the full effort of a worker with an ordinary spud wrench that brings the plies into firm contact. 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 or ASTM A490 and RCSC Specifications for Structural Joints Using ASTM A325 or A490 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 at all joints to maintain water tightness, unless noted otherwise on the drawings. All seal welds shall be shown and made as indicated on the shop drawings. Seal welds shall be made the minimum size weld as required in AWS D1.5M/D1.5 , unless noted otherwise on the drawings. Where sufficient standoff is not provided to wrap a fillet weld, a partial joint penetration weld shall be provided at the wrap with the same effective throat as the adjacent fillet weld. Wrapping of seal welds is required regardless of contrary requirements of 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 welds made to any fracture critical member according to AWS D1.5M/D1.5 Chapter 12.

d. Plate splices. Locations of plate splices, if required, shall be proposed on the shop drawings and approved by the COR. Horizontal splices shall be made at least 4 inches from horizontal plate connections, such as web plates. Vertical splices shall be made at least four inches from vertical plate connections, such as intercostals. Vertical splices are not allowed in Fracture Critical members except as noted on the drawings. Provide weld access holes to prevent intersecting welds. All splice welds shall be Complete Joint Penetration welds.

3.1.6 Shop Assembly

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

Field-welded splices of large components, such as the Crest Assembly, will not be accepted. 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 ASW component 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 surfaces in contact with the rubber seals shall be machine finished to a maximum roughness of 125 micro inches . 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 KO. Furnish specimens and samples for additional independent tests and analyses upon request by the KO.

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 KO.

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

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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 Carbon 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 applicable requirements of AWS D1.5M/D1.5 , subsection 6.26.1 and Chapter 12 (for Fracture Critical Members). 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. 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 Subsection 3.2.5.

(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…