05_60_05.00_28_Amend-0003.pdf

Little Goose Navlock Downstream Miter Gate Repair W912EF-16-R-0017 Amend-0003

SECTION TABLE OF CONTENTS

DIVISION 05 - METALS

SECTION 05 60 05.00 28

MITER GATE REPAIRS, INSTALLATION, AND TESTING

PART 1 GENERAL

1.1 REFERENCES

1.2 SUBMITTALS

1.3 DEFINITIONS

1.3.1 Welding Terms

1.3.2 Engineer of Record

1.4 SYMBOLS

1.5 APPLICABLE WELDING CODES

1.6 PRE-CONSTRUCTION REQUIREMENTS

1.6.1 Qualification of Welders and Welding Operators

1.6.2 Welding Procedure Specifications (WPS)

1.6.3 Fracture Critical Members (FCM)

1.6.4 Report of Government Furnished Property (GFP)

PART 2 PRODUCTS

2.1 BOLTS, NUTS, AND WASHERS

2.2 WELD FILLER METAL

2.3 BARS AND PLATES

2.4 STRUCTURAL STEEL

2.5 QUOIN AND MITER CONTACT BLOCKS

2.6 CONTACT BLOCK EPOXY FILLER

2.7 SPLASH ZONE EPOXY FILLER

2.8 RUBBER SEALS

2.9 SEAL BOLTS AND CAP SCREWS

2.10 SEAL RETAINER BARS

2.11 ALUMINUM COVER PLATES

2.12 TIMBER FENDERS

2.13 EYE BAR PIN

2.14 EYE BOLT

2.15 BRONZE BUSHINGS

2.16 BEARING BOLTS

PART 3 EXECUTION

3.1 WORK AREA DEWATERING

3.2 PROTECTION OF EXISTING STRUCTURES

3.3 HANDLING AND PROTECTION OF GOVERNMENT FURNISHED PROPERTY

3.4 EXISTING CONDITIONS

3.4.1 Existing Structural Condition

3.4.2 Debris Removal

3.4.3 Clean Gate Surfaces

3.5 PINTLE STRUCTURAL REPAIRS AND PINTLE REPLACEMENT

3.5.1 Remove Existing Pintles and Pintle Heels

3.5.2 Pintle Structural Repairs

3.5.3 Install New Pintle Heels

3.5.4 Install New Pintle

3.6 GUDGEON LINKAGE REPLACEMENT

3.6.1 Remove Existing Gudgeon Linkages and Transducers

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3.6.2 Install Gudgeon Linkages

3.7 QUOIN AND MITER CONTACT BLOCK REPLACEMENT

3.7.1 Remove Existing Wall Quoin, Gate Quoin, and Miter Contact

Blocks

3.7.2 Replace Wall Quoin, Gate Quoin, and Miter Contact Blocks

3.7.3 Install New Epoxy Pour Holes

3.7.4 Adjust Quoin and Miter Contact Blocks

3.7.4.1 Adjust Quoin Contact Blocks

3.7.4.2 Adjust Miter Contact Blocks

3.7.5 Tolerances for Contact Block Alignment

3.7.6 Placing Epoxy Filler

3.7.7 Final Tightening of Contact Blocks

3.8 GATE DIAGONAL TENSIONING

3.9 WELDING

3.9.1 Welding Operations

3.9.2 Workmanship Requirements

3.9.2.1 Welding Procedures

3.9.2.2 Welding Technique

3.9.2.3 Workmanship

3.10 Nondestructive Testing (NDT)

3.10.1 Visual Examination

3.10.1.1 Nondestructive Examination

3.11 Bolted Connections

3.11.1 Bolts, Nuts, and Washers

3.11.2 Bolt Holes

3.12 RUBBER SEAL REPLACEMENT

3.13 FABRICATE AND INSTALL NEW HAND RAILING

3.13.1 Gate Railing

3.13.2 Gudgeon Recess Railing

3.14 FABRICATE AND INSTALL ALUMINUM COVER PLATES

3.15 TIMBER FENDER REPLACEMENT

3.15.1 Existing Timber Fender Removal

3.15.2 New Timber Installation

3.16 LUBRICATION OF COMPONENTS

3.17 PAINTING

3.17.1 Edge Preparation

3.17.2 Preparation and Painting

3.18 WORKMANSHIP

3.19 OPERATIONAL TESTING

3.19.1 Initial Trial Operation and Test

3.19.2 Final Trial Operation and Test

3.19.3 Gate Seal Test

ATTACHMENTS:

DIAGONAL TENSIONING SEQUENCE

-- End of Section Table of Contents --

SECTION 05 60 05.00 28

SECTION 05 60 05.00 28

MITER GATE REPAIRS, INSTALLATION, AND TESTING

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 IRON AND STEEL INSTITUTE (AISI)

AMERICAN WELDING SOCIETY (AWS)

AWS A2.4 (2012) Standard Symbols for Welding, Brazing and Nondestructive Examination

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

AWS D1.1/D1.1M (2015) Structural Welding Code - Steel

AWS D1.2/D1.2M (2014) Structural Welding Code - Aluminum

AWS D1.5M/D1.5 (2015) Bridge Welding Code

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

AMERICAN WOOD PROTECTION ASSOCIATION (AWPA)

AWPA C2 (2003) Lumber, Timber, Bridge Ties and Mine Ties - Preservative Treatment by Pressure Processes

AWPA M4 (2015) Standard for the Care of Preservative-Treated Wood Products

ASME INTERNATIONAL (ASME)

ASME B4.1 (1967; R 2009) Preferred Limits and Fits for Cylindrical Parts

ASTM INTERNATIONAL (ASTM)

ASTM A153/A153M (2009) Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware

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

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ASTM A325 (2014) Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength

ASTM A490 (2014a) Standard Specification for Structural Bolts, Alloy Steel, Heat Treated, 150 ksi Minimum Tensile Strength

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

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

ASTM A668/A668M (2015) Standard Specification for Steel Forgings, Carbon and Alloy, for General Industrial Use

ASTM A709/A709M (2015) Standard Specification for Structural Steel for Bridges

ASTM A788/A788M (2015) Standard Specification for Steel Forgings, General Requirements

ASTM B148 (2014) Standard Specification for Aluminum-Bronze Sand Castings

ASTM B209 (2014) Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate

ASTM B271/B271M (2015) Standard Specification for Copper-Base Alloy Centrifugal Castings

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

ASTM D2240 (2005; R 2010) Standard Test Method for Rubber Property - Durometer Hardness

ASTM D395 (2014) Standard Test Methods for Rubber Property - Compression Set

ASTM D412 (2006a; R 2013) Standard Test Methods for Vulcanized Rubber and Thermoplastic Elastomers - Tension

ASTM D471 (2015a) Standard Test Method for Rubber Property - Effect of Liquids

ASTM D572 (2004; R 2010) Rubber Deterioration by Heat and Oxygen

ASTM D573 (2004; R 2010) Standard Test Method for Rubber - Deterioration in an Air Oven

ASTM D695 (2010) Standard Test Method for Compressive Properties of Rigid Plastics

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

ASTM E709 (2015) Standard Guide for Magnetic Particle Examination

ASTM F436 (2011) Hardened Steel Washers

ASTM F879 (2015) Standard Specification for Stainless Steel Socket Button and Flat Countersunk Head Cap Screws

WESTERN WOOD PRODUCTS ASSOCIATION (WWPA)

WWPA Tech Guide (2005) Lumber Technical Guide, Standards and Grading

1.2 SUBMITTALS

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

submittals having an "I" designation are for information only.

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, ST

Welding Procedure Specifications (WPS) ; G, ST

Fracture Control Plan (FCP) ; I, ST

Inspector Qualifications ; G, ST

Report of Government Furnished Property (GFP) ; I, ME

Pintle Removal Plan ; G, ME

SD-02 Shop Drawings

Quoin and Miter Contact Blocks ; I, ST

Pintle Heel Template ; G, ST

Structural Repair Fabrication Drawings ; G, ST

Gate Railing ; I, ST

Gudgeon Recess Railing ; I, ST

Aluminum Cover Plates ; I, ST

SD-03 Product Data

Contact Block Epoxy Filler ; I, ST

Splash Zone Epoxy Filler ; I, ST

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Rubber Seals ; I, ST

Anti-Seize Product Technical Data Sheet ; I, ST

Timber Fenders ; I, ST

Eye Bar Pin ; G, ME

Bronze Bushings ; G, ME

Bearing Bolts ; G, ME

SD-06 Test Reports

Nondestructive Examination ; I, ST

Gate Diagonal Tensioning Report ; G, ST

1.3 DEFINITIONS

1.3.1 Welding Terms

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

1.3.2 Engineer of Record

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.

1.4 SYMBOLS

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

1.5 APPLICABLE WELDING CODES

Welding of handrail shall be per AWS D1.1/D1.1M . Welding of miter gate structural steel, field-welding of the handrail to the gate, and any other structures or components welded to the gate, shall be in accordance with AWS D1.5M/D1.5 . References within this specification to AWS D1.1/D1.1M shall be applicable for materials and fabrication of the handrail.

References within this specification to AWS D1.5M/D1.5 shall be applicable for materials and fabrication of miter gate structural steel, attachment of handrail to the gate, and any other structures or components welded to the gate.

1.6 PRE-CONSTRUCTION REQUIREMENTS

1.6.1 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 D1.5M/D1.5 Section 12. Welders and welding operators shall pass the qualification tests prescribed by AWS D1.1/D1.1M or AWS D1.5M/D1.5 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.

1.6.2 Welding Procedure Specifications (WPS)

Submit a Welding Procedure Specification (WPS) with PQR and supporting test documentation on forms similar or equivalent to the sample forms in AWS D1.1/D1.1M or AWS D1.5M/D1.5 , Annex III, for each weld, including prequalified welds, in accordance with paragraph Welded Connections approved before fabrication is commenced. Approved WPS's are required prior to commencing fabrication. Approve all WPS's and PQR's submitted for Government approval by an approved CWI. Welding Procedure Specifications shall be individually identified and shall be referenced on the shop drawings. In case of conflict between this specification and AWS D1.1/D1.1M or AWS D1.5M/D1.5 as applicable, this specification governs.

1.6.3 Fracture Critical Members (FCM)

Girders 38 and 39 and all attachments and connections to these members are considered as Fracture Critical Members (FCM) as defined in AWS D1.5M/D1.5 .

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

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

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

Toughness test results shall meet the values specified in Table

12.1 of AWS D1.5M/D1.5 .

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

AWS D1.5M/D1.5 .

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

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

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

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

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

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

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

Minimum preheat for repair welding shall be as defined in AWS D1.5M/D1.5 section 12.17.6. All weld repairs to fracture critical members shall be considered critical welds in accordance with AWS D1.5M/D1.5 Section 12.17.3 and shall be approved by the engineer of record.

1.6.4 Report of Government Furnished Property (GFP)

The pintle, pintle heel, gudgeon eyebar linkages, link pins, and associated parts and components will be GFP as stated in the contract specifications and as shown on the contract drawings. As shown on sheet G-401, one existing gudgeon linkage assembly will be removed, refurbished as necessary, and painted in accordance with the contract drawings and specification. GFP will be located and available for inspection per SECTION 01 55 10.00 28 : CONTRACTOR WORK, ACCESS AND STORAGE AREAS. The Contractor shall verify all existing GFP parts and components for replacement of the pintles, pintle heels, gudgeon linkages, link pins, and associated parts and components. The Contractor will be responsible to verify condition of GFP and submit a report of all GFP within 60 days of Notice to Proceed. The report shall identify and describe any missing or deficient parts and components or any discrepancies between the actual GFP and what is shown on the contract drawings.

PART 2 PRODUCTS

2.1 BOLTS, NUTS, AND WASHERS

All bolts shall be high strength and conform to ASTM A325. Carbon steel nuts shall conform to ASTM A563. Washers shall conform to ASTM F436. Where specified, fasteners shall be hot-dip galvanized in accordance with

ASTM A153/A153M .

2.2 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 D1.5M/D1.5 . 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 D1.5M/D1.5 .

2.3 BARS AND PLATES

All splice bars and plates shall conform to ASTM A709/A709M grade 50.

2.4 STRUCTURAL STEEL

All structural steel used for fabrication and weld repairs shall conform to ASTM A709/A709M grade 50.

2.5 QUOIN AND MITER CONTACT BLOCKS

Quoin and miter contact blocks shall be fabricated from low alloy steel conforming to ASTM A668/A668M Class F. Alternatively, the Contractor may use AISI C1045 steel plate for fabrication of quoin and miter blocks.

Contractor shall submit shop drawings showing machining specifications in accordance with the contract drawings and these specifications.

Contractor shall submit steel mill certifications showing steel chemical composition and properties.

2.6 CONTACT BLOCK EPOXY FILLER

Contact block epoxy filler shall be Chockfast Orange or equal with a minimum compressive strength of 19,000 psi in accordance with ASTM D695.

Epoxy filler shall have a specific gravity of 1.5 to 1.7 and maximum shrinkage of 0.0002 inches per inch.

2.7 SPLASH ZONE EPOXY FILLER

Splash zone epoxy filler shall be ASTM A788/A788M two-part epoxy patching compound with V.O.C. of 0 lbs/gallon. Submit manufacturer's product data.

2.8 RUBBER SEALS

Contractor shall provide new rubber bottom seals and miter seal per contract drawings and as specified herein. 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 D412

Elongation at Break 400% (min.) ASTM D412

300% Modulus 900 psi (min.) ASTM D412

Durometer Hardness 60 to 70 ASTM D2240

TEST METHOD

PHYSICAL TEST TEST VALUE SPECIFICATION

(Shore Type A)

*Water Absorption 5% by weight (max.) ASTM D471

Compression Set 30% (max.) ASTM D395

Tensile Strength 80% of tensile ASTM D572 (after aging 48 hrs) strength (min.) ASTM D573

* 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 D471). 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.

2.9 SEAL BOLTS AND CAP SCREWS

Seal bolts, cap screws, nuts, washers, shall be 300 series stainless steel. Sizes are indicated on the drawings. Seal cap screws shall conform to ASTM F879 Group 1, 300 series. Nuts shall conform to ASTM A194/A194M UNS designation S21800 Grade 8S, which are referred to as nitronic 60 stainless steel nuts. The threads of fasteners used to secure the J-bulb seal between the back-up and bar clamp plates shall be coated with a non-curing calcium sulfonate based Marine Grade Anti-Seize material that meets the requirements of ASTM D1264 with a water washout of zero (0.0) percent. The anti-seizing material is intended to prevent galvanic corrosion. Submit the Anti-Seize Product Technical Data Sheet (or similar) specifying the product characteristics. The anti-seizing material shall be Loctite Marine Grade Anti-Seize, or an approved equal.

2.10 SEAL RETAINER BARS

Contractor shall re-use existing seal retainer bars per S-502.

2.11 ALUMINUM COVER PLATES

New cover plates and aluminum fabricated items shall be 6061 alloy, temper T6 in accordance with ASTM B209. The top surface of cover plates shall be manufactured checkered plate finish for traction. Contractor shall submit shop drawings showing material types and thicknesses, welding and fabrication details, and other details as necessary.

2.12 TIMBER FENDERS

New timber fenders shall be rough cut Douglas fir conforming to WWPA Tech Guide , grade No. 1 under rules for Posts and Timbers. The timbers should have nominal dimensions as shown on For Information Only drawings. All timbers shall be pressure treated in accordance with AWPA C2 using waterborne preservative ACZA to a retention level of 0.40 pcf intended for ground contact and fresh water use.

2.13 EYE BAR PIN

Pin shall be accurately machined to the tolerances shown on the drawings.

Pin is a fracture critical member. Supplementary Requirements S6, S7 and S11 of ASTM A668/A668M shall apply to Forged Fracture Critical Members.

Heat treatment will be required to accomplish the Charpy Impact Testing.

Charpy Impact Test specimens shall be machined and tested in accordance with ASTM TEST METHODS AND DEFINITIONS A370.

Forged Fracture Critical Members shall meet the following toughness requirements:

Material shall be Forged Steel and meet ASTM A668/A668M , Class K.

Forged Steel shall have a minimum average energy of 30 Ft-Lbs at 40 degrees F and minimum energy value of one specimen of 25 Ft-Lbs.

2.14 EYE BOLT

Eye bolt material shall conform to the requirements of ASTM A668/A668M , Class K.

2.15 BRONZE BUSHINGS

All bushings shall be accurately machined to the tolerances shown on the drawing. Bushing material shall be copper alloy UNS C95500, ASTM B148, or

ASTM B271/B271M .

2.16 BEARING BOLTS

Bearing bolts shall conform to the requirements of ASTM A325.

PART 3 EXECUTION

3.1 WORK AREA DEWATERING

The Government will unwater the lock chamber so the Contractor can work in the lock. The seals on the downstream floating bulkhead leak and water will run over the concrete gate sill into the work area. The Contractor shall install sandbags to contain the water leakage and either pump the water over the bulkhead 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 PROTECTION OF EXISTING STRUCTURES

The Contractor shall take care to protect existing structural and mechanical components, including grease lines, hydraulic lines, fasteners, and the existing paint system. The existing coating is vinyl paint and does not contain any lead or chromate pigments. Temporary plywood coverings, foam pads or other similar measures shall be taken to protect the existing paint coating and structure in heavily trafficked areas or in areas adjacent to cutting and weld repairs. Measures shall be sufficient to ensure that abrasion or hot metal spatter does not compromise the existing paint coating. Contractor shall frequently sweep or clean work areas to prevent abrasion due to grit and grime. All damaged areas shall be cleaned, prepared, and repainted in accordance with SECTION

09 97 02.00 28 PAINTING: HYDRAULIC STRUCTURES.

3.3 HANDLING AND PROTECTION OF GOVERNMENT FURNISHED PROPERTY

The Contractor will be responsible for handling and maintaining adequate staging and storage of all GFP prior to installation. Care shall be taken to prevent damage due to handling or exposure to adverse weather. Any GFP parts or components that are damaged due to mishandling or inadequate storage shall be replaced by the Contractor at no additional cost to the Government.

3.4 EXISTING CONDITIONS

3.4.1 Existing Structural Condition

The navigation lock and gate have been in service since 1971. The lower portion of the gate has been in constant immersion in water. Temporary repairs were made to girder 39 at both pintles in 2009 and most (but not all) of the bolts and cap screws were installed new. All other bolts, cap and set screws, and dowels on the pintles and gate including the rubber bottom seals are originals. The original items are likely corroded and may be difficult to remove, and may shear or snap during removal. All broken fasteners, regardless of whether they failed due to operation of the gate or during removal, shall be replaced with new fasteners.

3.4.2 Debris Removal

There will be piles of debris located on the upper and lower sills adjacent to the pintle areas. All debris shall be removed from both sills to provide a clean and safe work surface free of obstructions. Debris consists primarily of gravels and pieces of driftwood. The Contractor should expect up to 100 cubic yards of debris and a small front end loader may be necessary to load debris into containers. Debris shall be hoisted to the deck and loaded into trucks for removal. Debris shall not be pushed into the navigation lock chamber. Silts and other fine materials less than 1-inch may be washed into the navigation lock chamber.

3.4.3 Clean Gate Surfaces

The Contractor shall remove silt and debris and wash the areas of the gate to be repaired or that will have parts or components replaced or installed. There may be a significant accumulation of bird droppings in various areas, particularly near the quoin and miter ends of the gate leaves. Bird droppings will only be on portions of the gate leaves above the tailwater elevation. Pieces of driftwood and other large debris shall be removed and disposed of as specified herein. Wash the areas to be repaired so that the surfaces are clean and free of dirt, grime, bird droppings, or any other foreign substances. Silts and other fine materials less than 1-inch may be washed into the sill areas and/or navigation lock chamber.

3.5 PINTLE STRUCTURAL REPAIRS AND PINTLE REPLACEMENT

3.5.1 Remove Existing Pintles and Pintle Heels

After the gate leaves have been lifted and/or jacked and moved away to allow access to the pintles, the Contractor shall remove the existing pintles and pintle heels. The pintle heel, bushing, and circular J-seal will still be attached to the bottom of each gate leaf. The pintle ball and collar will be attached to the pintle base after the gate is moved.

The Contractor shall remove all bolts, cap screws and dowels, taking into consideration the instructions and information given in the paragraph above, "Existing Structural Condition". Disconnect and cap the grease supply and return lines. An eye bolt may be installed on the top of each of the existing pintle balls to lift them out of their respective pintle base. The fit between dowels, setscrews and holes as well as between the pintle collar and base plate are very tight machined fits and parts may be corroded together. Contractor shall ensure that the lifting direction is vertical and shall take care to not damage the existing pintle collar or base during removal of the pintle balls. Contractor shall submit a Pintle Removal Plan which details a proposed method to separate the pintle ball from the collar and the collar from the pintle base. The Contractor shall remove the pintle heel from the bottom of each gate leaf by removing the existing bolts and cap screws.

3.5.2 Pintle Structural Repairs

Contractor shall cut an access hole in the gate leaf skin plate and remove structural steel girder web and stiffeners as shown and per notes on sheet SD101. Contractor shall take extreme care to avoid overheating, gouging, bending, or otherwise damaging surrounding structural steel. Prior to removal of girder 39 horizontal web plate, a precise template or bolt hole mapping shall be made indicating the actual locations of the existing bolt holes that connect the pintle heel to the gate. Contractor shall submit the Pintle Heel Template and/or bolt hole mapping for approval prior to performing the work. The Pintle Heel Template shall be referenced to fixed points on the gate and pintle heel so that the template can be fastened to the gate in the correct location. Existing structural steel shall be removed and disposed of or salvaged in accordance with the instructions given on sheets SD101, S-301, S-302, and other sheets as applicable. New structural steel girder web and stiffeners shall be fabricated and installed per the contract drawings. All associated welding and weld repairs shall be performed in accordance with the specifications for welding provided in subsequent paragraphs. Contractor shall submit Structural Repair Fabrication Drawings for review and approval by the Government prior to performing the work. The Structural Repair Fabrication Drawings shall show sizes, shapes, locations, thicknesses, grade and type of materials, and weld types and sizes for the pintle structural repairs.

3.5.3 Install New Pintle Heels

Pintle heels shall be bolted to the gate bottom girder as shown on the contract drawings. It is imperative that the new pintle heel be located in precisely the same location as the old pintle heel. Holes shall be located on the bottom girder by using the pintle heel template described in the previous paragraph. Template hole pattern shall be compared to the hole pattern on the new pintle heel, any discrepancies shall be communicated to the contracting officer. Holes shall be drilled undersized and reamed to provide a Class LN2 fit in accordance with ASME B4.1 . The threads of the bolts shall be entirely outside of the holes. The body diameter of the bolts shall have tolerances as recommended by ASME B4.1 for the specified class of fit. All fasteners and hardware associated with the pintle repairs shall be replaced with new GFP, or with Contractor provided materials where GFP is not provided.

3.5.4 Install New Pintle

Pintles shall be installed as indicated on the drawings and as specified.

Before installing any threaded fasteners into existing parts that will remain in place, the threads shall be cleaned with a thread chaser and all cuttings and debris shall be removed from the holes. Surfaces of the pintle base that will be in contact with the pintle collar shall be cleaned, all rough spots shall be removed, and the surface shall be level and flat to ensure full contact between pintle collar and base. Dowel holes shall be cleaned and holes may need to be reamed oversize and oversized dowels may need to be provided. Machined surfaces shall not be damaged when handling and installing parts. The pintle ball shall be coated with grease prior to setting the gate leaf in place. Where fasteners and hardware are not furnished by the Government, the Contractor shall provide and install the proper fasteners and hardware in accordance with the contract drawings and specifications.

3.6 GUDGEON LINKAGE REPLACEMENT

Fall protection will be required to perform all gudgeon linkage replacement work. The handrails shall not be used as a fall protection measure. Two fall restraint anchorage points are available on the wall on the gudgeon landing. Additional fall protection measures may be necessary.

3.6.1 Remove Existing Gudgeon Linkages and Transducers

After jacking and shoring the gate, the Contractor shall verify that all loads have been removed from the gudgeon linkages before proceeding with the removal process. All grease lines must be disconnected prior to removing the existing gudgeon linkages. Grease lines shall be reinstalled after the new gudgeon linkages are installed. There are existing transducers mounted to the gudgeon anchorages on the south gate leaf. The Contractor shall take all necessary precautions to ensure that these transducers as well as their associated wiring and data acquisition boxes are protected and remain undamaged throughout the duration of this contract. The Contractor shall remove the existing gudgeon linkages and components. As shown on G-401, one existing gudgeon linkage on the south side was installed new in 2014. The Contractor shall salvage this gudgeon linkage and prepare it for reuse per the contract drawings and specifications.

3.6.2 Install Gudgeon Linkages

The gudgeon linkages shall be installed and attached to the gudgeon anchors in the lock walls. Before the gate leaves are lowered onto the new pintles, the Contractor shall ensure that the grease outlet port in the gudgeon pin will align with the center of the grease grooves in the bushing as shown on the contract drawings. The Contractor shall ensure that the COR is present and document the alignment process and procedure, including photographs, in their daily QC reports. After the gate leaves are installed on the pintle and the gudgeon linkages are attached to the gate leaves, the gudgeon linkage shall be adjusted so the center of the gudgeon pin is in vertical alignment with the center of the pintle with the gate in the mitered position and jacked or blocked up to relieve strain in the gudgeon linkage. The gudgeon pin shall be coated with grease before installation. Remove the blocking and swing the gate through the entire range of movement. Adjust the gudgeon linkage as necessary so that after final adjustment, the gate leaf shall swing freely and any point on the moving structure shall remain in a horizontal plane throughout the entire range of movement. The gate shall be blocked or jacked as previously described while in the mitered position when making any adjustments to the gudgeon linkage.

3.7 QUOIN AND MITER CONTACT BLOCK REPLACEMENT

3.7.1 Remove Existing Wall Quoin, Gate Quoin, and Miter Contact Blocks

The Contractor shall remove all quoin and miter contact blocks from the field splice at elevation 547.0 to the bottom of the gate, for each gate leaf. The area behind the existing quoin contact blocks is filled with a zinc filling as shown in the For Information Only drawings. The area behind the existing miter contact blocks is filled with an epoxy filler material. The Contractor will remove the existing filler materials and scrape the surface of the quoin and miter post to a clean, flat surface.

Remnants of filler material that are bonded to the quoin and miter posts shall be ground off so that the the surfaces of the quoin and miter posts are free of irregularities and protrusions that would prevent adequate installation of filler material after the new contact blocks are installed and adjusted.

3.7.2 Replace Wall Quoin, Gate Quoin, and Miter Contact Blocks

The Contractor shall replace all quoin and miter contact blocks from the field splice at elevation 547.0 to the bottom of the gate, for each gate leaf. See FIO drawing I-065 for details of miter and quoin block as-built information. Splices in contact blocks shall be made by an offset method so that there will not be a continuous joint across the block. Splices in gate leaf contact blocks shall occur only at the centerline of horizontal ribs or girders. Contact faces of contact blocks shall be milled at splices to assure watertight joints. Contact blocks shall be installed with new 3/4-inch cap screws as shown on the drawings. Contractor shall align and adjust quoin and miter blocks so that uniform bearing and tight seal is maintained when the gate is in the closed position and loaded hydrostatically. After alignment and proper bearing and sealing has been verified, the Contractor shall fill the space between the contact block mounting surface and the contact blocks with the contact block epoxy filler material specified herein. The Contractor shall submit the proposed method to align and adjust contact blocks and epoxy fill along with the Quoin and Miter Contact Blocks shop drawing submittal.

3.7.3 Install New Epoxy Pour Holes

The existing epoxy pour holes are spaced approximately 30 feet apart vertically in the quoin and miter posts. New pour holes may be drilled into the posts on maximum 5-foot centers. Holes shall be threaded and fitted with standard steel threaded plugs. Contractor shall apply teflon tape to the plug threads prior to installation.

3.7.4 Adjust Quoin and Miter Contact Blocks

After the gate leafs have been set in place on the new pintles and final adjustments to the gudgeon linkages have been made, the Contractor shall adjust the quoin and miter contact blocks so that there is continuous and uniform contact over the full height of the gate leaf when it is in the mitered (closed) position. The Contractor shall use the following procedures to ensure that miter and quoin contact blocks are adjusted to meet the tolerances specified in subsequent paragraphs. Adjusting screws shall be coated with grease or other bond breaker material to prevent adherence of the epoxy filler material. Contractor shall adjust quoin contact blocks first, and adjust miter contact blocks last.

3.7.4.1 Adjust Quoin Contact Blocks

Step 1 - The gate shall be swung so that intersection of the work line of the leaves on centerline of the lock will be 1/4 inch upstream of the theoretical miter (closed) position. With the gate in this position, the miter ends of the leaves shall be jacked or blocked to relieve stress on the gudgeon linkages.

Step 2 - The gate quoin contact blocks shall be adjusted to close contact with the wall quoin seal blocks. Particular care shall be taken to insure that the gate quoin contact block is forcibly wedged against the wall quoin over the lower portion of the quoin to guard against any horizontal thrust due to water load transmitted to the pintle when the gate is in the mitered position.

Step 3 - The blocking shall be removed and the gate swung open to provide at least 1/16 inch clearance between mating quoin contact blocks in order to allow expansion during curing of the epoxy filler material. Expansion is due to heat generated by the epoxy curing process.

Step 4 - The epoxy filler shall be poured in behind the quoin contact blocks in accordance with the specifications provided below.

3.7.4.2 Adjust Miter Contact Blocks

Step 1 - One leaf of the gate shall be set in its mitered position and jacked or blocked to relieve stress in the gudgeon linkages.

Step 2 - The miter contact blocks of this gate leaf shall be set in a true vertical position and epoxy filler shall be poured in behind the contact blocks.

Step 3 - The second gate leaf shall be swung to its mitered position and jacked or blocked to relieve stress in the gudgeon linkages.

The miter contact blocks shall be aligned and adjusted so that close contact is made with the contact blocks of the first gate leaf.

Step 4 - The blocking shall be removed and the second gate leaf swung open to provide at least 1/16 inch clearance between the miter contact blocks in order to allow expansion during curing of the epoxy filler. After blocking is removed and clearance is provided, the Contractor shall fill the area behind the miter contact blocks with epoxy filler as specified.

3.7.5 Tolerances for Contact Block Alignment

The centerline of the quoin contact blocks shall not deviate from the theoretical vertical line of contact by more than 1/16 inch at any point after placement of the epoxy filler. The centerlines of the miter seal blocks shall coincide and shall not deviate from the theoretical vertical line of contact by more than 1/2 inch at any point normal to the centerline of the lock after placing epoxy filler. All joints in quoin and miter contact blocks shall be made flush on the curved, contact side of the blocks.

3.7.6 Placing Epoxy Filler

The manufacturer's instructions and recommendations shall be strictly followed for placing epoxy filler. The Contractor shall submit an Epoxy Filling Plan for review and approval by the Government prior to performing the work. The filler material will be very fluid during installation and will escape through any opening or gap; Contractor shall use sealant or other means to prevent leakage of the filler material during placement.

At the time of placement, steel surfaces that will be in contact with the epoxy filler shall be within the temperature range specified by the epoxy manufacturer. The epoxy filler material shall be kept free of moisture, dust or other foreign materials during mixing and placement and for at least 48 hours after placement.

3.7.7 Final Tightening of Contact Blocks

After the epoxy filler has thoroughly cured, the quoin and miter contact blocks shall be drawn up tight against the filler material by tightening the adjusting bolts. After final tightening, the Contractor shall again verify that the gate leaves swing into the mitered position without interference of the quoin contact blocks. The Contractor shall also verify that the gate quoin contact blocks have uniform bearing and tight contact with the existing lock wall contact blocks.

3.8 GATE DIAGONAL TENSIONING

After installation of new pintles, gudgeon linkages, structural steel, quoin and miter blocks, rubber seals, and after each gate leaf is lowered onto the the pintle balls, the Contractor shall verify alignment of the gate leaves and tension in the diagonals. Due to disassembly and welding of structural steel, the pre-set TENSION in the diagonals will change relative to the "before work" condition. The Contractor shall verify alignment of the gate and tension the diagonals in accordance with the DIAGONAL TENSIONING SEQUENCE attached to this specification. The Contractor shall notify the Government at least 2 weeks prior to starting the gate diagonal tensioning sequence. The Contractor shall carefully monitor and record changes in stress during the diagonal tensioning sequence. After the tensioning process is complete, the Contractor shall remove all strain gages and monitoring equipment and touch-up paint areas where strain gages were welded to the gate. The Contractor shall submit a Gate Diagonal Tensioning Report describing the entire sequence from beginning to end. The report shall include an Executive Summary, Table of Contents, Structural Testing Procedures, Analysis of Data and Verification of Tensions, Notes for Future Diagonal Tensioning Specifications, and Conclusions. The report shall include photos of all electronic and mechanical equipment used and shall also include photos of the tensioning sequence from start to finish. The Contractor shall submit the report within 3 weeks of the date of completion of the diagonal tensioning sequence.

3.9 WELDING

3.9.1 Welding Operations

All welding of new structural steel and repair of cracked welds and cracked base metal performed for this work will be considered fracture critical repair welding as specified in AWS D1.5M/D1.5 , Section 12.17.

Welding of new structural steel and weld repair procedures shall be as indicated on the drawings and as specified herein.

3.9.2 Workmanship Requirements

3.9.2.1 Welding Procedures

Welding procedures 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 D1.1/D1.1M or AWS D1.5M/D1.5 as applicable for the structures being welded. 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.

3.9.2.2 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 D1.5M/D1.5 , Tables, 4.1, 4.2, or 12.1 as applicable. The AWS designation of the electrodes to be used shall be included in the schedule of welding procedures. Only low hydrogen electrodes shall be used for manual shielded metal-arc welding regardless of the thickness of the steel. A controlled temperature storage oven shall be used at the job site as prescribed by AWS D1.5M/D1.5 , Subsection 12.6 to maintain low moisture of low hydrogen electrodes. Controlled temperature storage ovens shall be powered at all times. FCAW filler metal shall be subjected to the storage and handling requirements defined in AWS D1.1/D1.1M or 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 D1.1/D1.1M or AWS D1.5M/D1.5 for all welds. Preheat for fracture critical welds shall be as defined in AWS D1.5M/D1.5 Table 12.3 and in accordance with the PQR/WPS. All AWS D1.5M/D1.5 welds shall be preheated to a minimum of 120 degrees; preheat for thicker weldments shall be increased as specified by AWS D1.5M/D1.5 . 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.

3.9.2.3 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 D1.5M/D1.5 .

(2) Tack and Temporary Welds. Tack and temporary welds required for fabrication and erection shall be made in accordance with AWS D1.1/D1.1M or AWS D1.5M/D1.5 under the controlled conditions prescribed herein for permanent work. All tack and temporary welds that are not be be incorporated into permanent work shall be removed and ground flush with the existing base metal. Tack welds that are to be incorporated into the permanent work shall be subject to the same quality requirements as the permanent welds.

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

(3) Weld 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.

3.10 Nondestructive Testing (NDT)

3.10.1 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 D1.5M/D1.5 , Sections 3 and 9 and all other applicable sections of AWS D1.5M/D1.5 or AWS D1.1/D1.1M .

3.10.1.1 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. All cracks to be repaired shall be tested prior to performing any crack repair work. The testing shall determine the extent of cracking so the correct repair procedure can be performed.

All new structural welds and completed crack repairs shall be tested to ensure no crack remains. 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 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. Certified Weld Inspectors (CWI) for repairs to the gate structural steel shall be qualified and certified in accordance with the provisions of AWS QC1 and shall be familiar with AWS D1.5M/D1.5 fracture critical member inspection as required in AWS D1.5M/D1.5 Section 12.16. Provide an AWS Certified Welding Inspector (CWI) as the primary point of contact for quality control of welding for gate structural repairs. When several CWI and NDT technicians are working, one primary individual shall be designated as having primary responsibility for all quality control in accordance with AWS D1.5M/D1.5 section 6.1.2.2. The CWI who serves as the primary point of contact shall obtain the AWS D1.5M/D1.5 Bridge Code Endorsement and/or achieve certification as a AWS Senior Certified Welding Inspector (SCWI). Non-certified inspectors and certified associate welding inspectors (CAWI) shall not be used for inspection under these specifications. The laboratory and all personnel performing nondestructive testing shall be qualified as specified.

Only individuals qualified for NDT Level II or Level III may perform nondestructive testing. The Level III NDT inspector who supervises all NDT shall posses a currently valid American Society for Nondestructive Testing (ASNT) Level III certificate for each of the processes for which they are qualified.