W912EF-17-B-0001_Amend-0002_TechSpec.pdf

McNary Nav-Lock D/S Gate 2017 Interim Repairs W912EF-17-B-0001 Amend-0002

SECTION TABLE OF CONTENTS

DIVISION 05 - METALS

SECTION 05 50 03.00 28

GUDGEON LINKAGE

PART 1 GENERAL

1.1 REFERENCES

1.2 SUBMITTALS

1.3 WELDING

1.4 DEWATER THE WORK AREA

1.5 MITER GATE INSPECTION

PART 2 PRODUCTS

2.1 FABRICATION

2.1.1 Machine Work

2.1.1.1 Finished Surfaces

2.1.1.2 Unfinished Surfaces

2.1.1.3 Pin Holes

2.1.2 Miscellaneous Provisions

2.1.2.1 Lubrication

2.1.3 EPOXY ADHESIVE ANCHORS

2.1.3.1 Nonshrink Grout

2.1.4 Rebar Scanner

2.2 NONDESTRUCTIVE TESTING

2.3 BOLTS, NUTS, AND WASHERS

2.4 KEEPER BARS

2.5 BUMPERS AND FENDERS

2.6 Vulcanizing

PART 3 EXECUTION

3.1 WORKMANSHIP

3.2 INSTALLATION

3.2.1 Alignment and Setting

3.3 PATCHING CONCRETE

3.4 PROTECTION OF FINISHED WORK

3.4.1 Machined Surfaces

3.5 TOUCH-UP PAINITNG

3.5.1 Preparation for Touch-up Painitng

3.5.2 Method of Paint Application

3.6 RUBBER SEAL INSTALLATION

3.7 COAL TAR REMOVAL AND REPAINTING

3.7.1 Wastewater

3.7.2 Coal Tar

3.7.3 Primer

3.7.4 Painting

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SECTION 05 50 03.00 28

GUDGEON LINKAGE

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 WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2008) Structural Welding Code - Steel

ASME INTERNATIONAL (ASME)

ASME B4.1 (1967; R 2004) Preferred Limits and Fits for Cylindrical Parts

ASME B46.1 (2002) Surface Texture (Surface Roughness, Waviness and Lay)

ASTM INTERNATIONAL (ASTM)

ASTM A 325 (2004b) Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength

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

ASTM A1011/A1011M (2014) Standard Specification for Steel, Sheet, and Strip, Hot-Rolled, Carbon, Structural, High-Strength Low-Alloy and High-Strength Low-Alloy with Improved Formability and Ultra-High Strength

ASTM A563M (2007; R 2013) Standard Specification for Carbon and Alloy Steel Nuts (Metric)

ASTM F436 (2011) Hardened Steel Washers

SOCIETY FOR PROTECTIVE COATINGS (SSPC)

SSPC SP 1 (2015) Solvent Cleaning

1.2 SUBMITTALS

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

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

SECTION 05 50 03.00 28

SD-01 Preconstruction Submittals

Bracing, Jacking and Shoring Plan ; G, ST

Seal Installation Inspector ; I, ST

Boring Procedure ; G, ME

SD-03 Product Data

Epoxy Adhesive Anchors ; G, ST

SD-07 Certificates

Seal Installation Inspection Document ; I, ST

Proof Of Training And Qualification

SD-08 Manufacturer's Instructions

Vulcanizing ; I, ST

1.3 WELDING

All welding performed by the Contractor shall be performed in accordance with AWS D1.1/D1.1M and include off site fabrication.

1.4 DEWATER THE WORK AREA

The Government will set the stoplogs and unwater the lock chamber so the Contractor can access the work area in the lock. The seals on the downstream stoplogs leak and water will run over the concrete gate sill in the work area. The Contractor shall install sandbags to contain the water leakage and either pump the water over the stoplog 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.

1.5 MITER GATE INSPECTION

The Contractor shall provide access for a Government inspection of the full height of the miter gate. The Government inspection shall occur within the first full work week of the outage and the Contractor shall allow two 10 hour days for the inspection to occur. The inspection will require hands-on access to both sides of the entire miter gate. Contractor shall provide a crane, crane operator and manbasket or other appropriate means of inspection access.

PART 2 PRODUCTS

2.1 FABRICATION

2.1.1 Machine Work

Tolerances, allowances and gauges for metal fits between plain, non-threaded, cylindrical parts shall conform to ASME B4.1 for the class of fit shown or required unless otherwise shown on approved detail drawings. Where fits are not shown they shall be suitable as approved.

SECTION 05 50 03.00 28

Tolerances for machine-finished surfaces designated by non-decimal dimensions shall be within 1/64 inch . Sufficient machining stock shall be allowed on placing pads to ensure true surfaces of solid material.

Finished contact or bearing surfaces shall be true and exact to secure full contact. Journal surfaces shall be polished and all surfaces shall be finished with sufficient smoothness and accuracy to ensure proper operation when assembled. Parts entering any machine shall be accurately machined and all like parts shall be interchangeable except that parts assembled together for drilling or reaming of holes or machining will not be required to be interchangeable with like parts. All drilled holes bolts shall be accurately located.

2.1.1.1 Finished Surfaces

Surface finishes indicated or specified shall be in accordance with ASME B46.1 . Values of required roughness heights are arithmetical average deviations expressed in microinches . These values are maximum. Lesser degrees will be satisfactory unless otherwise indicated. Compliance with surface requirements shall be determined by sense of feel and visual inspection of the work compared to Roughness Comparison Specimens in accordance with the provisions of ASME B46.1 . Values of roughness width and waviness height shall be consistent with the general type of finish specified by roughness height. Where the finish is not indicated or specified it shall be that which is most suitable for the particular surface, provide the class of fit required and be indicated on the detail drawings by a symbol which conforms to ASME B46.1 when machine finishing is provided. Flaws such as scratches, ridges, holes, peaks, cracks or checks which will make the part unsuitable for the intended use will be cause for rejection.

2.1.1.2 Unfinished Surfaces

All work shall be laid out to secure proper matching of adjoining unfinished surfaces unless otherwise directed. Where there is a large discrepancy between adjoining unfinished surfaces they shall be chipped and ground smooth or machined to secure proper alignment. Unfinished surfaces shall be true to the lines and dimensions shown and shall be chipped or ground free of all projections and rough spots. Depressions or holes not effecting the strength or usefulness of the parts shall be filled in an approved manner.

2.1.1.3 Pin Holes

Pin removal shall be completed without any damage to the existing gudgeons. Gudgeons are fracture critical members (FCM) and therefore shall be handled with care. Gudgeon anchor plates shall be trapped, supported and anchored down to permit the pin to be removed without inducing bending loads on the anchor plates. Welding of any kind is prohibited on the gudgeon assembly. Pin holes shall be bored true to gauges, smooth, straight and at right angles to the axis of the member.

The boring shall be done after the member is securely fastened in position. The Contractor shall supply a boring machine support bracket that mounts externally to the gudgeon assembly and shall not interfere with existing strain gauge equipment. Contractor shall submit a boring procedure prior to any work being done onsite.

2.1.2 Miscellaneous Provisions

2.1.2.1 Lubrication

The arrangement and details for lubrication shall be as shown. Before erection or assembly all bearing surfaces shall be thoroughly cleaned and lubricated with an approved lubricant.

2.1.3 EPOXY ADHESIVE ANCHORS

Epoxy anchors shall be suitable for underwater application. Nuts and washers shall be provided per manufacturer recommendation. Anchor diameters and embedment lengths shall be required to meet design parameters. Total anchor length shall be as recommended by the manufacturer for proper installation. The Contractor shall submit epoxy adhesive anchors, which includes the manufacturer's literature describing the epoxy adhesive and rod materials, hole drilling and cleaning, preparation, installation, and curing recommendations. Submittal shall also include any proposed variations from the manufacturer's recommendations and any site-specific actions necessary for proper installation.

2.1.3.1 Nonshrink Grout

Grout shall be a commercially available prepackaged material. The use of metallic iron in the grout will not be acceptable. Prepackaged non-shrink grout shall be either a gas-liberating or expansive-cement type of material needing only the addition of water and consisting of a commercial formulation suitable for the application proposed and meeting the requirements in ASTM C1107/C1107M .

2.1.4 Rebar Scanner

The contractor shall not damage existing rebar. Use a rebar scanner capable of scanning up to 6 inches prior to drilling anchor holes. If rebar is encountered offset hole to avoid rebar. If an anchor bolt hole is abandoned or no longer used it shall be filled with an approved grout.

2.2 NONDESTRUCTIVE TESTING

When doubt exists as to the soundness of any material part such part may be subjected to any form of nondestructive testing determined by the Contracting Officer (KO). This may include ultrasonic, magnaflux, dye penetrant, x-ray, gamma ray or any other test that will thoroughly investigate the part in question. The cost of such investigation will be borne by the Government. Any defects will be cause for rejection and rejected parts shall be replaced and retested at the Contractor's expense.

2.3 BOLTS, NUTS, AND WASHERS

All bolts shall be high strength and conform to ASTM A 325 . Carbon steel nuts shall conform to ASTM A563M. Washers shall conform to ASTM F436.

2.4 KEEPER BARS

Keeper bars shall be made of ASTM A1011/A1011M Type B as shown on the contract drawings.

2.5 BUMPERS AND FENDERS

Bumper and Fenders timbers shall be Douglas Fir graded as Select Structural. Bumpers and fenders shall be cut, beveled, or bored as required for installation. Timbers will remain untreated.

2.6 Vulcanizing

Submit the Seal Manufacture recommended vulcanizing requirements prior to vulcanizing.

Seal Manufacture is:

SEALS UNLIMITED, INC.

23050 NW JACOBSON RD

HILLSBORO OR 97124-9328

Point of Contact is:

Scott Birch 503-726-7962 scott.birch@sealsunlimited.com

PART 3 EXECUTION

3.1 WORKMANSHIP

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

3.2 INSTALLATION

The gate leaves will require jacking and shoring support during the replacement of the gudgeon pins. Contractor shall submit a bracing, jacking and shoring plan a minimum of 30 calendar days prior to beginning on-site construction. Plan shall include all required components and procedures to secure the gate while all boring and pin replacement operations take place. Shoring will require attachment to the top and bottom of the gate leaves by bolting. The top connection points are suggested to be located in the gate structure where the vertical 21WF62 beams connect to rib 1. Anchor points connecting the shoring to the concrete shall be designed for a concrete compressive strength of 3000 psi .

At the completion of the work, all bolt holes on the gate shall be filled with pretensioned structural bolts. Jacking points on the bottom of the gate leaves shall be centered on the 27WF177 enpost and/or the vertical 21WF62 members. Bearing plates between the jacks and the bottom of the concrete shall be designed for a compressive strength of 3000 psi .

Bracing, jacking and shoring plan shall be designed by a licensed Professional Engineer, include all calculations and engineer qualifications with the plan. Work cannot commence until this plan has been approved by the Government.

All parts to be installed shall be thoroughly cleaned. Packing compounds, rust, dirt, grit and other foreign matter shall be removed. Bolts shall be tightened firmly and uniformly but care shall be taken not to overstress the threads. Threads of all bolts and nuts shall be lubricated with an approved lubricant before assembly. Driving and drifting bolts or keys will not be permitted.

No welding is permitted on the Gudgeon eye bar or embedded Gudgeon frame.

3.2.1 Alignment and Setting

Each machinery or structural unit shall be accurately aligned by the use of steel shims or other approved methods so that no binding in any moving parts or distortion of any member occurs before it is fastened in place.

The alignment of all parts with respect to each other shall be true within the respective tolerances required.

3.3 PATCHING CONCRETE

All anchors installed to secure shoring of gate leaves shall be removed after completion of work to a depth of 3 inches. Use the non-shrink grout specified here-in for patching of anchor holes.

3.4 PROTECTION OF FINISHED WORK

3.4.1 Machined Surfaces

Machined surfaces shall be thoroughly cleaned of foreign matter. All finished surfaces shall be protected by suitable means. Unassembled pins and bolts shall be oiled and wrapped with moisture resistant paper or protected by other approved means. Finished surfaces of ferrous metals to be in bolted contact shall be washed with an approved rust inhibitor and coated with an approved rust resisting compound for temporary protection during fabrication, shipping and storage periods. Finished surfaces of metals which shall be exposed after installation except corrosion resisting steel or nonferrous metals shall be painted as specified.

3.5 TOUCH-UP PAINITNG

All ferrous surfaces that have paint removed, damaged or disturbed as the result of the work covered in this contract shall be repaired by touch-up painting. All new ferrous components shall be painted as specified below.

1st COAT 2nd COAT

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

3.5.1 Preparation for Touch-up Painitng

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

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

3.5.2 Method of Paint Application

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

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

3.6 RUBBER SEAL INSTALLATION

Contractor shall acquire the services of an experienced seal installation inspector from the seal manufacturer. Installation inspector shall be responsible for ensuring that the seal is installed in accordance with the guidelines of the seal manufacturer. Contractor shall submit proof of experience of seal installation inspector .The seal installation inspector shall submit a seal installation inspection document indicating the seals were installed per the manufactures requirements. All J seal vulcanized splices shall be performed under the guidance of the seal installation inspector. Contractor shall be trained and qualified by the seal manufacturer to perform required splicing and vulcanizing of the rubber seals. Contractor shall submit proof of training and qualification by the seal manufacturer 30 calendar days prior to performing splicing and vulcanizing of the rubber seals for this contract.

3.7 COAL TAR REMOVAL AND REPAINTING

The Contractor shall remove all existing coal tar and coal tar primer from the bottom seals assembles on both Downstream Miter Gate Leaves.

Acceptable removal of the coating system is defined as the removal of all visible coal tar and primer coats, in addition to any chemical residue resulting from its adhesion to the structural steel members. Bare steel is required to permit structural inspections.

3.7.1 Wastewater

All wastewater generated from the removal of the Coal Tar must be contained and disposed of offsite in accordance with section 01 57 20.00 28

ENVIRONMENTAL PROTECTION.

3.7.2 Coal Tar

The existing coal tar material was applied to the gate structure in 1949 and does not contain greater than 1% asbestos. The coal tar was originally manufactured to meet the requirements of American Water Works Association Specification 7A-5-1940. The coal tar was hot-applied to a minimum thickness of 3/32-inch and is anticipated to have a maximum thickness of 1-inch. The most recent experience with this material indicated that it is brittle throughout its full thickness and has a wrinkled irregular surface. The Contractor shall install suitable containment measures to protect the immediate and adjacent areas on the gate structure and Navigation Lock floor from spills, drips, and contamination from the removal activities. Special care shall be taken to prevent chemicals, materials, debris, etc. from entering existing joints, SECTION 05 50 03.00 28 cracks, openings, drains, culverts, etc. inside the Navigation Lock Chamber.

3.7.3 Primer

The existing primer material includes a coal tar pitch primer. The coal tar primer was originally manufactured to meet the requirements of American Water Works Association Specification 7A-5-1940.

3.7.4 Painting

After completion of coal tar removal, inspection, and repairs, all bare metal surfaces (surfaces of which coal tar paint has been removed and crack repair locations) shall be painted as specified herein.

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