A.07.24_Amend-0002_Section_05_50_05.00_26.pdf

LGA Turbine Maintenance Platform W912EF-17-R-0010 Amend - 0002

SECTION TABLE OF CONTENTS

DIVISION 05 - METALS

SECTION 05 50 05.00 26

TURBINE MAINTENANCE PLATFORM

PART 1 GENERAL

1.1 REFERENCES

1.2 SUBMITTALS

1.3 WORK PLAN

1.4 DETAIL DRAWINGS

1.5 SPARE PARTS

1.6 FABRICATION REQUIREMENTS

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Materials Orders

2.1.2 Materials List

2.1.3 Shipping Bill

2.1.4 Aluminum Sheet and Plate

2.1.5 Aluminum Extrusions

2.1.6 Aluminum Structural Shapes

2.1.7 Steel Properties

2.1.8 HSS Steel Properties

2.1.9 Corrosion Resistant (Stainless) Steel Properties

2.1.10 Steel Pipe

2.1.11 Steel Bolts, Nuts, and Washers

2.1.12 Plywood

2.1.13 Marine Adhesive

2.1.14 Turnbuckles

2.1.15 Shackles

2.1.16 Swivel Hook

2.1.17 Swivel Hoist Ring

2.1.18 Wire Rope Assembly

2.1.19 Hatch

2.1.20 Nameplate

2.1.21 Fixed Ladder

2.1.22 Carts for Turbine Maintenance Platform Storage

2.1.23 Self Retracting Lifeline

2.1.24 Safety Netting

2.1.25 Locking Pins

2.1.26 Outer Rim Blocking

2.1.27 Grip Hoists

2.1.28 Brass Threaded Plugs

2.1.29 Air Powered Chain Hoist

2.1.30 Sheave

2.1.31 Blade Scaffolding Modification

2.2 FABRICATION

2.2.1 Structural Fabrication

2.2.1.1 Fabrication Tolerances

SECTION 05 50 05.00 26 - Page 1 g4edddca Line

2.2.1.2 Dimensional Tolerances for Structural Work

2.2.1.3 Structural Aluminum Fabrication

2.2.2 Welding and Non-Destructive Examination of Weldments

2.2.3 Bolted Connections

2.2.3.1 Bolted Structural Steel Connections

2.2.3.2 Bolted Aluminum Connections

2.2.3.3 Bolts In Contact With Aluminum

2.2.4 Bolt Installation

2.2.5 Machine Work

2.2.5.1 Finished Surfaces

2.2.5.2 Unfinished Surfaces

2.2.5.3 Pin Holes

2.2.6 Zinc Coatings

2.2.7 Part Labels

PART 3 EXECUTION

3.1 ASSEMBLY

3.2 PROTECTION OF FINISHED WORK

3.2.1 Machined Surfaces

3.2.2 Aluminum

3.3 QUALITY CONTROL

3.3.1 Pontoon Weight and Floatation Test

3.3.2 Control Dimensions

3.3.3 Final Inspection and Load Test

3.3.3.1 Shop Assembly and Load Testing

3.3.3.2 Load Test

3.3.3.3 Repair and Non-Destructive Examination (NDE)

3.4 ON-SITE ASSEMBLY SERVICES

3.5 ASSEMBLY INSTRUCTIONS AND AS-FABRICATED DRAWINGS

-- End of Section Table of Contents --

SECTION 05 50 05.00 26 - Page 2

SECTION 05 50 05.00 26

TURBINE MAINTENANCE PLATFORM

PART 1 GENERAL

Fabricate, load test, and deliver one new complete turbine maintenance platform (TMP) for the Little Goose main unit turbines ready for installation as shown in the Contract drawings. Fabricate, deliver, and load test a draft tube access platform (DTP); and detail, fabricate, and deliver new transport/storage cart(s) on which to store the turbine maintenance platform components. Modify one existing Blade Scaffolding as shown. All items herein pertain to one complete TMP and DTP inclusive rigging and appurtenances as shown. This job includes, but is not limited to: the platforms, decking, ladder, hardware needed for installation, and transport carts. Deliver all fabricated items complete to Little Goose Lock and Dam.

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.

ALUMINUM ASSOCIATION (AA)

AA ADM (2015) Aluminum Design Manual

AMERICAN SOCIETY OF SANITARY ENGINEERING (ASSE)

ANSI/ASSE Z359 (2007; R2012, 2011, 2009) Fall Protection Code

AMERICAN WELDING SOCIETY (AWS)

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

APA - THE ENGINEERED WOOD ASSOCIATION (APA)

APA L870 (2010) Voluntary Product Standard, PS 1-09, Structural Plywood

ASME INTERNATIONAL (ASME)

ASME B30.26 (2010) Rigging Hardware

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

ASME B46.1 (2009) Surface Texture, Surface Roughness, Waviness and Lay

ASME HST-5 (2014) Performance Standard for Air Chain Hoists

SECTION 05 50 05.00 26 - Page 3

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM A123/A123M (2013) Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products

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

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

ASTM A325 (2010; E 2013) Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength

ASTM A36/A36M (2012) Standard Specification for Carbon Structural Steel

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

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

ASTM A563 (2007a; R2014) Standard Specification for Carbon and Alloy Steel Nuts

ASTM A780/A780M (2009) Standard Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings

ASTM B209 (2010) Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate

ASTM B221 (2013) Standard Specification for Aluminum and Aluminum-Alloy Extruded Bars, Rods, Wire, Profiles, and Tubes

ASTM B308/B308M (2010) Standard Specification for Aluminum-Alloy 6061-T6 Standard Structural Profiles

ASTM B633 (2013) Standard Specification for Electrodeposited Coatings of Zinc on Iron and Steel

ASTM D962 (1981; E 2008; R 2008) Aluminum Powder and Paste Pigments for Paints

ASTM F1145-05 (R 2011) Standard Specification for Turnbuckles, Swaged, Welded, Forged

ASTM F436 (2011) Hardened Steel Washers

SECTION 05 50 05.00 26 - Page 4

U.S. ARMY CORPS OF ENGINEERS (USACE)

EM 385-1-1 Safety and Health Requirements Manual

U.S. GENERAL SERVICES ADMINISTRATION (GSA)

FS RR-C-271F (Rev F) Chains and Attachments, Carbon and Alloy Steel

U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)

29 CFR 1910 Occupational Safety and Health Standards

29 CFR 1910.27 Fixed Ladders

1.2 SUBMITTALS

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

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Work Plan; G HDC

On-Site Assembly Schedule; G HDC

Pre-fabrication Meeting; G HDC

SD-02 Shop Drawings

Detail Drawings; G, HDC Detail Drawings -TMP Substructure (Pontoon, Beams, Connectors); G, HDC

Detail Drawings - TMP Decking; G, HDC Detail Drawings - DTP; G, HDC Detail Drawings - DT Personnel Hoist; G, HDC Detail Drawings - Blade Scaffold Modification and Scroll Case Stair;

G, HDC

Detail Drawings - Carts; G, HDC Detail Drawings - All remaining fixtures and appurtenances; G, HDC Detail Drawings - Assembly and Rigging; G, HDC

Detail drawings for metalwork, machine work, and rigging assemblies prior to fabrication or procurement.

Nameplate; G HDC

SD-03 Product Data

Load Test Apparatus; G HDC

Materials Orders; G HDC

Copies of purchase orders, mill orders, mill certifications, shop orders and work orders for materials, prior to the use of the

SECTION 05 50 05.00 26 - Page 5 materials in the work.

Materials List; G HDC

Materials list for fabricated items, at the time of submittal of detail drawings.

Plywood Marine Adhesive; G HDC Turnbuckles; G HDC Shackles; G HDC Swivel Hook; G HDC Swivel Hoist Ring; G HDC Wire Rope Assembly; G HDC Self Retracting Lifeline; G HDC Safety Netting; G HDC Locking Pins; G HDC Grip Hoists; G HDC Air Powered Chain Hoist; G HDC Sheave; G HDC

SD-06 Test Reports

Pontoon Weight and Floatation Test; G HDC

Load Test; G HDC

SD-07 Certificates

Qualified Person for Fall Protection

Competent Assembly Specialist

SD-08 Manufacturer's Instructions

Assembly Instructions; G HDC

SD-11 Closeout Submittals

Shipping Bill; G HDC

1.3 WORK PLAN

Submit a work plan for Government approval 30 days prior to start of work indicating the timeline of work and describing in sufficient detail the following items at minimum:

a. Means and methods used to separate ferrous from non-ferrous fabrication preventing contamination of aluminum weldments with ferrous and other deleterious materials.

b. Safety measures complying with EM 385-1-1 including methods and equipment to be used during execution of work on-site.

c. Work Schedule Show all critical tasks needed to complete the work, duration for each work task, and work task sequencing. Show shop drawing submittals, pre-fabrication meeting, critical hold points, load test dates, delivery dates.

d. Shop Assembly and NDE. Pertains to all work items within this

SECTION 05 50 05.00 26 - Page 6 contract including but not limited to turbine maintenance platform, rigging, netting, plywood extensions, draft tube maintenance platform, ladder, storage carts.

e. Shop Load Test. Includes turbine maintenance platform (TMP), rigging, netting, draft tube access platform (DTP), ladder. Inclusive all information regarding methods, fixtures used to support the turbine maintenance platform during the load test and the methods and materials used to apply the test load.

f. Site Access and Protection of Work.

1.4 DETAIL DRAWINGS

Submit detail drawings for metalwork and machine work, prior to fabrication, include within the detail drawings catalog cuts, templates, fabrication and assembly details, and type, grade, and class of material as appropriate. For elements of fabricated items inadvertently omitted on Contract drawings, provide and indicate the missing detail on the detail drawings. Cloud any discrepancies with the contract drawings and identify reason for discrepancy and suggested resolution. Detail drawings must be submitted and approved prior to commencing fabrication. Break the detail drawing submissions into the following major sub-assemblies and submit separately:

a) Detail Drawings -TMP Substructure (Pontoon, Beams, Connectors)

b) Detail Drawings - TMP Decking

c) Detail Drawings - DTP

d) Detail Drawings - DT Personnel Hoist

e) Detail Drawings - Blade Scaffold Modification and Scroll Case Stair

f) Detail Drawings - Carts

g) Detail Drawings - All remaining fixtures and appurtenances

h) Detail Drawings - Assembly and Rigging

1.5 SPARE PARTS

Frunish and deliver spare parts to the site, suitably packaged for long-term protection and storage. Label the packaging legibly to identify the spare parts. Furnish spare parts of the same material and workmanship, which meet the same requirements, and are interchangeable with the corresponding original parts furnished for systems as outlined in this Section. Furnish spare parts which conform to the drawings and include at a minimum:

Spares Furnished Per Complete Platform Set

- 1 inner gate beam

- 1 perimeter beam with associated brackets

- 1 middle beam with associated pinning bracket

- 1 radial beam with associated brackets

- 1 swivel hoist ring

- 1 swivel hook

SECTION 05 50 05.00 26 - Page 7

- 1 7/8 inch jaw and jaw end turnbuckle

- 1 hub attachment fixture- 5 tapered Beam Pins with cotter pins.

- 3 tapered Gate Beam Pin with cotter pin

- 50 bolt assemblies inclusive bolt, nut, washer for the turbine maintenance platform (TMP).

- 4 bolt assemblies inclusive bolt, nut, washer for the draft tube access platform (DTP).

- 30 stainless steel 3/8-inch diameter locking pins having 4 inches usable length

- 12 brass threaded plugs

1.6 FABRICATION REQUIREMENTS

Additional requirements for fabrication are as follows:

a. Contractor is required to weld a full scale prototype of a pontoon for the Turbine Maintenance Platform as shown on the drawings. If the full scale pontoon prototype is found to be of acceptable quality, the Contractor may be permitted to incorporate it into the final product.

Contractor is required to weld a representative prototype analog for one gate beam, and a decking panel for the Turbine Maintenance Platform as shown on the drawings. Prior to fabrication of any full scale prototype intended for incorporation into the final product, detail drawings for the prototypes must be submitted and approved and all necessary weld procedures and welder qualification must be complete.

b. Following approval of Contractor prepared shop drawings and the completion of the protype weldments, schedule an Pre-fabrication Meeting at the fabrication site. At minimum, detail drawings for all sub-assemblies a, b, c, and d must be submitted and have received a C code or better prior to the Pre-fabrication meeting. The Contractor, the Contractor's third party Certified Weld Inspector(s) (CWI), and person(s) directly responsible for fabrication are required to be present. Government personnel attending will be at minimum; the Contracting Officer's Representative (COR), the engineer of record, and the government quality assurance specialist (CWI). The meeting will cover at minimum: feasibility of all welds and detailing; clarity of weld symbols; possible detailing improvements for ease of fabrication; methods that are to be used to prevent distortion and to control temperatures; methods and means to prevent contamination; and storage of all materials and tooling needed to accomplish the work.

c. Utilize Gas Tungsten Arc Welding (GTAW) to fabricate all weldments consisting of 1/8th and thinner thicknesses of plate. Gas Metal Arc Welding (GMAW) processes may be utilized pending Contractor's sucessful demostration of welding design weld sizes. Success will be measured in terms of welding no more than 1/16-inch over design size in no more than two of 12-inches.

d. Contractor is not released to fabricate until receipt of written notice from the Government following the Pre-fabrication meeting and

SECTION 05 50 05.00 26 - Page 8 approval of detail drawings, weld procedures and welder qualifications.

e. Inspect formed items for cracking or defect prior to incorporating into welded fabrication.

g. Contractor QC Specialist is required to be present at fabrication facility during weld production and must be authorized to stop practices impacting quality.

h. Store aluminum materials intended for incorporation into the final product in such a manner as to prevent contamination with ferrous materials and prevent any alteration of the mechanical properties of the material.

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Materials Orders

Furnish five copies of purchase orders, mill orders, shop orders, and work orders for all materials orders prior to the use of the materials in the work. Where mill tests are required, purchase orders include the test site address and the name of the testing agency.

2.1.2 Materials List

Submit a list of the materials to be used in the fabrication of each item at the time of submittal of detail drawings.

2.1.3 Shipping Bill

Submit 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 item, the number of items,weight per box, pallet or combined package to be lifted, and the total weight. Promptly mail duplicate copies of shipping bills to Amanda Collins at Little Goose Lock and Dam, US Army Corps of Engineers, 1001 Little Goose Dam Road, Dayton, Washington, 99328.

2.1.4 Aluminum Sheet and Plate

Provide aluminum sheet and plate which complies with ASTM B209, 6061-T6, or 5052 H32 in locations as shown on the drawings.

2.1.5 Aluminum Extrusions

Provide aluminum extrusions which comply with ASTM B221, 6061-T6 in locations as shown on the drawings.

2.1.6 Aluminum Structural Shapes

Provide aluminum structural shapes which comply with ASTM B308/B308M .

2.1.7 Steel Properties

Provide steel meeting the requirements of ASTM A36/A36M Grade 50 steel and galvanized as per ASTM A123/A123M following fabrication.

SECTION 05 50 05.00 26 - Page 9

2.1.8 HSS Steel Properties

Provide ASTM A500/A500M Grade B for square or rectangular hollow structural sections (HSS) and galvanized as per ASTM A123/A123M following fabrication.

2.1.9 Corrosion Resistant (Stainless) Steel Properties

Provide corrosion resistant (stainless) steel meeting the requirements of ASTM A276/A276M type 304.

2.1.10 Steel Pipe

ASTM A53/A53M, Grade B, black or galvanized (final weldment for pins to be hot dip galvanized), nominal size and weight class or outside diameter and nominal wall thickness as shown, plain ends.

2.1.11 Steel Bolts, Nuts, and Washers

Provide galvanized steel bolts meeting the criteria of ASTM A325 , washers meeting ASTM F436 Type 1, and nuts meeting ASTM A563.

2.1.12 Plywood

C-D Grade, Exterior Exposure durability classification, Span rating of 24/16 or greater, thickness of 1/2 inch. Mark each sheet with the mark of a recognized association or independent inspection agency that maintains continuing control over the quality of the plywood and which identifies the plywood by species group or span rating, exposure durability classification, grade, and compliance with APA L870 .

2.1.13 Marine Adhesive

Provide marine adhesive/sealant which is one part moisture cured polyurethane polymer capable of bonding with aluminum. Surface preparation, primer, application, cure time and temperature must be as per manufacturer's printed instructions. A product complying with these requirements is 3M Marine Adhesive/Sealant Fast Cure 5200 as manufactured by 3M Marine, phone 1-877-366-2746.

2.1.14 Turnbuckles

Provide turnbuckles which are galvanized 7/8 inch thread by 12 inch adjustment jaw and jaw end turnbuckles rated for a working load limit of 7,200 lbs, or better, and safety factor = 5. Turnbuckles are required to be "Crosby HG-228 Series", or approved equal, meeting ASTM F1145-05 and ASME B30.26 with center to center of 3/4 inch diameter pins measuring approximately 22 inches at minimum and 35 inches at maximum adjustment.

Quantity six turnbuckles are required per each turbine maintenance platform.

2.1.15 Shackles

Provide shackles which are galvanized 5/8 inch nominal size with 3/4 inch diameter screw pin. Shackles are required to be rated for a working load limit of 3.25 ton, or better, and safety factor = 6. The shackles are required to be "Crosby G-209 Series", or approved equal, meeting FS RR-C-271F , Type IVA, Grade A, Class 2 and ASME B30.26 . Quantity twelve shackles are required per each turbine maintenance platform.

SECTION 05 50 05.00 26 - Page 10

2.1.16 Swivel Hook

Provide swivel hooks which are an alloy steel of 3/4 inch nominal size, capable of rotating when not under load, and supplied with a latch assembly. Swivel hooks are required to be rated for a working load limit of 5 Ton, or better, and minimum safety factor = 4. The swivel hooks are required to be "Crosby L-322 AN Series", or approved equal, meeting certification in accordance with ABS 2007 Steel Vessel Rules 1-1-17.7 and ABS Guide for Certification of Cranes. Quantity six swivel hooks are required per each turbine maintenance platform.

2.1.17 Swivel Hoist Ring

Provide swivel Hoist Rings rated for 5,000 pound working load at a safety factor = 5. Swivel hoist rings are required to be "Crosby HR-125 Series" frame size 2, or "Carr-Lane CL-5000-SHR-1", or approved equal, with 3/4 inch-10 UNC Grade 8 bolt having minimum 0.95 inch to maximum 1.3 inch thread projection length for anchoring purposes. Quantity six swivel hoist rings are required to secure each turbine maintenance platform plus on addtional swivel hoist ring used to secure SRL to DT liner. Drill and tap of holes in the draft tube liner for the swivel hoist rings are by others.

2.1.18 Wire Rope Assembly

Wire rope assemblies shall be made using 5/8 inch galvanized IWRC wire rope, 6x19 strands or better, meeting FS RR-W-410 and rated for minimum

3.0 ton working load at safety factor = 5, and shall measure 22-inches for inboard rigging and 34-inches for outboard rigging from eye to eye. These assemblies shall consist of two eye ends complete with standard 5/8 inch galvanized thimbles ("Crosby G-411 Series"), or approved equal, meeting FS FF-T-276B, Type II, and having mechanical spliced and swaged end connections. This entire wire rope assembly shall meet minimum 30,000 pound breaking strength requirement and the vendor shall provide proof that each assembly was load tested to 6000 lbs. Quantity six wire rope assemblies of each length are required for a total of 12 wire rope assemblies.

2.1.19 Hatch

Provide aluminum hatch as shown. Provide hatch completely assembled with hinges similar to those shown capable of opening more than 120 degrees such that hatch opening is not impeded by hatch components. Secure the hinges with a minimum amount of bolts such that the hinges can be easily removed and the hatch cover used as a simple hatch cover. Hatch cover action must be smooth through its entire range with an operating pressure of approximately 30 pounds. Hatch cover must be level with surrounding decking when in the closed position and have no projections or holes that could constitute a tripping hazard. Provide hatch cover with a non-skid surface.

2.1.20 Nameplate

Submit nameplates for Little Goose Turbine Maintenance Platform and the Draft Tube Door Access Platform for approval as part of the detail drawings. Upon approval, fabricate and permanently affix nameplates to the respective platforms in a location as approved by the COR. The nameplate

SECTION 05 50 05.00 26 - Page 11 is required to list the name of the platform, the platform weight fully assembled, the maximum distributed live load equal to 25 psf, the maximum live load carrying capacity of 12,000 pounds for the Turbine Maintenance Platform and 750 pounds for the Draft Tube Door Access Platform, the name of the fabricator, and the date (month and year) of manufacturer. The nameplate must be legible with letters at least 3/8 inch in height and made of durable material that is inert when in contact with the aluminum scaffold material. Attach the nameplate in a visible location using inert fasteners or alternate method not susceptible to galvanic corrosion.

Submit nameplate for Little Goose Draft Tube Hoist for approval. Upon approval, fabricate and permanently affix nameplate the hoist frame in a location as approved by the COR. The nameplate is required to list the following information. DRAFT TUBE PERSONNEL HOIST, HOIST RATED LOAD: 300 LBS, HOIST SPEED: 33 FT/MIN, MODEL: TIRAK XE 301 P. The nameplate must be legible with letters at least 3/8 inch in height and made of durable material that is inert when in contact with the steel frame material.

Attach the nameplate in a visible location using inert fasteners or alternate method not susceptible to galvanic corrosion.

2.1.21 Fixed Ladder

Provide a fixed-rail metal ladder conforming to the requirements of EM 385-1-1 , to Section 7 of 29 CFR 1910.27 , 29 CFR 1910 , and to details shown. Fabricate the ladder of aluminum as shown. Fabrication of ladders will consist of solid-section rod rungs fitted into holes in bar side rails and welded. Make any splices in side rails using full penetration welds and provide a flush and smooth transition between connecting ends. Grind all welds smooth. Attach ladder rails to supporting structure as shown. The bottom of the ladder will protrude through the opening in the draft tube access platform. Provide a means to secure it to the lower platform once the elevation of the upper platform is set.

2.1.22 Carts for Turbine Maintenance Platform Storage

Provide six (6) carts suitable for storing pontoons with gate beams attached as shown similar to informational drawings provided. Provide four

(4) carts for storing deck segments as shown similar to informational drawings provided. Provide two (2) carts suitable for storage of access hatch frame, cover, and grab bar; deck segments B1 and C1; with all draft tube access platform components as shown similar to informational drawings provided..

2.1.23 Self Retracting Lifeline

Provide a Self Retracting Lifeline (SRL) which is an Ultra-lock self retracting lifeline (SRL), 30 ft long with 3/4 in hook throat size, stainless steel cable, and stainless steel hook. The SRL is required to be compatible with DBI Sala safety systems. All items for the SRL and rigging to blade are required to be specified or designed by a Qualified Person for Fall Protection as per EM 385-1-1 and comply with ANSI/ASSE Z359 Fall Protection Code. The SRL will be located above the hatch in the turbine maintenance platform and attached to the draft tube liner using a swivel hoist ring as specified.

2.1.24 Safety Netting

Provide safety netting which complies with EM 385-1-1 and ANSI/ASSE Z359

SECTION 05 50 05.00 26 - Page 12 with maximum opening of 4 inches wide and 16 square inches. Although the safety netting is to be designed as if for fall protection in terms of strength, its' actual usage is for a guard system/walking surface rather than fall arrest. For this reason, impact load testing of the netting is not required and will not be permitted when the netting is attached to the turbine maintenance platform. The netting may be tested with a 250 lb statically applied load when attached to the turbine maintenance platform.

Should impact load testing be required for the netting to remain certified the netting must be secured in a similar fashion as when attached to the platform. Secure the netting to the inner hub-side support lugs through attachment points sewn in to the netting using the 5/8 in Crosby shackles provided together with the netting. Assure that the drape is low enough to clear the turbine hub and that when secured in position the netting leaves no gaps between the netting and the turbine maintenance platform decking. All items for the netting and rigging to pontoon platform shall be specified or designed by a Qualified Person for Fall Protection as per EM 385-1-1 and shall comply with ANSI/ASSE Z359 Fall Protection Code.

2.1.25 Locking Pins

Provide Locking Pins used for connecting deck segments which are 18-8 stainless steel locking pins with wire lock, square retainer with hook closure, 3/8-inch diameter, 4 inches usable length. Product number at McMaster-Carr is 98480A645 for a product meeting the above requirements.

Quantity sixty-two locking pins are required per each turbine maintenance platform.

2.1.26 Outer Rim Blocking

Provide outer rim blocking assemblies as shown. Wood blocks are to be kiln dried, quarter sawn, natural grade with small knots and no knot holes having the grain aligned with the direction of the hole for the bungee cord. Wooden blocks may also be built up provided final assembly is dimensionally stable, water resistant, durable, relatively light weight, and a single piece weighing no more than 40-lbs. Provide bungee cord material which is black, weather resistant, EPDM rubber 3/4 inch diameter.

Determine length of bungee cords based on maximum stretched length with the bungee cord securing the wooden blocking between the pontoon end and the draft tube liner with the platform in the low, outside supported elevation as shown. Provide bungee cord attachment to swivel hoist ring which is a self locking, stainless steel carabiner.

2.1.27 Grip Hoists

Provide lever operated manual grip hoists. Grip hoists are required to be rated for a working load limit of 2,000 lbs, man riding load limit of 1,500 lbs, or better. Minimum of 50 feet manufacturer specified grip hoist wire rope on a reeler with a minimum rope break strength of 10,000 lbs is to be provided. Grip hoist and wire rope connections are to be hooks with safety latches. The grip hoists are required to be "Griphoist TU-17", or approved equal, being UL Classified for load capacity. Quantity six grip hoists and wire ropes are required.

2.1.28 Brass Threaded Plugs

Provide brass threaded plugs to protect the swivel hoist spacer threads.

Plugs are to be manufactured of High Brass, 3/4 inch-10 UNC threads, and

1.25 inches long. The head of the plug shall be flat and machined to accept a 0.375 inch hexagon socket. Quantity seventy two brass plugs are

SECTION 05 50 05.00 26 - Page 13 required.

2.1.29 Air Powered Chain Hoist

Provide air powered chain hoist rated for a working load limit of 200 lbs minimum but not to exceed 300 lbs. Hoist lift required 25 ft minimum but not to exceed 35 ft. Hoist required to be controlled by pendant. Pendant lenght to be minimum lenght of 20 ft but not exceed 25 ft. Hoist suspension points are required to be hooks with safety latches. A load chain bucket is required. Air powered chain hoist shall conform to

ASME HST-5.

2.1.30 Sheave

Rope sheave shall be designed and fabricated by a sheave manufacturing company. Sheave profile shall be for a 5/16 inch wire rope. The sheave shall be rated for 6000 lbs radial load, 3000 lbs rope tension, 250 lbs side load, and 33 feet per minute linear rope speed or beter. Rope sheaves must be made of rolled or cast steel, with all grooves machined or ground smooth. Bushings shall be SAE 600 bronze with figure 8 grease grooves.

Sheave shall have a nominal outside diameter of 8 inchs and use a 2 inch sheave pin. Lubricate sheave by an individual grease passage located within the sheave pin. Submit design and material specifications and drawings for approval.

2.1.31 Blade Scaffolding Modification

The existing Blade Scaffolding will be government furnished. Contractor is required to transport the Blade Scaffolding to be modified from the project site to the Contractor's facility where the modifications to the connector plates as detailed in the contract drawings will be made. The modified Blade Scaffolding will be assembled at the Contractor's facility following modification in order to verify fit and function. Following successful assembly and government approval the modified Blade Scaffolding will then be delivered to the government site. Modifications to the Blade Scaffolding at government site will not be permitted without government approval.

2.2 FABRICATION

2.2.1 Structural Fabrication

Material must be straight before being laid off or worked. If straightening is necessary, straighten by methods that will not impair the metal. Sharp kinks or bends will be cause for rejection of the material.

Material with welds will not be accepted except where welding is definitely specified, indicated, or otherwise approved. Make bends using approved dies, press brakes, or bending rolls. Where heating is required, take precautions to avoid overheating the metal and allow metal to cool in a manner that will not impair the original properties of the metal.

Proposed flame cutting of material other than structural steel is subject to approval and must be indicated on detail drawings. Shearing must be accurate and all portions of the work neatly finished. Corners must be square and true unless otherwise shown. Re-entrant cuts must be filleted to a minimum radius of 3/4 inch unless otherwise approved. Finished members must be free of twists, bends, and open joints. Bolts, nuts, and screws must be tight.

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2.2.1.1 Fabrication Tolerances

A fabricated member must not vary from straight or from its intended curvature by more than its length divided by 960.

2.2.1.2 Dimensional Tolerances for Structural Work

Measure dimensions using a calibrated steel tape or calibrated micrometers of approximately the same temperature as the material at the time of measurement. The overall dimensions of an assembled fabricated unit are required to be within the tolerances indicated on the drawings or as specified in the Section pertaining to the specific item of work. For Contract and reference drawings only, individual measurements should not deviate from the dimensions shown on the drawings by more than 1/16 inch, unless otherwise specified.

2.2.1.3 Structural Aluminum Fabrication

Lay out and cut aluminum in accordance with the AA ADM.

a. Cut by shearing, sawing, nibbling, routing, arc cutting, laser, or abrasive water jet. Plane edges which have been arc or laser cut to remove edge cracks.

b. Cut edges must be true, smooth, and free from excessive burrs or ragged breaks.

c. Re-entrant corners must be filleted to radii as required by AA ADM.

d. Oxygen cutting is prohibited.

e. Bend radii must be large enough to avoid cracking.

2.2.2 Welding and Non-Destructive Examination of Weldments

Welding of aluminum and non-destructive examination of weldments conforms to AA ADM or AWS D1.2/D1.2M and be performed in accordance with Section

05 14 00.13 26 WELDING STRUCTURAL ALUMINUM.

2.2.3 Bolted Connections

2.2.3.1 Bolted Structural Steel Connections

Provide bolts, nuts, and washers of the type specified or indicated.

Equip all nuts with washers. Bolt holes must be accurately located, smooth, perpendicular to the member, and cylindrical. Holes for regular bolts may be drilled or subdrilled and reamed in the shop and must not be more than 1/16 inch larger than the diameter of the bolt.

2.2.3.2 Bolted Aluminum Connections

Punching, drilling, reaming, and bolting for bolted aluminum connections conforms to the requirements of AA ADM.

2.2.3.3 Bolts In Contact With Aluminum

Washers must be used under both bolt heads and under nuts for fastening aluminum. Carbon steel bolts, nuts, and washers in contact with aluminummust be hot-dip galvanized to ASTM A153/A153M or electrogalvanized

SECTION 05 50 05.00 26 - Page 15 to ASTM B633 and have hardness less than Rockwell Hardness RC35.

Galvanizing thickness must be adequate to provide corrosion protection for the anticipated service. Lubricate galvanized steel fasteners to eliminate galling and assure adequate preload.

2.2.4 Bolt Installation

Tighten all bolted connections to the snug-tight condition using hand tools only. 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.

2.2.5 Machine Work

Tolerances, allowances, and gauges for metal fits between plain, non-threaded, cylindrical parts conforms 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 will be suitable as approved. Tolerances for machine-finished surfaces designated by non-decimal dimensions are within 1/64 inch. Sufficient machining stock will be allowed on placing pads to ensure true surfaces of solid material. Provide finished contact or bearing surfaces true and exact to secure full contact. Polish journal surfaces and finish all surfaces with sufficient smoothness and accuracy to ensure proper operation when assembled. Parts entering any machine must be accurately machined and all like parts 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.

Accurately locate all drilled holes for bolts.

2.2.5.1 Finished Surfaces

Provide surface finishes, indicated or specified, 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. Determine compliance with surface requirements 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 must be consistent with the general type of finish specified by roughness height. Where the finish is not indicated or specified use 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.

2.2.5.2 Unfinished Surfaces

Lay out all work to secure proper matching of adjoining unfinished surfaces unless otherwise directed. Where there is a large discrepancy between adjoining unfinished surfaces chip and grind smooth or machine to secure proper alignment. Unfinished surfaces must be true to the lines and dimensions shown and be chipped or ground free of all projections and rough spots. Fill in depressions or holes not affecting the strength or

SECTION 05 50 05.00 26 - Page 16 usefulness of the parts in an approved manner.

2.2.5.3 Pin Holes

Pin holes are to be bored true to gauges, smooth, straight, and at right angles to the axis of the member. Perform boring after the member is securely fastened in position.

2.2.6 Zinc Coatings

Apply zinc coatings in a manner and of a thickness and quality conforming to ASTM A123/A123M . Where zinc coatings are destroyed by cutting, welding, or other causes, regalvanize the affected areas. Repair coatings less than 2 ounces in accordance with ASTM A780/A780M .

2.2.7 Part Labels

Pontoons, gate beams, middle beams, radial beams, perimeter beams, and decking panels must be clearly, permanently labeled on both sides of the part with the name of the part and its number. Use a stencil having characters at least two inches in height.

PART 3 EXECUTION

3.1 ASSEMBLY

Thoroughly clean all parts to be assembled. Remove packing compounds, rust, dirt, grit, and other foreign matter. Examine enclosed chambers or passages to make sure that they are free from damaging materials. Where units or items are shipped as assemblies, inspect prior to assembly. Do not use pipe wrenches, cold chisels, or other tools likely to cause damage to nuts or other parts for assembling and tightening parts. Tighten bolts firmly and uniformly to snug tight using hand tools only and take care not to overstress the threads. Lubricate threads of all bolts, except high strength bolts, and nuts with an approved lubricant before assembly.

Coat threads of corrosion-resisting steel bolts and nuts with an approved anti-galling compound. Driving and drifting bolts or keys will not be permitted.

3.2 PROTECTION OF FINISHED WORK

3.2.1 Machined Surfaces

Thoroughly clean foreign matter off machined surfaces. Protect all finished surfaces by suitable means. Oil and wrap unassembled pins and bolts with moisture resistant paper or protect them by other approved means. Wash finished surfaces of ferrous metals to be in bolted contact, with an approved rust inhibitor and coat them with an approved rust resisting compound for temporary protection during fabrication, shipping, and storage periods.

3.2.2 Aluminum

Protect aluminum, that will be in contact with grout or concrete, from galvanic or corrosive action with a coat of zinc-chromate primer and a coat of aluminum paint. Protect aluminum, in contact with structural steel, against galvanic or corrosive action with a coat of zinc-chromate primer and a coat of aluminum paint. Provide aluminum paint consisting of a aluminum paste conforming to ASTM D962, spar varnish, and thinner

SECTION 05 50 05.00 26 - Page 17 compatible with the varnish. Field mix the aluminum paint in proportion of 2 pounds of paste, not more than one gallon of spar varnish, and not more than one pint of thinner.

3.3 QUALITY CONTROL

Provide quality control as per the provisions of this Section and Section

05 14 00.13 26 WELDING STRUCTURAL ALUMINUM.

3.3.1 Pontoon Weight and Floatation Test

Following complete fabrication of pontoons, inclusive floatation chamber being sealed shut, test pontoons for floatation. Use a 250 lb concentrated weight for floatation testing. Record the weight of each pontoon and the amount of draft. Mark the center of buoyancy permanently on the pontoon. The floatation test will be evaluated based on meeting a draft of an average of 10 inches of the pontoon body (not including the support lugs) remaining above water while loaded with a 250-lb weight.

Record the amount of time the pontoon remains in the water and measure and record the amount of water leaking into the floatation chamber once the pontoon is removed from the water. Excessive leakage may require resealing at no addtional cost to the Government. Excessive leakage is defined as greater than one cup in 15 minutes.

3.3.2 Control Dimensions

Control dimensions are shown in the drawings and are as follows:

a. Overall assembled platform inner diameter.

b. Overall assembled platform outer diameter.

c. Overall pontoon dimensions in length, height, and width.

d. Overall length of individual components.

e. Center to center spacing and alignment of pinned connections.

3.3.3 Final Inspection and Load Test

3.3.3.1 Shop Assembly and Load Testing

Assemble and load test the completed draft tube maintenance platform inclusive decking in the shop. Tolerances are required not exceed those shown. Closely check each unit assembled to ensure that all required dimensions have been met. Assemble in the shop in the same position and support in a similar manner as final installation in the field 1) from the interior hub side support lugs with the lowest pontoon edge(s) blocked from swinging radially inward and 2) from the rim side support lugs with the rim ends blocked from swinging radially outward; or 3) from the draft tube mandoor (DTP only). Submit load test apparatus data inclusive detailed drawings, calculations, and product data for all rigging, hub and draft tube liner analogs, and supports needed to complete load testing.

Perform assembly, load testing, and disassembly work in the presence of the Contracting Officer (CO) or a Government representative designated by the CO unless expressly waived in writing. Immediately remedy errors or defects observed during the testing without cost to the Government.

Before disassembly for shipment, match mark each piece per COR's direction to facilitate erection in the field.

3.3.3.2 Load Test

a. Assemble and load test the platform(s) to 100 percent of the allowable working load. Apply the load for a minimum of 15 minutes.

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Distribute the load uniformly over the platform. Conduct the test prior to delivery of platform. Notify the CO in writing a minimum of fourteen days prior to testing.

b. Submit the test results. Provide a printed copy along with an electronic copy of the tests results to the CO prior to platform delivery. The test results are required to contain the following at minimum :

(1) Loads applied and indicate how the platform was loaded.

(2) Duration the load was applied.

(3) Recorded Measurements of Control Dimensions

(4) Provide deflection results for the pontoons, beams A & B, gate beams, and radial beams.

(5) Results indicating any signs of stress.

(6) Inspection of ALL bolt holes after testing.

(7) 100 percent VT and 100 percent PT inspection results of welds after testing.

(8) Inspection of the beams.

(9) Photographs of the test.

(10) Testing agent name.

(11) Date tested.

c. Following the load test dissassemble and then reassemble the turbine maintenance platform to check for changes in fit and effects of possible warping.

d. Bring any negative results of the load test and final inspection to the attention of the CO and remedy any damage or defects prior to delivery.

3.3.3.3 Repair and Non-Destructive Examination (NDE)

Following the completion of the load test for the platform(s), inspect the platform and remedy any defects in accordance with the provisions of the specifications by the Contractor without cost to the Government. Submit inspection results following the remedy of any defects for approval.

3.4 ON-SITE ASSEMBLY SERVICES

Provide the services of competent assembly specialist familiar with the fabrication and assembly of all items provided and capable of guiding the project staff during the first on-site assembly in the assembly bay. The competent assembly specialist is responsible to clarify assembly instructions, check the assembly, and make any field adjustments necessary to correctly assemble the platforms and scaffolding according to the approved design as documented in the final as-fabricated detail drawings.

The competent assembly specialist shall be the lead person performing the Contractor's shop assembly and/or load testing per this specification section. Submit name and proof of this specialist and receive acceptance of this person prior to on-site assembly. Proof includes copies of assembly and/or test documentation signed by this person.

The first at-site assembly will be performed by Project personnel and will occur on the erection/assembly bay. Provide the load test apparatus supports used during shop load testing for use at the project site during site assembly in order to facilitate on site assembly of the TMP from the inner support lugs and the DTP supported from the draft tube door analog.

Provide all special tools, timber cribbing and any other item(s) needed

SECTION 05 50 05.00 26 - Page 19 for assembly at the site. Submit in writing an on-site assembly schedule with proposed times and dates for Government approval 10 days prior to on-site assembly.

3.5 ASSEMBLY INSTRUCTIONS AND AS-FABRICATED DRAWINGS

Prepare detailed step-by-step written instructions on the assembly of the turbine maintenance platform and the draft tube door access platform together with the final as-constructed detail drawings. Include illustrative figures and photographs which explicate the step-by-step assembly instructions. Submit the assembly instructions seven days prior to shipment. The Contractor's assembly specialist is required to use the instructions during the first on-site assembly. Record any changes found to be necessary to the instructions and submit the revised assembly instructions to the Government within 10 calendar days of the on-site assembly of the platforms and scaffold.

-- End of Section --

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