Technical Specifications Amendment 0001.pdf

Ice Harbor Turbine Maintenance Platform W912EF26BA002

1HLDTMP25

PROJECT TABLE OF CONTENTS

DIVISION 01 - GENERAL REQUIREMENTS

01 00 00.00 28 GENERAL REQUIREMENTS

01 11 01.00 28 SUPPLEMENTARY REQUIREMENTS

01 14 00.10 28 PROJECT SITE RESTRICTIONS

01 14 00.90 28 INTEGRATING ANTITERRORISM (AT) AND OPERATIONS SECURITY

(OPSEC)

01 32 16.00 28 SMALL PROJECT PROGRESS SCHEDULES

01 33 00 SUBMITTAL PROCEDURES

01 42 00 SOURCES FOR REFERENCE PUBLICATIONS

01 45 01.00 28 RESIDENT MANAGEMENT SYSTEM CONTRACTOR MODE (RMS CM)

01 45 04.00 28 CONTRACTOR QUALITY CONTROL

01 78 00.00 28 CLOSEOUT SUBMITTALS

DIVISION 05 - METALS

05 05 23.16 26 STRUCTURAL STEEL WELDING AND FABRICATION

05 14 00.13 26 STRUCTURAL ALUMINUM WELDING AND FABRICATION

05 50 05.01 26 TURBINE MAINTENANCE PLATFORM - ICE HARBOR

DIVISION 14 - CONVEYING EQUIPMENT

14 41 19.10 26 PERSONNEL HOISTING EQUIPMENT

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PROJECT TABLE OF CONTENTS

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SECTION TABLE OF CONTENTS

DIVISION 05 - METALS

SECTION 05 50 05.01 26

TURBINE MAINTENANCE PLATFORM - ICE HARBOR

PART 1 GENERAL

1.1 REFERENCES

1.2 SUBMITTALS

1.3 WORK PLAN

1.4 DETAIL DRAWINGS

1.5 SPARE PARTS

1.6 PRE-FABRICATION CONFERENCE

1.7 FABRICATION REQUIREMENTS

PART 2 PRODUCTS

2.1 REQUIRED SUBMITTALS

2.1.1 Materials Test Reports

2.1.2 Product Data

2.1.3 Shipping Bill

2.2 MATERIALS

2.2.1 Aluminum Sheet and Plate

2.2.2 Aluminum Extrusions

2.2.3 Aluminum Structural Shapes

2.2.4 Slip Resistant Floor Plate

2.2.5 Steel Properties

2.2.6 HSS Steel Properties

2.2.7 Corrosion Resistant (Stainless) Steel Properties

2.2.8 Steel Pipe

2.3 PRODUCTS

2.3.1 Slip Resistant Coating

2.3.2 Slip Resistant Safety Tape

2.3.3 Steel Bolts, Nuts, and Washers

2.3.4 Wood Screws

2.3.5 Drain Plugs

2.3.6 Plywood

2.3.7 Marine Adhesive

2.3.8 Turnbuckles

2.3.9 Shackles

2.3.10 Swivel Hook

2.3.11 Swivel Hoist Ring

2.3.12 Wire Rope Assembly

2.3.13 Perimeter Safety Fencing

2.3.14 Square Stainless Steel Locking Pins for Decking

2.3.15 Stainless Steel Retainer Pins for Steel Beam Pins

2.3.16 Grip Hoists for Raising/Lowering TMP

2.3.16.1 Draft Tube Liner Mounts

2.3.17 PVC Threaded Rod

2.3.18 Fireproof Sleeves

2.3.19 UHMW BLOCKING

SECTION 05 50 05.01 26 Page 1

2.3.20 Rubber Sheet

2.3.21 UHMW SHEET

2.3.22 Extension Ladder

2.3.23 Wire Rope Safety Ladder

2.3.24 Magnetic Lifting Anchor

2.3.25 1/2 Ton Wire Cable Winch Puller

2.4 ASSEMBLIES

2.4.1 Nameplate

2.4.2 Wood Blocking

2.4.3 TMP Access Ladder

2.4.4 Hatches

2.4.5 Units 1-3 Blade Access Scaffolding

2.4.5.1 Unit 2 BAS Support

2.4.6 Units 4-6 Blade Access Scaffolding

2.4.7 Nose Cone Access Scaffolding

2.4.8 Storage Carts

2.4.8.1 Carts for Turbine Maintenance Platform

2.4.8.2 Carts for Draft Tube Access Platform

2.4.8.3 Cart for Personnel Hoist

2.4.8.4 Carts for Blade Access Scaffolding

2.5 OPERATION AND MAINTENANCE (O&M) MANUALS

PART 3 EXECUTION

3.1 FABRICATION

3.1.1 General

3.1.2 Part Labels

3.2 ASSEMBLY

3.3 QUALITY CONTROL

3.3.1 Control Dimensions

3.3.2 Final Inspection and Load Test

3.3.2.1 Shop Assembly and Load Testing

3.3.2.2 Pontoon Weight and Floatation Test

3.3.2.3 Pontoon Air Pressure Testing

3.3.2.4 Load Test

3.3.2.5 Repair and Non-Destructive Examination (NDE)

3.4 ON-SITE ASSEMBLY SERVICES

3.5 ASSEMBLY INSTRUCTIONS AND AS-FABRICATED DRAWINGS

3.5.1 Preliminary Assembly Instructions for TMP

3.5.2 Preliminary Assembly Instructions for DTAP

3.5.3 Preliminary Assembly Instructions for DT Personnel Hoist &

Frame

3.5.4 Preliminary Assembly Instructions for Blade Access Scaffolding

(BAS)

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SECTION 05 50 05.01 26 Page 2

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SECTION 05 50 05.01 26

TURBINE MAINTENANCE PLATFORM - ICE HARBOR

PART 1 GENERAL

Fabricate, load test, and deliver to Ice Harbor Lock and Dam:

a. One (1) Turbine Maintenance Platform (TMP) with necessary appurtenances, rigging, and assembly aids ready for installation as specified and shown in the Contract drawings.

b. One (1) Draft Tube Access Platform (DTAP) with necessary appurtenances, rigging, and assembly aids ready for installation as specified and shown in the Contract drawings.

c. One (1) Personnel Hoist Frame as specified and shown on the contract drawings. See SECTION 14 41 19.10 26 for additional requirements.

d. One (1) complete assembly of U1-3 Blade Access Scaffolding with necessary appurtenances, cone access scaffolding, rigging, and assembly aids ready for installation as specified and shown in the Contract drawings.

e. One (1) complete assembly of U4-6 Blade Access Scaffolding with necessary appurtenances, rigging, and assembly aids ready for installation as specified and shown in the Contract drawings.

f. New transport storage cart(s) as specified.

g. Miscellaneous assembly aids and components shown on the contract drawings and as specified in PART 2.

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 D1.2/D1.2M (2014; Errata 1 2014; Errata 2 2020) Structural Welding Code - Aluminum

APA - THE ENGINEERED WOOD ASSOCIATION (APA)

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

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME B30.26 (2015; R 2020) Rigging Hardware

ASME 30.20 BTH-1 (2017) Design of Below-the-Hook Lifting Devices

SECTION 05 50 05.01 26 Page 3

ASTM INTERNATIONAL (ASTM)

ASTM A123/A123M (2017) Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products

ASTM A276/A276M (2024) Standard Specification for Stainless Steel Bars and Shapes

ASTM A500/A500M (2023) Standard Specification for Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and Shapes

ASTM A53/A53M (2024) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

ASTM A563 (2021; E 2022a) Standard Specification for Carbon and Alloy Steel Nuts

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

ASTM B221 (2021) Standard Specification for Aluminum and Aluminum-Alloy Extruded Bars, Rods, Wire, Profiles, and Tubes

ASTM B308/B308M (2010; R 2020) Standard Specification for Aluminum-Alloy 6061-T6 Standard Structural Profiles

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

ASTM D2000 (2018) Standard Classification System for Rubber Products in Automotive Applications

ASTM F436 (2011) Hardened Steel Washers

ASTM INTERNATIONAL (ASTM)

ASTM A572/A572M (2021; E 2021) Standard Specification for High-Strength Low-Alloy Columbium-Vanadium Structural Steel

ASTM D638 (2014) Standard Test Method for Tensile Properties of Plastics

ASTM D2240 (2015; E 2017) Standard Test Method for Rubber Property - Durometer Hardness

ASTM F3125/F3125M (2019) Standard Specification for High Strength Structural Bolts and Assemblies, Steel and Alloy Steel, Heat Treated, Inch Dimensions 120 ksi and 150 ksi Minimum Tensile Strength, and Metric Dimensions 830 MPa and 1040 MPa Minimum Tensile

SECTION 05 50 05.01 26 Page 4

Strength

U.S. ARMY CORPS OF ENGINEERS (USACE)

EM 385-1-1 Safety and Occupational Health Requirements

The Contractor is responsible for complying with the current edition and all changes posted on the web as of the effective date of this solicitation.

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 1926 Safety and Health Regulations for Construction

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

Pre-fabrication Conference ; G, HDC

Work Plan ; G, HDC

On-Site Assembly Schedule ; G, HDC

SD-02 Shop Drawings

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

Detail Drawings - TMP Decking ; G, HDC

Detail Drawings - DTAP ; G, HDC

Detail Drawings - DT Personnel Hoist ; G, HDC

Detail Drawings - Blade Access Scaffolding ; G, HDC

Detail Drawings - Carts ; G, HDC

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

Detail Drawings - Assembly and Rigging ; G, HDC

Nameplate ; G, HDC

SD-03 Product Data

SECTION 05 50 05.01 26 Page 5

Materials List ; G, HDC

Material Test Reports ; G, HDC

Product Data

Load Test Apparatus ; G, HDC

SD-06 Test Reports

Pontoon Weight and Floatation Test ; G, HDC

Pontoon Air Pressure Testing ; G, HDC

Load Test ; G, HDC

SD-07 Certificates

Competent Assembly Specialist ; G, EC

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 and protection from ferrous tools 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 conference, critical hold points, load test dates, delivery dates.

d. Shop Assembly and NDE. Pertains to all work items within this contract including but not limited to turbine maintenance platform, rigging, draft tube maintenance platform, ladder, storage carts, and blade scaffolding.

e. Shop Load Test. Includes turbine maintenance platform (TMP), rigging, netting, draft tube access platform (DTAP), ladder, and blade scaffolding. 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.

SECTION 05 50 05.01 26 Page 6

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. Include the applicable WPS and WPS in weld tails for all welds. Include a Bill of Materials (BOM) within the drawing package.

Include weights within the BOM for each component and assemblies. 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 - DTAP

d) Detail Drawings - DT Personnel Hoist

e) Detail Drawings - Blade Access Scaffolding

f) Detail Drawings - Carts

g) Detail Drawings - All remaining fixtures and appurtenances

h) Detail Drawings - Assembly and Rigging

1.5 SPARE PARTS

Furnish and deliver spare parts to the site, suitably packaged for long-term protection and indoor 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 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

- 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).

SECTION 05 50 05.01 26 Page 7

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

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

1.6 PRE-FABRICATION CONFERENCE

Following approval of Contractor prepared shop drawings and prior to any fabrication, schedule and hold a Pre-fabrication Conference at the fabrication site. At minimum, detail drawings for all sub-assemblies a, b, and c, as listed under Paragraph Detail Drawings, must be submitted and have received a C code or better prior to the Pre-fabrication conference.

The Contractor, fabricator, the Contractor's third party Certified Weld Inspector(s) (CWI), Contractor's lead QC for the project, Contractor's Project Manager, Shop Foreman, 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 Representative (GQAR). The meeting will cover at minimum: the review of contract and shop drawings; the review of these specifications; discussion of the fabricator's quality control plan; identification of roles and responsibilities; 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.

1.7 FABRICATION REQUIREMENTS

Additional requirements for fabrication are as follows:

a. 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.

b. 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 successful demonstration 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 and have proper termination in accordance with AWS D1.2/D1.2M .

c. Contractor is not released to fabricate until receipt of written notice from the Government following the Pre-fabrication conference and approval of detail drawings, weld procedures and welder qualifications.

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

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

f. The Contractor is required to weld a full scale prototype of a pontoon for the Turbine Maintenance Platform contract as shown on the

SECTION 05 50 05.01 26 Page 8 drawings. 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, detail drawings for the prototypes must be submitted and approved and all necessary weld procedures and welder qualification must be complete.

g. Contractor is required to weld a full scale prototype of a U2 BAS Support as shown on the drawings, to include the Ultra high molecular weight polyethylene (UHMW) Sheet Supports. Prior to fabrication of any full scale prototype, detail drawings for the prototypes must be submitted and approved and all necessary weld procedures and welder qualification must be complete. Ship the prototype to Ice Harbor Lock and Dam for verification of functionality in the unit. After fabrication and functionality testing, minor dimensional changes may be determined necessary to improve fit and adjustment to intermitent welds may be coordinated to limit distortion.

PART 2 PRODUCTS

2.1 REQUIRED SUBMITTALS

2.1.1 Materials Test Reports

Submit a Materials List of the materials to be used in the fabrication of each item at the time the detail drawings are submitted. Submit Material Test Reports together with purchase orders for all material used in fabrication prior to incorporation into the structure. Purchase orders must include the test site address and the name of the testing agency.

2.1.2 Product Data

Submit product data together with purchase orders for all materials that do not require material test reports prior to the use of the materials in the work.

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:

ATTN: Engineering Dept Ice Harbor Lock and Dam 2763 Monument Dr.

Burbank, WA 99352

2.2 MATERIALS

2.2.1 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.

2.2.2 Aluminum Extrusions

Provide aluminum extrusions which comply with ASTM B221, 6061-T6 in

SECTION 05 50 05.01 26 Page 9 locations as shown on the drawings.

2.2.3 Aluminum Structural Shapes

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

2.2.4 Slip Resistant Floor Plate

For all walking surfaces on the Turbine Maintenance Platform , incorporate slip resistant floor plating into the fabrication as shown. The slip resistant floor plating must be made from aluminum sheet conforming to ASTM B209, 6061 T6 or 5052 H32 as shown and have deposits of the same type of metal applied by a laser Computer Numerical Control (CNC) deposition process causing the deposits to penetrate the metal substrate to produce a permanent bond. Deposit height is nominally 0.025", and deposit density should exceed 1,000 deposits per square foot, and result in a coefficient of friction of at least 0.97 COF.

2.2.5 Steel Properties

Provide steel meeting the requirements of ASTM A572/A572M Grade 50 steel and galvanized as per ASTM A123/A123M following fabrication.

2.2.6 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.

2.2.7 Corrosion Resistant (Stainless) Steel Properties

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

2.2.8 Steel Pipe

Provide ASTM A53/A53M Grade B for steel pipe and galvanized per ASTM A123/A123M . Provide pipe with nominal size and weight class or outside diameter and nominal wall thickness as shown, plain ends.

2.3 PRODUCTS

2.3.1 Slip Resistant Coating

For all decking bearing surfaces on the top of the TMP, provide two part epoxy slip resistant coating, capable of bonding to plywood and aluminum, and having aggregate added to the epoxy during cure in order to achieve slip resistant surface with a coefficient of friction greater than 1.57.

Coating must be durable having excellent chemical and abrasion resistance.

2.3.2 Slip Resistant Safety Tape

For structural walking surfaces on the DTAP which do not use slip resistant floor plate, provide anti-slip rubber tape on the walking surfaces. Tape must be rated for outdoor use and be NFSI certified for high traction. In addition, the tape must have the following characteristics:

(1) minimum grit size of 60.

SECTION 05 50 05.01 26 Page 10

(2) minimum thickness of 2 mil.

(3) minimum tensile strength of 20 lb/in.

2.3.3 Steel Bolts, Nuts, and Washers

Provide galvanized steel bolts meeting the criteria of ASTM F3125/F3125M Grade A325, wide (series W) washers meeting ASTM F436 Type 1, and nuts meeting ASTM A563. Refer to SECTION 05 14 00.13 26 for additional bolting requirements.

2.3.4 Wood Screws

Provide exterior rated deck screws design for wood. Provide the size indicated on the contract drawings.

2.3.5 Drain Plugs

Provide chemically-resistant polyvinyl chloride (PVC) drain plugs with external octagon drive head and NPT type threads. Install plugs using Teflon tape to ensure a watertight seal.

2.3.6 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 .

2.3.7 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.

2.3.8 Turnbuckles

Provide turnbuckles which are galvanized steel 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 meet 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.

2.3.9 Shackles

Provide shackles which are galvanized steel 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 meet 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 05.01 26 Page 11

2.3.10 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 meet 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.

2.3.11 Swivel Hoist Ring

Provide alloy steel, quenched and tempered, swivel Hoist Rings rated for 5,000 pound working load at a safety factor = 5 and meeting the requirements of ASME B30.26 . Swivel hoist ring to have 360-degree swivel action and 180-degree pivot action. Swivel hoist rings are required to have a 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 additional swivel hoist ring used to secure a self retracting lifeline (SRL) to the draft tube liner. Drill and tap of holes in the draft tube liner for the swivel hoist rings are by others.

2.3.12 Wire Rope Assembly

Wire rope assemblies are required to 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. These assemblies must consist of two eye ends complete with standard 5/8 inch galvanized thimbles meeting FS FF-T-276B, Type II, and having mechanical spliced and swaged end connections. This entire wire rope assembly is required to meet minimum 30,000 pound breaking strength requirement and the vendor must 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 18 wire rope assemblies. Eye to measurements are to be:

a. 24", quantity 6

a. 36", quantity 6

a. 48", quantity 6

2.3.13 Perimeter Safety Fencing

Provide 4'x100' roll of orange safety fencing for use as a guard system, not for 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 rigging. Provide stainless steel carabineer to attach to swivel hoist ring and turnbuckle.

2.3.14 2.1.22 Square Stainless Steel Locking Pins for Decking

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

SECTION 05 50 05.01 26 Page 12

2.3.15 Stainless Steel Retainer Pins for Steel Beam Pins

Provide stainless steel coiled bent-wire locking pins which are 18-8, 1/8-inch diameter, 2 inches usable length for use in retaining the Beam Connector Pins. Quantity thirty-six retainer pins are required per each turbine maintenance platform.

2.3.16 Grip Hoists for Raising/Lowering TMP

Provide lever operated manual grip hoists. Grip hoists are required to be rated for a working load limit of 4,000 lbs, man riding load limit of 3,000 lbs, or better, and be UL Classified for load capacity. Minimum of 60 feet manufacturer specified grip hoist wire rope on a reeler with a minimum rope break strength of 20,000 lbs is to be provided. Grip hoist and wire rope connections are to be hooks with safety latches. Quantity six grip hoists and wire ropes are required.

2.3.16.1 Draft Tube Liner Mounts

Provide Draft Tuber liner mounts as shown on the contract drawings.

Fabricate the mounts using ASTM A572/A572M grade 50. Weathering steel grades will not be permitted.

2.3.17 PVC Threaded Rod

Provide chemical-resistant polyvinyl chloride (PVC) threaded rod to protect the tapped swivel hoist threads in the draft tube liner. Rods are to be manufactured of PVC, 3/4 inch-10 UNC threads, and one 1 foot long.

Quantity twenty four (24) PVC threaded rods are required.

2.3.18 Fireproof Sleeves

Provide fireproof silicone rubber coated fiberglass sleeve with Velcro closure to protect the turnbuckles. The fireproof sleeves must be capable of withstanding a continuous 500 degrees F rating with weld splatter. The fireproof sleeve must be heat and flame resistant silicone rubber coated fiberglass. The fireproof sleeve must have Velcro closure to allow the sleeve to be installed and removed without taking the turnbuckle apart.

2.3.19 UHMW BLOCKING

Provide removable UHMW blocks as shown. Plastic fabrications must comprise of 100 percent virgin crosslinked, UV-stabilized ultra-high molecular weight polyethylene (UHMWPE) conforming to the following requirements:

a. Minimum Tensile yield strength of 3000psi and minimum tensile ultimate strength of 5000psi measured in accordance with ASTM D638.

b. A minimum 65 Shore D hardness per ASTM D2240

2.3.20 Rubber Sheet

Provide nitrile (buna-N) rubber conforming to ASTM D2000, Type BG, 50 durometer Shore A Hardness for rubber seals as a water tight rubber gasket.

2.3.21 UHMW SHEET

Utilize UHMW sheets comprised of 100 percent virgin crosslinked, UV-stabilized ultra-high molecular weight polyethylene (UHMWPE) conforming

SECTION 05 50 05.01 26 Page 13 to the following requirements:

a. Minimum Tensile yield strength of 3000psi and minimum tensile ultimate strength of 5000psi measured in accordance with ASTM D638.

b. A minimum 65 Shore D hardness per ASTM D2240

2.3.22 Extension Ladder

Provide a 20 foot extension ladder with a maximum safe working height of at least 17 feet. The ladder must be of aluminum construction and rated for a minimum of 375 lbs. Provide ladder walk through from the same manufacturer and compliant with OSHA 1910 requirements. Provide adjustable ladder stabilizer from the same manufacturer capable of a stand-off distance of 29.5 inches.

2.3.23 Wire Rope Safety Ladder

Provide a 12' wire rope safety ladder allowing access to units 1 and 3 blades, meeting the requirements of ANSI Z359.1, and rated to support 310 lbs. The ladder must have standoffs for foot clearance.

2.3.24 Magnetic Lifting Anchor

Provide a magnetic lifting anchor with a working load limit (WLL) of at minimum 1200 pounds in the vertical direction and 600 pounds in the horizontal direction. The device must be compliant with the requirements of ASME 30.20 BTH-1 . The maximum weight of the device must not exceed 40 pounds and proof load tested to a minimum 3 times the WLL. The device must be functional on both round and flat surfaces.

2.3.25 1/2 Ton Wire Cable Winch Puller

Provide (6) ratcheting winch wire cable puller to be used to secure the TMP pontoon end blocking supports. The single line capacity must be 1000 lbs with a full load handle pull not to exceed 80 pounds. The minimum distance between hooks is 16" and the weight of each puller cannot exceed 8 pounds.

2.4 ASSEMBLIES

2.4.1 Nameplate

Submit nameplates for Ice Harbor 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 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 maximum "riding" live load limit of 3,600 pounds well balanced during assembly for the Turbine Maintenance 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.

SECTION 05 50 05.01 26 Page 14

2.4.2 Wood Blocking

Provide six wood blocking assemblies as shown on the contract drawings.

Wooden blocks must be built up using waterproof glue and provided final assembly is dimensionally stable, water resistant, durable, and a single assembly weighing no more than 50-lbs. If necessary, reduce weight using drilled holes. Indicate locations of wood holes and sizes on the shop drawings. Provide attachments on both ends which is a self-locking, stainless steel carabineer and can attach to swivel hoist ring and turnbuckle using the cable puller.

2.4.3 TMP Access Ladder

Provide a fixed-rail metal ladder conforming to the requirements of EM 385-1-1 , 29 CFR 1926 subpart L, and as shown in the contract drawings.

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.

2.4.4 Hatches

Provide aluminum hatches 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 covers 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.

2.4.5 Units 1-3 Blade Access Scaffolding

Fabricate and provide a complete Blade Access Scaffolding (BAS) assembly as shown. The Blade Scaffolding assembly is comprised of five segments connected together with pins as shown. Each segment of Blade Scaffolding is made of a commercially available aluminum painters stage platform with custom attachment plates welded to the ends as shown. Aluminum stage platforms are 20 inches wide, 12 feet in length modified to a nominal length of as shown on the drawings, with 4" inch depth side rails and 2 inch side rail flanges having a 32 man, 750500 lb capacity, and weighing approximately 60 lbs without attachments. Provide 1 1/2 inch diameter aluminum schedule 80 posts and top rails as shown. Provide commercially available, aluminum, structural, slip-on fittings, set screws and hex keys for securing 1 1/2 inch pipe. Slip-on fittings are as shown and include:

post supports which bolt to the rail of the aluminum stage and are provided with rectangular type off-set wall-mount flanges; tee with through hole; adjustable angle wye.

2.4.5.1 Unit 2 BAS Support

Provide five aluminum weldments to support the BAS in Unit 2 as shown on the contract drawings. They are comprised of welded aluminum plate and

SECTION 05 50 05.01 26 Page 15

Amend-0001

UHMW sheets which are attached with bolting. The UHMW sheets must be CNC'd using a provided electronic file; the files will be provided in ".ipt" file format. It is critical that the UHWM sheets be located in the shown dimensional location in order to fit. Do not install the bolt holes and aluminum stopper plates until the rest the weldment is completed to allow for adjusting the final position to account for any weld distortion. Cover the top of the BAS surface with non-slip safety tape.

2.4.6 Units 4-6 Blade Access Scaffolding

Fabricate and provide Blade Access Scaffolding as shown. Each Blade Scaffolding set is comprised of 6 segments connected together as shown.

Each segment of Blade Scaffolding is made of a commercially available aluminum painters stage platform with custom attachment plates welded to the ends as shown. Aluminum stage platforms are 20 inches wide, 12 feet in length modified to a nominal length as shown on the drawings, with 4" inch depth side rails and 1-3/8 inch side rail flanges having a 2 man, 500 lb capacity, and weighing approximately 40 lbs without attachments. Provide 1 1/2 inch diameter aluminum schedule 80 posts and top rails as shown.

Provide commercially available, aluminum, structural, slip-on fittings, set screws and hex keys for securing 1 1/2 inch pipe. Slip-on fittings are as shown and include: post supports which bolt to the rail of the aluminum stage and are provided with rectangular type off-set wall-mount flanges;

tee with through hole; adjustable angle wye.

2.4.7 Nose Cone Access Scaffolding

Fabricate and provide Nose Cone Access Scaffolding as shown. The scaffolding is comprised of commercially available aluminum painters stage platform, some of which are modified with guard railing. Aluminum stage platforms required include:

a. 20" wide by 12' long, quantity 3

b. 12" wide by 12' long, quantity 2

c. 24" wide by 12' long, quantity 1

d. 24" wide by 8' long , quantity 2

All work stages have 4" inch depth side rails and 1-3/8 inch side rail flanges having a 3 man, 750 lb capacity, and weighing approximately 40 lbs without attachments. Provide 1 1/2 inch diameter aluminum schedule 80 posts as shown. Provide commercially available, aluminum, structural, slip-on fittings, set screws and hex keys for securing 1 1/2 inch pipe.

Slip-on fittings are as shown and include: post supports which bolt to the rail of the aluminum stage and are provided with rectangular type off-set wall-mount flanges; tee with through hole; adjustable angle wye.

2.4.8 Storage Carts

Provide carts constructed of aluminum unless specified otherwise. The carts will be fabricated and delivered to Ice Harbor Lock and Dam concurrently with the TMP components. Provide all storage carts with four pivoting wheels at the corners and two fixed, high-centered in-line wheels with brakes in the middle of the cart to allow ease in maneuvering.

Storage carts are required to have shop drawings prepared and submitted for approval. Include recommended component storage arrangement on the drawings.

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2.4.8.1 Carts for Turbine Maintenance Platform

Provide six (6) carts each suitable for storing and transporting 1/6th of the substructure (a pontoon with gate, middle, radial, and perimeter beams) similar to informational drawings provided. Provide four (4) carts for storing deck segments as shown similar to informational drawings provided. The decking carts must be provided with 2 rigging points and strapping to secure the decking, allowing the loaded carts to be hoisted through the access hatch.

2.4.8.2 Carts for Draft Tube Access Platform

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

2.4.8.3 Cart for Personnel Hoist

Provide one (1) cart for storing all the draft tube personnel hoist and hoist frame components. Provide a cart constructed of welded steel. Powder coat the cart safety yellow. Provide four lifting attachment points on the frame of the DT Personnel Hoist cart which can safely be used to attach slings and rigging provided by others which can be utilized to raise and lower the cart and all items to be stored on the cart. Carts must be sized to be able to be lowered down all access hatches to the draft tube gallery.

2.4.8.4 Carts for Blade Access Scaffolding

Provide one (1) cart suitable for storage of the U1-3 blade access scaffolding (BAS) components. Provide one (1) cart suitable for storage of the U4-6 BAS. Provide one (1) cart for storage of the U2 BAS support stands and hub access platform.

2.5 OPERATION AND MAINTENANCE (O&M) MANUALS

In the completed O&M Manuals, in addition to the requirements outlined in specification SECTION 01 78 00.00 28 , include at minimum the following information: Design Standards; Loads, Load Combinations & Safety Factor;

Nameplate Data; Required Inspection, Maintenance, and Load Testing;

Assembly Procedures; Bill of Materials; As Fabricated Shop and Contract Drawings.

PART 3 EXECUTION

3.1 FABRICATION

3.1.1 General

Fabricate all structural aluminum items as per the approved shop drawings, the requirements of this specification, and the requirements of SECTION 05 14 00.13 26 . Fabricate all structural steel items as per the approved shop drawings, the requirements of this specification, and the requirements of SECTION 05 05 23.16 26 .

3.1.2 Part Labels

Trusses, gate beams, middle beams, radial beams, perimeter beams, and decking panels must be clearly, permanently labeled on both sides of the

SECTION 05 50 05.01 26 Page 17 part with the name of the part and its number. Utilize black paint for labeling. Use a stencil having characters at least two inches in height.

Do not stamp. Part labels are to match drawing part names/numbers as shown on the drawings.

3.2 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.

3.3 QUALITY CONTROL

Provide quality control as per the provisions of this specification, SECTION 05 14 00.13 26 , and SECTION 05 05 23.16 26 .

3.3.1 Control Dimensions

Control dimensions and tolerances are provided for the assembled features to ensure the platform system will function as intended. After fabrication of the TMP, record the actual fabricated dimensions on the "control dimensions" chart provided on drawing S-001 and submit for Approval.

Utilize tools that are capable of measuring the control dimensions within the contract tolerances shown. Record the most adverse tolerance dimension within the control dimension chart. Verify control dimensions prior to shipping. Flatness of walking surface and bearing contact of decking panels at points designed must also be verified. Adjustment of shims to provide stable decking may be necessary and at no additional cost to the Government.

3.3.2 Final Inspection and Load Test

3.3.2.1 Shop Assembly and Load Testing

Assemble and load test the completed platforms inclusive decking in the shop. Tolerances are required not exceed those shown and specified.

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 man door (DTAP 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

SECTION 05 50 05.01 26 Page 18 facilitate erection in the field.

3.3.2.2 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 to match the section "Parts Labeling". 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 additional cost to the Government. Excessive leakage is defined as greater than one quarter cup in 15 minutes.

3.3.2.3 Pontoon Air Pressure Testing

Apply pressurized air to the pontoon to a pressure between 1 and 2 PSI. Do not exceed 2 PSI at any time during testing. Using a spray bottle, apply soapy water to all welds and observe any areas showing signs of air leakage. Repair any welds which show signs of leakage.

3.3.2.4 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.

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 and supported.

(2) Duration the load was applied.

(3) Recorded Measurements of Control Dimensions

(4) Provide deflection results for the trusses and beams.

(5) Results indicating any signs of stress.

(6) Inspection of ALL bolt holes after testing.

(7) Weld inspection results after load testing. Perform 100 percent VT for all welds, 100 percent PT for pontoons and beams, and 25 percent PT for remaining welds.

(8) Inspection of the beams.

(9) Air pressure test of pontoons following completion of load test showing "water-tightness" of float chamber comparable to

SECTION 05 50 05.01 26 Page 19 satisfactory float test, unless float test occurs after load test.

(10) Photographs of the test.

(11) Testing agent name.

(12) Date tested.

c. Following the load test disassemble and then reassemble the TMP and DTAP 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.

e. The main TMP must be tested from the hub mount supports and from the draft tube mount supports. The DTP need only be tested hanging from one support condition; however, fit up of alternate units connectors must be demonstrated.

3.3.2.5 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. If any structural repairs are required following the load test, perform another load test after all structural repairs have been completed at no additional cost to the Government.

3.4 ON-SITE ASSEMBLY SERVICES

a. 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 according to the approved design as documented in the final as-fabricated detail drawings. The competent assembly specialist is required to 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.

b. The first at-site assembly will be performed by Project personnel and will occur on the erection/assembly bay and not in the draft tube. 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, DTP, DT Personnel Hoist & Frame, and Blade Scaffold; these are not to be delivered and are to be removed from site at completion of assembly. No anchorage of load test apparatus supports will be permitted to the erection bay floor;

provide cribbing or other aids to eliminate the use of anchors.

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

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3.5 ASSEMBLY INSTRUCTIONS AND AS-FABRICATED DRAWINGS

For each assembly, prepare detailed step-by-step written instructions with the final as-fabricated 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 assembly 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.

The assembly steps included below are the starting point of full assembly instructions and address only the minimum needed to assemble the items as shown on the contract drawings. Additional steps must be added for full installation and assembly in the draft tube for the particular site.

3.5.1 Preliminary Assembly Instructions for TMP

1. Attach pontoon door bracket to DT door.

2. Place through the DT door and float first pontoon secured with tether from inboard lug to assure pontoon remains upright. Support small end on door bracket and send person out on pontoon. Pontoons remain tethered throughout assembly.

3. Pin gate beam to first pontoon. Ease first pontoon off of the door bracket.

4. Float second pontoon with tether.

5. Pin gate beam to second pontoon.

6. Pin middle beam to both pontoons.

7. Pin perimeter beam to both pontoons. Remove second pontoon from door bracket.

8. Rotate assembly and repeat above steps until all substructure is complete except the radial beams.

9. Place all deck segments except the middle segment (A) which is located over the radial beam.

10. Install radial beams by placing at an angle and rotating horizontally until pin and bolt holes align. Pin and place all radial beams, then bolt.

11. Pin deck segments together starting with deck panels at lugs. If installing platform in lower position, install interior decking extension and pin fully retracted.

12. Blocking between pontoon and draft tube liner required when platform is supported at outside supports prior to use at rated live load.

13. Platform may be lifted from assembly elevation to working elevation using not less than three of the six lifting points.

Lifting points selected must be symmetrical, live loads placed on the platform must be distributed/placed for balanced lifting, and live loads during lifting must be limited to 1/3 of the maximum live load (i.e. 4,000 pound limit during lifts).

14. If required, place the nose cone access platforms. Secure the scaffolding sections together to prevent shifting during…