A22 - SPEC_SOL-2024-08-13-PI - AMD0001.pdf

AMEND. 0001

13 AUGUST 2024

The following modifications are made to SECTION 35 01 41.

SECTION 35 01 41

a. ALL PAGES. Delete Section 35 01 41 in its entirety, and substitute therefore revised Section 35 01 41, Amendment 001, dated 13 August 2024.

DRAWINGS (SUPERSEDED)

a. Revised drawings listed below are being issued with this Amendment.

Such revised drawings supersede those of the same sheet identification numbers listed in the INDEX OF DRAWINGS included in the set of drawings furnished with Solicitation No. W912EK24B0019, dated August 1, 2024.

SHEET 01G-002, 52M-542, 52M-544, 52M-545, 52M-546, 52M-551, 52M-552,

52M-553, 56M-542, 56M-544, 56M-545, 56M-546, 56M-551, 56M-552, 56M-553

ATTACHMENTS: Section 35 01 41; and 01G-002, 52M-542, 52M-544, 52M-545, 52M-546, 52M-551, 52M-552, 52M-553, 56M-542, 56M-544, 56M-

545, 56M-546, 56M-551, 56M-552, 56M-553

LaGrange Lock and Dam 1200-FT Lock W912EK24B0019 PI - HSs and Operating Machinery

SECTION TABLE OF CONTENTS

DIVISION 35 - WATERWAY AND MARINE CONSTRUCTION

35 01 41

OPERATING MACHINERY FOR LOCKS AND DAMS

08/20, CHG 3: 05/23

PART 1 GENERAL

1.1 REFERENCES

1.2 SUBMITTALS

1.3 QUALITY ASSURANCE

1.3.1 Manufacturer and Assembler

1.3.2 Quality Control

1.4 DELIVERY, STORAGE, AND HANDLING

1.4.1 Delivery, Storage and Handling of Equipment

1.4.1.1 Packaging

1.4.1.2 Shipping, Preservation, and Storage

PART 2 PRODUCTS

2.1 MISCELLANEOUS METALS FABRICATION

2.1.1 Stainless Steel Plate, Sheet, and Strip

2.1.2 Steel Forgings

2.1.2.1 Pins

2.1.3 Aluminum Bronze Castings

2.1.4 Bolts, Nuts, and Washers

2.1.4.1 High-Strength Bolts, Nuts, and Washers

2.1.4.2 Bolts, Nuts, and Washers (Other Than High-Strength)

2.1.5 Screws

2.2 EQUIPMENT

2.2.1 Machinery

2.2.2 Equipment Submittal Data

2.2.2.1 Pillow Block and Sleeve Bearing

2.3 BEARINGS

2.3.1 Sector Shaft Bearing Assemblies

2.3.2 Flanged Sleeve Type Plain Pillow Block Bearing Assemblies

2.3.3 Spherical Bearing Assemblies

2.4 SHAFTS

2.5 SECTOR ARM

2.6 STRUT ARM

2.6.1 Casing

2.6.2 Buffer Yoke

2.6.3 Sector Connection

2.7 STRUCTURAL BASES AND SUPPORTS

2.8 PINTLE BUSHING AND CAP

2.9 PINTLE BALL

2.10 PINTLE SHOE

2.11 PINTLE BASE

2.12 GUDGEON TERMINALS

2.13 SPLIT NUT

2.14 GUDGEON BUSHINGS

2.15 KEYS AND KEYSEATS

SECTION 35 01 41 Page 1 AMEND 0001

12 AUG 2024

2.16 HYDRAULIC STEEL STRICTURES IDENTIFICATION NUMBERS

2.17 PAINTING

2.18 SHOP ASSEMBLY AND TESTS

2.18.1 General

2.18.2 Alignment

2.18.3 Anti-Seize Lubricant

2.18.4 Acceptance

PART 3 EXECUTION

3.1 MACHINE WORK

3.1.1 Finished Surfaces

3.1.2 Unfinished Surfaces

3.1.3 Pin Holes

3.2 NONDESTRUCTIVE EXAMINATION

3.2.1 NDT Agency Requirements

3.2.2 Nondestructive Testing (NDT) for Flaws

3.2.3 Quality Assurance Measurements

3.2.4 Pintle Component Nondestructive Testing Examination

3.2.5 Terminal Eyes/Fork and Split Nut Thread Testing

3.3 WELDING

3.4 MISCELLANEOUS PROVISIONS

3.4.1 Cleaning of Corrosion-Resisting Steel

3.4.2 Protection of Finished Work

3.4.3 Lubrication

3.5 SPARE PARTS

3.5.1 Miter Gate Spare Parts

3.5.2 Miter Gate Operating Machinery Spares

3.6 Equipment Warranty

-- End of Section Table of Contents --

SECTION 35 01 41 Page 2 AMEND 0001

12 AUG 2024

35 01 41

OPERATING MACHINERY FOR LOCKS AND DAMS

08/20, CHG 3: 05/23

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

AEROSPACE INDUSTRIES ASSOCIATION OF AMERICA, INC. (AIA/NAS)

AIA/NAS NAS410 (2014; Rev 4) NAS Certification & Qualification of Nondestructive Test Personnel

AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING (ASNT)

ANSI/ASNT CP-189 (2020) ASNT Standard for Qualification and Certification of Nondestructive Testing Personnel

ASNT SNT-TC-1A (2020) Recommended Practice for Personnel Qualification and Certification in Nondestructive Testing

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME B17.1 (1967; R 2017) Keys and Keyseats

ASME B18.2.1 (2012; Errata 2013) Square and Hex Bolts and Screws (Inch Series)

ASME B18.2.2 (2022) Nuts for General Applications:

Machine Screw Nuts, and Hex, Square, Hex Flange, and Coupling Nuts (Inch Series)

ASME B18.3 (2012) Socket Cap, Shoulder, Set Screws, and Hex Keys (Inch Series)

ASME B18.6.2 (2020) Square Head Set Screws and Slotted Headless Set Screws (Inch Series)

ASME B18.6.3 (2013; R 2017) Machine Screws, Tapping Screws, and Machine Drive Screws (Inch Series)

ASME B18.21.1 (2009; R 2016) Washers: Helical Spring-Lock, Tooth Lock, and Plain Washers (Inch Series)

ANSI/ASME B18.22.1 (R2003) Plain Washers

ASME B46.1 (2020) Surface Texture, Surface Roughness, SECTION 35 01 41 Page 3 AMEND 0001

12 AUG 2024

LaGr ange Lock and Dam 1200- FT Lock W912EK24B0019 PI - HSs and Oper at i ng Machi ner y

Wavi ness and Lay

ASTM I NTERNATI ONAL ( ASTM)

ASTM A27/ A27M ( 2020) St andar d Speci f i cat i on f or St eel Cast i ngs, Car bon, f or Gener al Appl i cat i on

ASTM A240/ A240M ( 2023a) St andar d Speci f i cat i on f or Chr omi um and Chr omi um- Ni ckel St ai nl ess St eel Pl at e, Sheet , and St r i p f or Pr essur e Vessel s and f or Gener al Appl i cat i ons

ASTM A290/ A290M ( 2016; R 2021) St andar d Speci f i cat i on f or Car bon and Al l oy St eel For gi ngs f or Ri ngs f or Reduct i on Gear s

ASTM A307 ( 2021) St andar d Speci f i cat i on f or Car bon St eel Bol t s, St uds, and Thr eaded Rod 60 000 PSI Tensi l e St r engt h

ASTM A320/ A320M ( 2022a) St andar d Speci f i cat i on f or Al l oy- St eel and St ai nl ess St eel Bol t i ng f or Low- Temper at ur e Ser vi ce

ASTM A380/ A380M ( 2017) St andar d Pr act i ce f or Cl eani ng, Descal i ng, and Passi vat i on of St ai nl ess St eel Par t s, Equi pment , and Syst ems

ASTM A388/ A388M ( 2016) St andar d Pr act i ce f or Ul t r asoni c Exami nat i on of St eel For gi ngs

ASTM A564/ A564M ( 2019) St andar d Speci f i cat i on f or Hot - Rol l ed and Col d- Fi ni shed Age- Har deni ng St ai nl ess St eel Bar s and Shapes

ASTM A609/ A609M ( 2012; R 2023) St andar d Pr act i ce f or Cast i ngs, Car bon, Low- Al l oy, and Mar t ensi t i c St ai nl ess St eel , Ul t r asoni c Exami nat i on Ther eof

ASTM A668/ A668M ( 2023) St andar d Speci f i cat i on f or St eel For gi ngs, Car bon and Al l oy, f or Gener al I ndust r i al Use

ASTM A705/ A705M ( 2023) St andar d Speci f i cat i on f or Age- Har deni ng St ai nl ess St eel For gi ngs

ASTM A709/ A709M ( 2021) St andar d Speci f i cat i on f or St r uct ur al St eel f or Br i dges

ASTM B148 ( 2014) St andar d Speci f i cat i on f or Al umi num- Br onze Sand Cast i ngs

ASTM B584 ( 2022) St andar d Speci f i cat i on f or Copper Al l oy Sand Cast i ngs f or Gener al Appl i cat i ons

ASTM D3233 ( 1993; R 2014) St andar d Test Met hods f or Measur ement of Ext r eme Pr essur e Pr oper t i es

SECTI ON 35 01 41 Page 4 AMEND 0001 of Fl ui d Lubr i cant s ( Fal ex Pi n and Vee Bl ock Met hods)

ASTM D3951 ( 2018) Commer ci al Packagi ng

ASTM D4172 ( 1994; R 2016) St andar d Test Met hod f or Wear Pr event i ve Char act er i st i cs of Lubr i cat i ng Fl ui d ( Four - Bal l Met hod)

ASTM E94/ E94M ( 2022) St andar d Gui de f or Radi ogr aphi c Exami nat i on Usi ng I ndust r i al Radi ogr aphi c Fi l m

ASTM E1030/ E1030M ( 2015) St andar d Test Met hod f or Radi ogr aphi c Exami nat i on of Met al l i c Cast i ngs

ASTM E1032 ( 2019) St andar d Pr act i ce f or Radi ogr aphi c Exami nat i on of Wel dment s Usi ng I ndust r i al X- Ray Fi l m

ASTM E1444 ( 2022a) St andar d Pr act i ce f or Magnet i c Par t i c l e Test i ng f or Aer ospace

ASTM E1742/ E1742M ( 2018) St andar d Pr act i ce f or Radi ogr aphi c Exami nat i on

ASTM E1955 ( 2004; R 2014) St andar d Radi ogr aphi c Exami nat i on f or Soundness of Wel ds i n St eel by Compar i son t o Gr aded ASTM E 390 Ref er ence Radi ogr aphs

ASTM F436/ F436M ( 2019) St andar d Speci f i cat i on f or Har dened St eel Washer s I nch and Met r i c Di mensi ons

ASTM F3125/ F3125M ( 2019) St andar d Speci f i cat i on f or Hi gh St r engt h St r uct ur al Bol t s and Assembl i es, St eel and Al l oy St eel , Heat Tr eat ed, I nch Di mensi ons 120 ksi and 150 ksi Mi ni mum Tensi l e St r engt h, and Met r i c Di mensi ons 830 MPa and 1040 MPa Mi ni mum Tensi l e St r engt h

I NTERNATI ONAL ORGANI ZATI ON FOR STANDARDI ZATI ON ( I SO)

I SO 10360- 2 ( 2009) Geomet r i cal Pr oduct Speci f i cat i ons ( GPS) — Accept ance and Rever i f i cat i on Test s f or Coor di nat e Measur i ng Machi nes ( CMM) — Par t 2: CMMs Used f or Measur i ng Li near Di mensi ons

1. 2 SUBMI TTALS

Gover nment appr oval i s r equi r ed f or submi t t al s wi t h a " G" c l assi f i cat i on.

Submi t t al s not havi ng a " G" c l assi f i cat i on ar e f or i nf or mat i on onl y. When used, a code f ol l owi ng t he " G" c l assi f i cat i on i dent i f i es t he of f i ce t hat wi l l r evi ew t he submi t t al f or t he Gover nment . Submi t t he f ol l owi ng i n accor dance wi t h Sect i on 01 33 00 SUBMI TTAL PROCEDURES:

SECTI ON 35 01 41 Page 5 AMEND 0001

SD-01 Preconstruction Submittals

Equipment Protection Plan ; G, ECD

Materials List ; G, ECD

SD-02 Shop Drawings

Materials Orders

Shipping Bills

Keys And Keyways ; G, ECD

Cleaning of Corrosion-Resisting Steel ; G, ECD

SD-03 Product Data

Manufacturer's Literature and Equipment Data ; G, ECD

Sleeve Bearings ; G, ECD

SD-06 Test Reports

Shop Assembly and Tests

Records ; G, ECD

Contractor Tests ; G, ECD

SD-07 Certificates

Equipment Manufacturer's and Fabricator's Qualifications

Equipment Warranty

Nondestructive Examination Certification

1.3 QUALITY ASSURANCE

1.3.1 Manufacturer and Assembler

Manufacturing and assembly of the miter gate and tainter valve, machinery units is to be performed by a Contractor and fabrication company that has been normally and regularly engaged in assembly, and manufacture of heavy machinery over the preceding 10 years. Changes to the dimensions shown on the drawings and in the Bill of Materials for the Gate and Valve Machinery (including structural supports) requires written approval from the Contracting Officer. Submit Equipment Manufacturer's and Fabricator's Qualifications showing evidence and years of experience for each of the equipment manufacturers and fabricators. Identify any certifications, standards, and/or professional organizations the manufacturers comply with or are members of.

1.3.2 Quality Control

Establish and maintain quality control for operations to assure compliance with Contract requirements and maintain records of quality control for all materials, fabricated parts, equipment, and construction operations. In

SECTION 35 01 41 Page 6 AMEND 0001 addition, establish and maintain surveillance for quality control over sub-Contractors, suppliers, or manufacturers. The Contractor's quality control to include a minimum of two shop inspections during manufacture and assembly of each of the following items: the hydraulic cylinder assemblies, hydraulic rotary actuators, hydraulic power units, and manifolds. The quality control includes, but not be limited to, the following:

a. Materials and workmanship.

b. Cleaning and flushing.

c. Shop assembly and tests.

d. Damage and defects.

e. Controls system software and hardware compatibility and supportability (off-the-shelf items with future manufacturers support).

Submit these records and Contractor tests , as well as the records of corrective action taken.

1.4 DELIVERY, STORAGE, AND HANDLING

1.4.1 Delivery, Storage and Handling of Equipment

Protect equipment and components from corrosion, deformation, and other types of damage. Store items in enclosed and secured areas free from contact with soil. Provide moisture proof weather protection for all equipment stored in outdoor locations. Transport, handle and store all equipment in accordance with the manufacturer's written instructions.

Remove and replace damaged items with new items. Do not prepare the major pieces of lock operating equipment and subassemblies for shipment until they have been inspected and accepted for shipment at origin by the Contracting Officer, unless inspection has been waived in writing. Ship each subassembly completely assembled. Submit the shipping bills with the delivery of finished pieces to the site. The major pieces of equipment and subassemblies for this contract are defined to include the following:

a. Miter Gate Operating Machinery

b. Pintle Assembly

c. Gudgeon Assembly

1.4.1.1 Packaging

Provide equipment and subassemblies with adequate protective pads, supports, and blocking. Securely restrain equipment and subassemblies to prevent distortion or damage to the painted surfaces in transit. Any loss or damage during shipment, including damage to the painted surfaces, is the responsibility of the Contractor. Replace or repair lost or damaged items without cost to the Government. Coat all parts with a rust preventative, wrap in heavy-duty plastic, and securely contain in wooden crates. Clearly mark each crate with its contents (including contract number and Corps mark number) on the outside, with a non-ferrous metal tag, engraved with the contents, and secured to the crate with non-ferrous screws. Provide a means for inspection of the crate's contents without destroying the crate. Pack all accessories and spare parts separately in containers plainly marked "ACCESSORIES ONLY," or "SPARE PARTS ONLY."

Package each spare part or spare part assembly in a durable treated wooden

SECTION 35 01 41 Page 7 AMEND 0001 crate with metallic, plastic or suitable outer shell for weathertight protection and with provisions for handling and long-term storage (60 months). Provide and deliver the component and assembly spare parts as delineated on the drawings. Place a separate packing list, listing the contents of each crate, in a moisture-proof envelope securely fastened to the outside of the crate. Standard commercial packaging in accordance with ASTM D3951 is acceptable except where a different method or standard of packaging is specified.

1.4.1.2 Shipping, Preservation, and Storage

Provide all packing, crating, e.g., necessary to ensure safe shipment of equipment. The crates become the property of the Government unless specifically waived. Protect stored equipment from the weather, humidity, temperature variation, dirt and dust, or other contaminants.

PART 2 PRODUCTS

2.1 MISCELLANEOUS METALS FABRICATION

Refer to Section 05 50 14 STRUCTURAL METAL FABRICATIONS general fabrication requirements

2.1.1 Stainless Steel Plate, Sheet, and Strip

Provide in accordance with ASTM A240/A240M , UNS S43000. Plate finish to be hot-rolled and annealed or heat treated, and blast cleaned or pickled.

Sheet and strip finish to be No. 1.

2.1.2 Steel Forgings

2.1.2.1 Pins

Provide pins in accordance with ASTM A564/A564M XM-13, H1100 , SAE AISI 4140, or ASTM A564/A564M type 630, H1025 as indicated.

2.1.3 Aluminum Bronze Castings

Provide in accordance with ASTM B584, Copper Alloy UNS No. C93200 or ASTM B148 C95700 as indicated .

2.1.4 Bolts, Nuts, and Washers

Provide bolts, nuts, and washers of the material, grade, type, class, style and finish indicated or best suited for intended use.

2.1.4.1 High-Strength Bolts, Nuts, and Washers

Provide in accordance with ASTM F3125/F3125M , Grade A490, Type I hot-dip galvanized.

2.1.4.2 Bolts, Nuts, and Washers (Other Than High-Strength)

a. Bolts and Nuts - Provide in accordance with ASTM A307 , Grade A, hot-dip galvanized or ASTM A320/A320M , Austenitic Steel, Class 2.

b. Bolts - Provide in accordance with ASME B18.2.1 .

c. Nuts - Provide in accordance with ASME B18.2.2 .

SECTION 35 01 41 Page 8 AMEND 0001

12 AUG 2024

d. Washers

(1) Plain Washers - Provide in accordance with ANSI/ASME B18.22.1 ,Type B.

(2) Lock Washer - Provide in accordance with ASME B18.21.1 .

(3) Beveled Washers - Provide in accordance with ASTM F436/F436M , Type I, Beveled.

2.1.5 Screws

Provide material, grade, type, style, and finish indicated or best suited for use intended.

a. Cap Screws: Provide in accordance with ASME B18.2.1 , ASME B18.3 , or ASME B18.6.2 as required.

b. Machine Screws: Provide in accordance with ASME B18.6.3 .

2.2 EQUIPMENT

2.2.1 Machinery

Furnish equipment under this specification consisting of four Ohio type gate operating machinery units. Furnish complete units including base supports, shafts, bearings, covers, guards, and other necessary items to provide a complete and operable system.

2.2.2 Equipment Submittal Data

Submit Data Package 5 in accordance with Section 01 78 00 CLOSEOUT SUBMITTALS for limit switches and any other shop fabricated items and factory built miter gate and tainter valve machinery. Provide all details of fabrication and assembly to include shipping and long term storage instructions. Shop drawings lacking this information will be rejected.

Approval of the material submitted in no way relieves the Contractor from the responsibility of complying with the requirements of the specifications as to the suitability and quality of materials and workmanship and the adequacy of capacity, operating speed and other essential characteristics of the gate and valve drives. Submit drawings, catalogs, and design data necessary to clearly show the details of any changes proposed in conformity with the requirements of this specification. Equipment, materials, and articles of construction installed or used without such approval will be at the risk of subsequent rejection.

Submit a materials list for fabricated items at the time as the detail drawings submittal.

Submit copies of all materials orders including purchase orders, mill orders, shop orders and work orders for materials prior to using the materials in the work.

Submit Manufacturer's Literature and Equipment Data for approval. Provide catalog cuts and material data for the proposed equipment that clearly indicates compliance with the requirements of these specifications and the Contract Drawings. Submit AGMA ratings for gear quality of all gears and

SECTION 35 01 41 Page 9 AMEND 0001 gear reducers. Include the names of the manufacturers of all machinery and other equipment contemplated for incorporation into the work, performance capacities and other pertinent information about the equipment. As a minimum, include the following Manufacturer's Literature and Equipment Data:

2.2.2.1 Pillow Block and Sleeve Bearing

Submit the following data for the sleeve bearings .

Manufacturer's Name Type Size Bearing Housing Material Sleeve Bearing Material/Grade Coefficient of Friction Coefficient of Thermal Expansion Bearing Bore Diameter

Type of Bearing

Static Capacity of Bearing

2.3 BEARINGS

2.3.1 Sector Shaft Bearing Assemblies

The sector shaft bearing assemblies include the bearings, housings, and hardware. Housings are to be split type, with painted cast steel machined base housing with a tapped, four bolt base. Except as otherwise specified, shaft bearings are to be self-lubricating flanged plain bearings suitable for the installation and conform to the requirements of ASTM B584, Alloy C93200. For self lubrication information see Section

35 05 40.17 SELF-LUBRICATED MATERIALS, FABRICATION, HANDLING, AND ASSEMBLY.

2.3.2 Flanged Sleeve Type Plain Pillow Block Bearing Assemblies

Provide one piece type bearing pillow block, painted forged steel conforming to ASTM A668/A668M Class E machined base housing with a tapped, bolted base. Slip the sleeve type plain bearings into the bearing housing bore. Use bolts to secure the plain sleeve bearings. Provide machined grease and oil grooves in the interior of the bearing unless otherwise shown. Break all edges of the grease grooves to provide a minimum 1/16 inch fillet radius.

2.3.3 Spherical Bearing Assemblies

The spherical block bearing assemblies include the bearings, housings, and hardware. Housings are to be split type, with painted forged steel machined base housing with a bolt base. Except as otherwise specified, shaft bearings are to be plain bearings suitable for the installation and conform to the requirements of ASTM B584, Alloy C93200. Provide machined grease and oil grooves in the interior of the bearing unless otherwise shown. Break all edges of the grease grooves to provide a minimum 1/16 inch fillet radius.

SECTION 35 01 41 Page 10 AMEND 0001

2.4 SHAFTS

The sector shaft must be ASTM A564/A564M type 630, H1025 to the dimensions and tolerances indicated.

2.5 SECTOR ARM

Fabricate sector arm from steel forgings conforming to ASTM A668/A668M Class J. Machine sector arm to meet the dimensions, surface finish and tolerances indicated. Weight saving regions in the center do not require machining.

2.6 STRUT ARM

2.6.1 Casing

Fabricate casing from a steel forging conforming to ASTM A668/A668M Class E. Machine casing to meet the dimensions, surface finish and tolerances indicated.

2.6.2 Buffer Yoke

Fabricate buffer yoke from a steel forging conforming to ASTM A668/A668M Class E. Machine buffer yoke to meet the dimensions, surface finish and tolerances indicated.

2.6.3 Sector Connection

Fabricate sector connection from a steel forging conforming to ASTM A668/A668M Class E. Machine sector connection to meet the dimensions, surface finish and tolerances indicated.

2.7 STRUCTURAL BASES AND SUPPORTS

Structural bases and supports including the support base and actuator frame are welded steel fabricated from steel conforming to ASTM A709/A709M Grade 36.

For specific requirements for welded structural steel bases, frames, and supports see Section 05 50 14 STRUCTURAL METAL FABRICATIONS.

2.8 PINTLE BUSHING AND CAP

Fabricate pintle cap from forged steel conforming to ASTM A668/A668M .

Provide a grease lubricated alloy bronze pintle bushing to the dimensions and tolerances indicated. For the bushing material use bronze conforming to ASTM B584, C93200. Machine the bushing from a solid piece of material to acquire the shape and surface finishes indicated. Provide a surface finish of 16 micro-inches or better on the running bearing surface.

Mechanically secure the bushing into the gate as indicated without distortion or altering the fit with the mating pintle ball.

The maximum static bearing pressure for the pintle bushing are not to exceed 4000 psi when a normal load of 575 kips is applied at an angle of

41.7 degrees from horizontal. Pintle bushings will operate submerged.

2.9 PINTLE BALL

Fabricate pintle ball(s) from steel castings conforming to ASTM A705/A705M , SECTION 35 01 41 Page 11 AMEND 0001

12 AUG 2024

T635 condition A, minimum hardness 40 Rc. Machine pintle ball(s) to meet the dimensions, surface finish and tolerances as indicated. Any casting patterns developed become property of the Government and are to be packaged for long term storage with the pertinent part identification provided on the exterior packaging. Free float the pintle ball into the pintle shoe as indicated without distortion or altering the fit with the mating pintle bushing. Furnish removable lifting eyes with the pintle ball for lifting. Mate the pintle ball bearing surface with the pintle bushing through metrology methods and the use of a calibrated scanning probe coordinate measuring machine that meets the requirements of ISO 10360-2 , by lapping mating components to achieve the indicated tolerances and compared with contact tape to confirm uniform bearing contact. Test the contact area between the mating components, witnessed by the Government, to achieve a bearing contact area of 85 percent or better to be acceptable. Match-mark the pintle ball with the bushing when fitted and so erected in the field.

2.10 PINTLE SHOE

Fabricate pintle shoes from steel castings conforming to ASTM A27/A27M, Grade 70-36. Machine pintle shoes to meet the dimensions, surface finish and tolerances indicated. Any casting patterns developed become property of the Government and are to be packaged for long term storage with the pertinent part identification provided on the exterior packaging.

2.11 PINTLE BASE

Fabricate pintle bases from steel castings conforming to ASTM A668/A668M , Class K. Steel casting conforming to ASTM A27/A27M Grade 65-35 is an acceptable substitute. Machine pintle bases to meet the dimensions, surface finish and tolerances indicated. Any casting patterns developed become property of the Government and are to be packaged for long term storage with the pertinent part identification provided on the exterior packaging. Drill and ream bolt holes for attaching pintle cap to gate leaf after the pintle cap is assembled with gate leaf. Connect pintle cap to the bottom of the lower girder web of the gate leaf with stainless steel bolts.

2.12 GUDGEON TERMINALS

Fabricate gudgeon terminals from steel castings conforming to ASTM A668/A668M Class J. Machine terminals to meet the dimensions, surface finish and tolerances indicated. Any casting patterns developed become property of the Government and are to be packaged for long term storage with the pertinent part identification provided on the exterior packaging. Die stamp terminals with identification numbers as indicated.

Connect gudgeon terminal eyes/fork by a pin to the gudgeon embedded anchorage and provide a threaded section for adjustment of the gate leaf.

2.13 SPLIT NUT

Fabricate split nuts from steel forgings conforming to ASTM A668/A668M Class J. Machine split nuts to meet the dimensions, surface finish and tolerances indicated. Provide the threaded section of the split nut with ACME threads of differing thread count such that rotating the split nut results in adjustment as shown. Minimum allowable backlash between terminal with 7.750 – 1.00 ACME-4C RH external thread and sleeve nut with

7.750 – 1.00 ACME-4C RH internal thread is 0.005 inch and the maximum

SECTION 35 01 41 Page 12 AMEND 0001 allowable backlash is 0.015 inch. Minimum allowable backlash between anchor bar with 7.750 – 1.33 ACME-4C RH external thread and sleeve nut with 7.750 – 1.33 ACME-4C RH internal thread is 0.005 inch and the maximum allowable backlash is 0.015 inch.

2.14 GUDGEON BUSHINGS

Fabricate bushings from bronze bushing conforming to ASTM B584 C93200.

2.15 KEYS AND KEYSEATS

All shafts are to have standard keyways and keys in accordance with ASME B17.1 , Class 2. Submit all fabricated dimensions of the keys and keyways .

2.16 HYDRAULIC STEEL STRICTURES IDENTIFICATION NUMBERS

Prior to painting apply identification numbers. Identification numbers are 1/2 inch tall characters, low-stress die-stamped into the steel fabrications in the locations shown. The low-stress die stamps have a minimum tip radios of 0.020 inch and a nominal impression width for a

0.010 inch depth of 0.062 inch.

2.17 PAINTING

Paint all exposed ferrous surfaces in accordance with Section 09 97 02 PAINTING: HYDRAULIC STRUCTURES. Paint equipment and components not otherwise specified by Section 09 97 02 PAINTING: HYDRAULIC STRUCTURES with Paint System 5-E-Z.

2.18 SHOP ASSEMBLY AND TESTS

2.18.1 General

a. Each machinery unit consisting of the strut arm, support base, gudgeon, pintle and bearings is to be completely assembled with its respective mating components in the shop and checked for fit.

b. Match mark the various assemblies prior to shipment. Machinery that arrives on site without the machinery base installed will be rejected.

2.18.2 Alignment

Conform alignment of interconnecting shafts to the installation requirements of the coupling and gear manufacturers in accordance with standard AGMA practices. Accurately align each machinery or structural unit by the use of stainless steel shims or other approved methods so that no binding in any moving parts or distortion of any member occurs before it is fastened in place. The alignment of all parts with respect to each other is to be true within the respective manufacturer's tolerances required. Set machines true to the elevations indicated.

2.18.3 Anti-Seize Lubricant

Assemble threaded portions of the assemblies using an anti-seize lubricant that prevents galling of parts and corrosion, allows for easy disassembly of parts, and reduces friction unless otherwise noted or specified.

Select anti-seize lubricant that is a standard product designed for the

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2.18.4 Acceptance

All readings taken from the equipment, components or assemblies are required to be within the specified limits. Failure of any part to meet these contract requirements is cause for rejection of the entire quantity until action is taken to correct defects and prevent recurrence and such actions have been approved by the Contracting Officer. Retesting is subject to the same random sampling and testing procedures as the original lots.

PART 3 EXECUTION

3.1 MACHINE WORK

3.1.1 Finished Surfaces

a. Surface finishes indicated or specified herein, are to be in accordance with ASME B46.1 . Determine compliance with specified surface by sense of feel and by 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 are not specified but have to be consistent with the general type of finish specified by roughness height. Flaws such as scratches, ridges, holes, peaks, cracks, or checks which will make the part unsuitable for the intended use are cause for rejection.

b. Where the finish is not indicated or specified, the type of finish is that which is most suitable for the particular surface and provides the class of fit required. Maximum surface roughness of any surface is 250 micro-inch . Indicate surfaces to be machine finished by symbols which conform to ASME B46.1 .

3.1.2 Unfinished Surfaces

In so far as practicable, lay out all work to secure proper matching of adjoining unfinished surfaces. Where there is a large discrepancy between adjoining unfinished surfaces, chip and grind smooth or machine to secure proper alignment. Unfinished surfaces are to be true to the lines and dimensions indicated and have to be chipped or ground free of all projections and rough spots. Fill depressions or holes not affecting the strength or usefulness of the parts in a manner approved by the Contracting Officer.

3.1.3 Pin Holes

Bore pin holes true to gages, smooth, straight, and at right angles to the axis of the member. Perform the boring after the member is securely fastened in position.

3.2 NONDESTRUCTIVE EXAMINATION

3.2.1 NDT Agency Requirements

Conduct NDT examinations using a testing agency adequately equipped and competent to perform such services or using suitable equipment and qualified personnel. In either case, provide written approval of the examination procedures and perform the examination tests in the presence

SECTION 35 01 41 Page 14 AMEND 0001 of the Contracting Officer. Persons performing the NDT examination are to be qualified for the specific procedure used in accordance with ASNT SNT-TC-1A . Submit nondestructive examination certification of qualified persons, procedures and equipment performing or used for nondestructive testing.

3.2.2 Nondestructive Testing (NDT) for Flaws

For all components to be furnished ultrasonically scan a quantity representing approximately 5 percent of the total supplied quantity for internal defects as specified. Select components, specified below, require (100 percent) of the quantities furnished to be NDT examined to satisfy the specific requirements herein. The minimum quantities and requirements for testing are shown in TABLE 2, below. Lots from which examined specimen parts are selected have to consist of at least 25 percent of the total quantity of each type part to be furnished. A lot is the completed components of a given type available at the inspection site. The Contracting Officer will select parts to be examined at random. Notify the Government one week prior to when the lots are available for specimen selection. Flawed specimens (excessive inclusion size, out-of-tolerance dimension or hardness, or excessive surface roughness) are subject to rejection.

Testing of castings must be according to ASTM A609/A609M , and testing of forgings must be according to ASTM A388/A388M .

3.2.3 Quality Assurance Measurements

Conduct inspections to supplement the Quality Control NDT in the presence of the Contracting Officer. This testing is to verify that dimensions, hardness and finish are within required tolerances. Perform this testing of the chain components at the fabrication site.

Quantities subject to this testing are specified in Table 2. Parts to be examined will be selected at random by the Contracting Officer. Lots from which inspected parts are selected consist of at least 25 percent of the total quantity of each type part to be furnished. A lot is the completed components of a given type available at the inspection site. Notify the Government one week prior to when the lots are available for specimen selection and inspection. More than one testing date may be required.

TABLE 2 QUALITY ASSURANCE TESTING

ITEM MEASURED AND RECORDED PARAMETERS

Hinge Anchorage Pin Hinge Gudgeon Pin Miter-op Strut Arm Vertical Pin Miter-op Strut Arm Horizontal Pin Miter-op Sector Arm Pin

OD, FINISH, UST OD, FINISH, UST

OD, FINISH, UST OD, FINISH, UST

OD, FINISH, UST OD, FINISH, UST

OD, FINI SH, UST OD, FINISH, UST

Miter-op Strut Arm Buffer Yoke OD, WIDTH, FINISH

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TABLE 2 QUALITY ASSURANCE TESTING

ITEM MEASURED AND RECORDED PARAMETERS

Miter-op Sector Shaft OD, BHN, FINISH, UST

Terminals (Fork, Long and Short) ID, FINISH, UST

Pintle Shoe ID, FINISH, UST

Pintle Base UST

Pintle Ball OD, FINISH, UST

Pintle Cap ID, FINISH, UST

Sector Arm ID, FINISH, UST

TABLE 2 Notes:

a. OD = Outside Diameter, ID = Inside Diameter, BHN = Brinell Hardness Number, FINISH = Surface Finish, UST = Ultrasonic Scan Test

b. Take two measurements per parameter per specimen.

c. Test specimen quantities shown are at least 5 percent of the total quantity furnished.

d. Measure inside diameters of both bores and take one measurement per bore. Measure pitch tolerance derived from sidebar inside diameter edge to edge measurements. Take two hardness readings per specimen.

Take two width measurements per specimen.

e. Measure inside and outside diameter of each selected Bearing (three measurements per bore and three measurements per OD).

3.2.4 Pintle Component Nondestructive Testing Examination

All Pintle bushings, balls and fabricated pintle components are to have ANSI/ASNT CP-189 , ASNT SNT-TC-1A , AIA/NAS NAS410 qualified personnel perform radiographic NDT testing in accordance with the guidelines, practices and applicable testing standards set forth in ASTM E94/E94M, ASTM E1742/E1742M , ASTM E1030/E1030M , and ASTM E1032. Also test the pintle components by magnetic particle NDT methods in accordance with supplementary requirement S3.1 of ASTM A290/A290M . Other NDT methods are subject to Government approval. Radiographic acceptance criteria for castings satisfies the minimum severity level requirements for a Grade I condition as defined by ASTM E1955.

Any cracks found are unacceptable and reason for immediate rejection.

Evaluate all relevant indications greater than 1/16 inch in length present on radiographic films against the specified acceptance criteria. Where the length of each indication (li) within an area of interest and along a continuous straight line oriented in the direction of interest are measured. If the distance between two indications is smaller in length than the length of the smaller indication then both indications have to be

SECTION 35 01 41 Page 16 AMEND 0001 added and treated as a single indication to include the distance of both indications as well as the distance between the indications. The total indication length is obtained as the sum of all indication lengths on a straight line within the area of interest. The maximum total indication length (lim) on any such single straight line is used to assess acceptance of the casting being evaluated.

3.2.5 Terminal Eyes/Fork and Split Nut Thread Testing

The anchorage bar threads must be tested 100 percent by wet fluorescent magnetic particle inspection in accordance with ASTM E1444.

3.3 WELDING

See Section 05 59 20 FABRICATION OF HYDRAULIC STEEL STRUCTURES for welding requirements.

3.4 MISCELLANEOUS PROVISIONS

3.4.1 Cleaning of Corrosion-Resisting Steel

After fabrication, remove oil, paint, and other foreign substances from corrosion-resisting steel surfaces. Clean by vapor degreasing or by the use of cleaners of the alkaline, emulsion, or solvent type. After the surfaces have been cleaned, final rinse with clean water followed by a 24 hour period during which the surfaces are intermittently wet with clean water and then allowed to dry for the purpose of inspecting the clean surfaces. Visually inspect the surfaces for evidence of paint, oil, grease, welding slag, heat treatment scale, iron rust, or other forms of contamination. If evidence of foreign substance exists, clean the surface in accordance with the applicable provisions of ASTM A380/A380M . Submit the proposed method of treatment. After treatment visually reinspect the surfaces. Brushes used to remove foreign substances may only have stainless steel or nonmetallic bristles. Remove any contamination occurring subsequent to the initial cleaning by one or more of the methods indicated above.

3.4.2 Protection of Finished Work

Submit an equipment protection plan with detailed information on the methods proposed to protect the existing equipment from such operations as power washing, abrasive blast cleaning, welding, placement of concrete, and painting. Thoroughly clean machined surfaces of foreign matter.

Protect all finished surfaces by suitable means. Unassembled pins and bolts are to be oiled and wrapped with moisture-resistant paper or protected by other approved means.

3.4.3 Lubrication

Lubricate all the components of the equipment requiring lubrication using only the lubricants specified. Provide and lubricate the components and assemblies, in their entirety, after assembly with a lubricant which meets the following minimum characteristics:

ISO Grade 46

Four Ball Wear Test ( ASTM D4172) 0.39 mm

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Falex EP ( ASTM D3233) 100 pounds force

3.5 SPARE PARTS

3.5.1 Miter Gate Spare Parts

SPARE PARTS LIST

Part Name Spare Qty Req'd

Pintle Ball 4

Pintle Bushing 4

Terminal Eye Short 4

Anchorage pin 2

Anchorage Pin Bushing 2

Anchorage Keeper Plate 4

Anchorage Spacer Ring 2

Split Nut Top 4

Split Nut Bottom 4

Split Nut Shim 8

Terminal Fork 3 Terminal Eye Long 3

Gudgeon Pin 3

Gudgeon Pin Bushing 1

Gudgeon Keeper Plate 2

Gudgeon Pin Bushing Long 1

3.5.2 Miter Gate Operating Machinery Spares

SPARE PARTS LIST

Part Name Spare Qty Req'd

Upstream Sector Arm 1

Downstream Sector Arm 1

Sector Shaft 1

Strut Arm Vertical Pin 2

Strut Arm Horizontal Pin 2

Upstream Strut Arm Beam 1

Downstream Strut Arm Beam 1

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Strut Arm Buffer Yoke 1

Strut Arm Bushing 1

Strut Arm Bushing 2 1

Strut Arm Bushing 3 1

Strut Arm Casing 1

Strut Arm Casing Cover 1

Strut Arm Casing Cover 2 1

Strut Arm Bushing Bottom 1

Strut Arm Bushing Top 1

Strut Arm Central Sleeve 1

Strut Arm Buffer Sleeve 1

Strut Arm Sector Connection 1

Strut Arm Follower 4

Strut Arm Collar 1

3.6 Equipment Warranty

Submit manufacturer's standard warranty or guarantee for equipment, e.g., speed reducers, or any other equipment. Identify any warranties that extend beyond a 1-year period.

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