Specs_25R0009AM0001_Amendment0001.pdf

SF 30 CONTINUATION SHEET

Canaveral Lock Sector Gate Replacement Brevard County, Florida

W912EP25R0009 1 Amendment 0001

SUMMARY OF CHANGES

1. SPECIFICATIONS:

Volume 1:

No Change.

Volume 2:

DELETE Section 01 10 00 and REPLACE with the attached Section 01 10 00.

DELETE Section 05 50 13 and REPLACE with the attached Section 05 50 13.

DELETE Section 06 73 01 and REPLACE with the attached Section 06 73 01.

DELETE Section 06 90 00 and REPLACE with the attached Section 06 90 00.

2. DRAWINGS:

No Change.

(End of Summary of Changes)

SECTION TABLE OF CONTENTS

DIVISION 01 - GENERAL REQUIREMENTS

SECTION 01 10 00

STATEMENT OF WORK

PART 1 GENERAL

1.1 REFERENCES

1.2 SUBMITTALS

1.3 PROJECT DESCRIPTION

1.3.1 Project Objectives

1.3.2 Optional Work

1.3.2.1 Furnishment of Spare Lower Pintle and Upper Hinge

Assemblies (Option Item)

1.3.2.2 Furnishment of Spare Gate Seals (Option Item)

1.3.2.3 Furnishment of Wire Rope (Option Item)

1.3.2.4 Furnishment of Spare Manatee Screens (Option Item)

1.3.2.5 Training (Option Item)

1.3.3 Location

1.3.4 Bridging Documents

1.3.5 Section Organization

1.4 UNITS OF MEASURE

1.5 SCOPE

1.5.1 General

1.6 GENERAL REQUIREMENTS

1.6.1 Design Requirements

1.6.2 Delivery, Storage, and Handling

1.6.2.1 On-Site Assembly

1.6.2.2 Barge Delivery

1.6.3 Architectural Requirements

1.6.4 Mechanical Requirements

1.6.5 Fire Protection

1.6.6 Manatee Protection System

1.6.7 Fabricator's Representation During Government Installation

1.7 APPLICABLE CRITERIA

1.7.1 Industry Criteria

1.7.2 Military Criteria

1.8 TECHNICAL REQUIREMENTS

1.8.1 Structural Design

1.8.1.1 Finite Element Analysis (FEA)

1.8.1.2 Loads and Load Combinations

1.8.1.3 Serviceability Requirements and Deflection

1.8.1.4 Thermal Expansion

1.8.1.5 Gate Seals

1.8.1.6 Framing

1.8.1.7 Pintles and Hinges

1.8.1.8 Gate Stops

1.8.1.9 Fender System

1.8.1.10 Jacking Supports

1.8.1.11 Lifting Points

1.8.1.12 Walkways

1.8.1.13 Manatee Protection

1.8.2 Mechanical Design

SECTION 01 10 00 Page 1 W912EP25R0009 Amendment 0001

1.8.2.1 Design Forces

1.8.2.2 Gate Bottom Seals

1.8.2.3 Lower Pintle Assembly

1.8.2.4 Upper Hinge

1.8.2.5 Machinery

1.8.2.5.1 Wire Rope Cable Guide Track

1.8.2.5.2 Limit Switches

1.9 TECHNICAL SUPPORT DURING INSTALLATION SUPPORT

1.9.1 Meetings

1.9.2 Technical Input/Recommendations

PART 2 PRODUCTS (NOT USED)

PART 3 EXECUTION (NOT USED)

ATTACHMENTS:

Attachment A Bridging Plans

Attachment B Site Photos

Attachment C As-Built Drawings

Attachment D Design Loads

Attachment E Delivery Location

Attachment F Barge Hydrographic Survey

Attachment G Manatee Protection System

-- End of Section Table of Contents --

SECTION 01 10 00 Page 2

SECTION 01 10 00

STATEMENT OF WORK

PART 1 GENERAL

1.1 REFERENCES

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

AMERICAN COMPOSITES MANUFACTURER'S ASSOCIATION (ACMA)

ACMA Code (2011) Code of Standard Practice: Industry Guidelines for Fabrication and Installation of Pultruded FRP Structures

AMERICAN IRON AND STEEL INSTITUTE (AISI)

AISI S100 (2012) North American Specification for the Design of Cold-Formed Steel Structural Members

AMERICAN SOCIETY OF CIVIL ENGINEERS (ASCE)

ASCE 7-22 (2022; Supp 1 2023; Supp 2 2023) Minimum Design Loads and Associated Criteria for Buildings and Other Structures

ASCE 74-23 (2023) Load And Resistance Factor Design (LRFD) for Pultruded Fiber Reinforced Polymer (FRP) Structures

ASCE MOP 102 (2011) Design Guide for FRP Composite Connections

AMERICAN WELDING SOCIETY (AWS)

AWS-03 (2011) Welding Handbook, Volumes 1 thru 4

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME B18.16.6 (2022) Prevailing Torque Locknuts (Inch Series)

ASME BTH-1 (2014) Design of Below-the-Hook Lifting Devices

ASTM INTERNATIONAL (ASTM)

ASTM D4956 (2013) Standard Specification for Retroreflective Sheeting for Traffic Control

SECTION 01 10 00 Page 3

ASTM E84 (2023) Standard Test Method for Surface Burning Characteristics of Building Materials

FLORIDA DEPARTMENT OF TRANSPORTATION (FDOT)

FDOT Specifications (2023) Standard Specifications for Road and Bridge Construction

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE 1100 (2005) Emerald Book IEEE Recommended Practice for Powering and Grounding Electronic Equipment

IEEE C2 (2023) National Electrical Safety Code

INTERNATIONAL CODE COUNCIL (ICC)

ICC IBC (2021) International Building Code

ICC IMC (2021) International Mechanical Code

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2023) National Electrical Code

NFPA 70E (2021) Standard for Electrical Safety in the Workplace

U.S. ARMY CORPS OF ENGINEERS (USACE)

EM 1110-2-2610 (2013) Engineering and Design -- Mechanical and Electrical Design for Lock and Dam Operating Equipment

EM 1110-2-3200 (2016) Wire Rope for Civil Works Structures

EM 1110-2-3402 (2022) Barge Impact Forces For Hydraulic Structures

EM 1110-2-1424 (2016) Engineering and Design -- Lubricants and Hydraulic Fluids

EM 1110-2-1604 (2006) Hydraulic Design of Navigation Locks

EM 1110-2-2107 (2022) Design of Hydraulic Steel Structures

EM 1110-2-2602 (1995) Planning and Design of Navigation Locks

ER 1110-2-1086 (2016) Earthquake Design and Evaluation for Civil Works Projects

U.S. DEPARTMENT OF DEFENSE (DOD)

UFC 1-300-02 (2014; with Change 3, 2021) Unified Facilities Guide Specifications (UFGS) Format Standard

SECTION 01 10 00 Page 4

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

Delivery Plan and Drawing(s)

1.3 PROJECT DESCRIPTION

1.3.1 Project Objectives

This supply contract's objective is to design, fabricate, and deliver a quantity of two Fiberglass Reinforced Polymer (FRP) sector gates for the Canaveral Lock. The eastern set of gates is known as the upper gates, the western set of gates is known as the lower gates. The set of upper gates are slightly taller than the lower set. This project is for fabrication of the two upper gates and appurtenances, the two lower gates are not included.

In addition to the gates, this contract also includes fabrication of gate appurtenances including both the lower pintle and upper hinge assemblies.

The Contractor is responsible for delivering the gates to the project site via barge. The gates must be assembled prior to delivery. Installation of the gate into the lock recess is not part of this contract.

Fabricate the entire gate out of FRP composites with the exception of the hinge, pintle, and lifting assemblies, and operating machinery connections.

It is the Government's objective that the gates have a 100 year service life. The design and fabrication must provide an appropriate level of quality to ensure the continued use of the gates over that time period with the application of reasonable preventive maintenance and repairs that would be industry-acceptable to a major civilian sector project owner.

Requirements stated in this contract are minimums.

1.3.2 Optional Work

Refer to Section 00010A LINE ITEMS AND PRICING SCHEDULE and Section 01 20 00 PRICE AND PAYMENT PROCEDURES for further information.

1.3.2.1 Furnishment of Spare Lower Pintle and Upper Hinge Assemblies (Option Item)

The base contract requires the Contractor fabricate the lower pintle and upper hinge assemblies, as stated in the paragraph above. This optional item includes additional costs which include Contractor fabrication and furnishment of additional spare components beyond the required quantities

SECTION 01 10 00 Page 5 within the base items.

1.3.2.2 Furnishment of Spare Gate Seals (Option Item)

Provide an additional quantity of both lower and side seals for each gate.

1.3.2.3 Furnishment of Wire Rope (Option Item)

Provide an additional quantity of wire rope in accordance with Section

35 01 70.13 WIRE ROPE FOR GATE OPERATING DEVICES.

1.3.2.4 Furnishment of Spare Manatee Screens (Option Item)

Provide spare manatee screens for a complete replacement within an entire sector gate. The screens must be cut to the arrangement and sizes depicted on the approved design.

1.3.2.5 Training (Option Item)

Conduct training as specified within Section 35 20 16.39 HYDRAULIC SECTOR GATES Paragraph TRAINING.

1.3.3 Location

The project site and delivery location is Canaveral Lock: 1000 Mullet Rd, Cape Canaveral, FL 32920.

1.3.4 Bridging Documents

Bridging documents are provided in Attachment A and within this set of specifications. CAD drawings and SpecsIntact SEC files will be provided to the Contractor after award.

These documents convey scope and technical requirements which present the project concept, and consist of plans and specifications. Concept drawings show gate elevations and sections, and a superstructure system consisting of fiberglass panels radiating from the hinge and pintle centerline to the skin gate, and trusses connecting between those. However, the Government may also be willing to accept an alternative system such as a truss-type system in lieu of the fiberglass panels radiating from the hinge and pintle centerline. This alternative system must be proposed within the Offeror's proposal for technical evaluation by the Government. Changing systems after contract award is contingent upon Government approval.

No matter the structural framing system chosen, the new gate weight in the dry must not exceed the current weight of 183 kips, which includes all appurtenances such as fendering, walkways, etc. The Contractor's design must follow the overall intent of the bridging plans. Specification sections beyond Division 01 which are included within this contract must be placed in the Contractor's design package with minimal edits, unless otherwise stated.

The following scope of work takes precedence over the bridging plans in the event of a conflict. Refer to paragraph ORDER OF PRECEDENCE in Section

01 33 16 DESIGN AFTER AWARD.

1.3.5 Section Organization

This Section is organized under 5 major "Paragraphs".

SECTION 01 10 00 Page 6

a. This paragraph, PROJECT DESCRIPTION, is intended to define the project objectives.

b. Paragraph SCOPE describes the scope of the project.

c. Paragraph TECHNICAL REQUIREMENTS provides the functional, operational, and specific design criteria for the project.

d. Paragraph APPLICABLE CRITERIA lists applicable industry and Government design criteria, unless otherwise indicated in the Section.

It is not intended to be all-inclusive. Other industry and Government standards may also be used, where necessary to produce professional designs, unless they conflict with those listed.

e. Paragraph TECHNICAL REQUIREMENTS contains Army Standard Design Criteria, generally applicable to all facility types, unless otherwise indicated in the Section.

1.4 DAMAGE TO WORK

The responsibility for damage to any part of the permanent work will be as set forth in Clause PERMITS AND RESPONSIBILITIES in Volume 1. However, if, in the judgment of the Contracting Officer, any part of the permanent work performed by the Contractor is damaged by flood, earthquake, hurricane, or tornado, which damage is not due to the failure of the Contractor to take reasonable precautions or to exercise sound engineering and fabrication practices in the conduct of the work, make the repairs as ordered by the Contracting Officer and full compensation for such repairs will be made at the applicable Contract unit or job prices as fixed and established in the Contract. If, in the opinion of the Contracting Officer, there are no contract unit or job prices applicable to any part of such work, an equitable adjustment pursuant to Clause CHANGES in Volume 1 will be made as full compensation for the repairs of that part of the permanent work for which there are no applicable contract unit or job prices. Except as herein provided, repair damage to all work, utilities, materials, equipment and plant to the satisfaction of the Contracting Officer at the Contractor's expense, regardless of the cause of such damage.

1.4 UNITS OF MEASURE

The standard U.S. system must be utilized by the Contractor in the performance of work. Clearly denote which system of measure is being utilized, referenced or discussed on all survey records, official documentation, engineering data, and all correspondence, including any submittals and shop drawings. Any omission or inaccurate use of a unit of measure will not relieve the Contractor of their responsibilities under the Contract terms. The unit of measure used in this specification is the standard U.S. system. The contract drawings denote both standard U.S.

system and metric system where appropriate. If no unit of measure is indicated on the drawing such as on ranges, stations, slope elevations, and distance numbers, then they are to be considered the standard U.S.

system.

1.5 SCOPE

1.5.1 General

This contract is broken into design, fabrication, and delivery of the east

SECTION 01 10 00 Page 7

(upper) set of sector gates. No work is to be performed for the lower (western) set of gates. The differences between the east and west gates are minimal. The east gates are approximately 2 feet taller than the west due to higher hydraulic forces against them. Ensure while reviewing as-built drawings and other documentation provided for information only that the correct set of gates is being reviewed.

Required contract work is identified throughout this section. Work includes designing and fabricating two new FRP gates including pintle and split pintle bushing, upper hinge bracket, pin, and bushing, gate machinery connections, seals, fenders, walkways, etc. Any other supporting appurtenances which are required for installation of the gates by others must be included.

1.6 GENERAL REQUIREMENTS

1.6.1 Design Requirements

Design work includes all necessary disciplines, however is not limited to the following: structural and mechanical. All designers must be registered Professional Engineers by any state within the U.S. Design requirements and work products are identified in Section 01 33 16 DESIGN AFTER AWARD.

Design two sector gates for a hydraulic lock made of FRP that consists of two gates joined at the center of the lock, which rotate into recesses in the lock wall when opened. Each gate is shaped like a sector of a cylinder with a vertical axis. The dimensions of the FRP gates must be such that the gates join properly at the center of the lock when closed and fit into the existing lockwall recesses when opened. On the channel and recess faces, the surface areas (openings) must be designed in such way that the hydrodynamic loading exerted by operating forces (e.g., direct and reverse heads, friction from pintle, hinge, and seals), as well as unpredictable forces (e.g., silt, debris, wear, and wind) do not exceed the existing machinery's load capacity. Drainage must be provided where water may accumulate to ensure complete drainage when in service or dewatered.

Refer to the bridging plans in Attachment A for further details about the dimensions of the sector gates and lock structure.

1.6.2 Delivery, Storage, and Handling

Delivery includes all costs related to hauling from the place of fabrication to the Canaveral Lock (FOB Destination), by waterway and barge. Delivery by land is not allowed. As there will be a schedule gap between delivery and installation, it is required to moor the barges on site for a length of time until the gates can be installed by the Government, which will be paid for as delivery detention fees. The Government is responsible for performing the lifts to remove the gates from the barges. Store, handle, and ship the gate leaves in a manner to prevent permanent deflection, distortion, or other damage. Submit delivery plan and drawing(s) to show provisions for delivery.

Prepare the sector gate assemblies for delivery upon acceptance by the Government at the Contractor's facility. Ship the new sector gate assemblies by barge to the Canaveral Lock, as applicable. Notify the Contracting Officer a minimum of 30 days advance written notice that the sector gate assembly is being prepared for shipping and dates that the transportation readied gate can be inspected. Coordinate delivery with the Contracting Officer. Ship sector gate leaves at the Contractor's

SECTION 01 10 00 Page 8 responsibility and expense. Coordination with a local towing service or fleeting service for delivery of the individual barge or barges to the Government Facility will be at the responsibility and expense of the Contractor. Transport the gate leaves vertically with the lifting assemblies installed. Include a detailed description of the transportation method, stability computations of the barge/gate unit, location and placement of the gate on the barge, securing of the gate to the barge and route to be used for delivery of the sector gate assembly to the respective facility, as applicable, in the delivery plan. The Contractor is responsible for repair of any damages (structural or coating system) to the sector gate assembly at no additional cost to the Government until final delivery and acceptance at the delivery location.

Include the specifications of the barge to be used en route between the fabricator and delivery location in the delivery plan. Provide a list of items required to lift and assemble the gate to the Government. The Contracting Officer will be present during the placement of the gates on the transportation barge.

The Government will unload the sector gate and remove any brace(s), support(s) or dunnage from the barge at Government expense. Removal of any welded fixtures {brace(s), support(s)} to the barge will be done by the Government by flame cutting (cutting torch) and smoothing with an abrasive wheel on a right-angle grinder to a smooth finish similar to normal repairs to barge(s) at Government expense. Refer to Attachment E for the site delivery location. Refer to Paragraph DAMAGE TO WORK above for any damage to the materials or Government property during delivery.

1.6.2.1 On-Site Assembly

Full gate assembly includes all structural and non-structural components which allows the Government to lift and drop the gate into the lock recess. Assembly includes but is not limited to, structure, pintle assembly, fenders, walkway, guardrail, and grating. Appurtenances such as seals, pintles, hinges, walkway grating, etc., may be provided separately for later Government installation. If on-site assembly at Canaveral Lock is needed, the Government will perform assembly with Contractor supervision. Ensure dimensional tolerances, fit, and function, prior to requesting the Government conduct an inspection of the completely assembled gates for final acceptance and payment.

1.6.2.2 Barge Delivery

All items must be delivered at the same time and must be fully assembled to the maximum extent practical prior to delivery, as the gates must arrive in a condition the Government can easily attach rigging and perform a lift, to prevent delays to other vessels within the federal navigation channel. Coordinate with the Government no sooner than 180 calendar days on the proposed delivery date as the Government will need to coordinate lifting equipment. As the Government is responsible and assumes liability for performing lifts, the gates will be fully inspected at delivery by the Government, prior to performing any lifts. A punch list will be performed and if there are any unacceptable items the Contractor must accept responsibility for those and correct prior to the Government performing the lifts in January 2028. Refer to Attachment F for a hydrographic survey of the federal channel. Updated hydrographic data will be provided as it becomes available. The Government will have a barge-mounted crane which will lift from the Contractor's barge and install the gates.

SECTION 01 10 00 Page 9

1.6.3 Architectural Requirements

Color FRP members with pigment during fabrication. Color for FRP members:

Federal Standard 13591 OSHA Safety Yellow.

1.6.4 Mechanical Requirements

For each gate, a new lower pintle assembly is required that supports the full gate design load. Include new pintle seals. A new upper hinge assembly is also required for each gate. The split pintle bushing which is recessed into the new gate must be installed at the fabricator's shop to check for fit and then removed for later reinstallation by the Government.

1.6.5 Fire Protection

All structural components and systems must be in conformance with the applicable USACE EMs and code requirements, including fire resistive and other life-safety specifications to protect the public from injury or death resulting from structural collapse or from the spread of fire, smoke, or toxic products of combustion.

Provide FRP products that have a flame spread rating of 25 or less as specified in ASTM E84, Tunnel Test. The fabrication specifications must include this requirement and a test report submittal for approval.

1.6.6 Manatee Protection System

There is an existing manatee protection system which has been installed and is maintained by a third party contractor. In summary, the system has a collection of acoustic transmitters and receivers which sense if a manatee is within the gate area, and if so, automatically stop gate movement to prevent harm to manatees. This system will be removed and replaced under a separate contract action.

The third party contractor will participate in review of designs submitted under this contract to ensure the manatee protection system will be compatible with the new gates, as well as for assistance in planning how the manatee protection system will be re-installed on the new gates.

Refer to Attachment G for further information.

1.6.7 Fabricator's Representation During Government Installation

Include costs within the base bid as directed within Section 01 20 00 PRICE AND PAYMENT PROCEDURES for costs associated with having the Fabricator's representative(s) on site during Government installation of gate. Schedule is expected weeks to months after the gates are delivered.

Include labor and travel costs for at minimum one individual competent in the gate fabrication process. The purpose of this site visit will be to answer questions by the Government installation crews. Personnel will not perform any manual labor, the role is only to observe, inform, and answer questions. Ensure personnel brings all applicable Personal Protective Equipment (PPE) for an active construction zone.

1.7 APPLICABLE CRITERIA

If a standard or reference is included by name and not date, use criteria from the most current publication, including any applicable addenda, unless otherwise stated in the contract or task order, as of the date of

SECTION 01 10 00 Page 10 the issuance of this solicitation. In the event of conflict between References and/or Applicable Military Criteria, apply the most stringent requirement, unless otherwise specifically noted in the contract.

1.7.1 Industry Criteria

Applicable design and fabrication criteria references are listed below.

This list is not intended to include all criteria that may apply or to restrict design and fabrication to only those references listed.

References cited herein are not necessarily incorporated in their entirety. Refer to specific design requirements established in Paragraph GENERAL TECHNICAL REQUIREMENTS for applicability extents or limits. The most current version published at the time of award shall be used if no date is shown.

American Iron and Steel Institute (AISI)

AISI S100 North American Specification for the Design of Cold-Formed Steel Structural Members

American Society of Civil Engineers (ASCE)

ASCE 7-22 Minimum Design Loads for Buildings and Other Structures

ASCE 74-23 for Load & Resistance Factor Design (LRFD) of Pultruded Fiber Reinforced Polymer (FRP) Structures

ASCE MOP 102 Design Guide for FRP Composite Connections

American Composites Manufacturer's Association (ACMA)

ACMA Code Code of Standard Practice: Industry Guidelines for Fabrication and Installation of Pultruded FRP Structures

American Society of Mechanical Engineers (ASME)

ASME BTH-1 Design of Below-the-Hook Lifting Devices

American Welding Society (AWS)

AWS-03 WHB Welding Handbook, Ninth Edition Vol.1-4; Eighth Edition Vol. 3

Welding Codes and Specifications (As Applicable)

International Code Council (ICC)

ICC IBC International Building Code

ICC IMC International Mechanical Code

Institute of Electrical and Electronics Engineers (IEEE)

IEEE C2 National Electrical Safety Code

IEEE 1100 IEEE Emerald Book: IEEE Recommended Practice for Powering and Grounding Electronic Equipment

National Fire Protection Association (NFPA)

SECTION 01 10 00 Page 11

NFPA 70 National Electrical Code

NFPA 70E Standard for Electrical Safety in the Workplace

Occupational Safety and Health Administration (OSHA)

29 CFR 1926 Safety and Health Regulations for Construction

State & Local Regulations

State Specific Environmental Control Requirements

1.7.2 Military Criteria

The project shall conform to the following criteria. Certain design impacts and features due to these criteria are noted for the benefit of the offeror; however, all requirements of the referenced criteria shall be applicable, whether noted or not, unless otherwise specified herein.

a. Unified Facilities Criteria (UFC)

UFC 1-300-02 Unified Facilities Guide Specifications (UFGS) Format Standard

b. U.S. Army Corps of Engineers (USACE)

Publications may be found at the following web address:

https://www.publications.usace.army.mil/

ER 1110-2-1086 Earthquake Design and Evaluation for Civil Works Projects

EM 1110-2-2107 Design of Hydraulic Steel Structures

EM 1110-2-2602 Planning and Design of Navigation Locks

EM 1110-2-2610 Mechanical and Electrical Design for Lock and Dam Operating Equipment

EM 1110-2-3402 Barge Impact Forces For Hydraulic Structures

EM 1110-2-1604 Hydraulic Design of Navigation Locks

EM 1110-2-1424 Lubricants and Hydraulic Fluids

1.8 TECHNICAL REQUIREMENTS

1.8.1 Structural Design

1.8.1.1 Finite Element Analysis (FEA)

Refer to Section 01 33 16 DESIGN DATA (DESIGN AFTER AWARD) Paragraph DESIGN ANALYSIS for further requirements.

1.8.1.2 Loads and Load Combinations

The design requirements must be developed using relevant USACE Engineer Manuals (EMs) identified within Paragraph APPLICABLE CRITERIA above. Sound

SECTION 01 10 00 Page 12 engineering judgement may be required in areas where there is not clear guidance. Refer to Section 06 90 00 FIBER-REINFORCED POLYMER (FRP) COMPOSITE STRUCTURE for material requirements. The design methodology is

ASD.

A summary of the hydraulic loads in accordance with EM 1110-2-2107 are included in Attachment D. Consider as minimum the load combinations included in Attachment D.

Submit proposed load cases and load combinations including all adjustment factors for approval before design commences. This information must be included within the Design Analysis as well. A submittal for this item can be found within 01 33 16 DESIGN AFTER AWARD.

1.8.1.3 Serviceability Requirements and Deflection

Design the new FRP gates including all individual members, connections, and connectors such that they do not impair operability or performance under service loads. Limit the deflection of the gates, and do not exceed 1 inch, so that maximum allowable strains are not exceeded, that gate seal contact surfaces are maintained within acceptable tolerances, and design assumptions are not compromised. The allowable deflection must not reduce the gate's bottom clearance of 1 inch.

1.8.1.4 Thermal Expansion

Thermal effects must be considered when designing the FRP sector gates to ensure that any contraction or expansion is accommodated. Similarly, seals must also be designed to allow for thermal expansion and contraction. The overall dimensions of an assembled structural unit must be within the tolerances indicated on the drawings or as specified for the item of work.

1.8.1.5 Gate Seals

Match and align the gate bottom seal to the center of the bottom seal beam plate. Consider following EM 1110-2-2107 Plate 16.4, with modifications, as appropriate for the bottom seal design. Match drill all seals and retainer bars accounting for curvature and geometry. Use bolt through connections for attaching the seals to the gate. Do not use embedded bolts or nuts.

Match and align the gate vertical side seals to the existing embeds and pre-sets at each recess slot. For the corner, where the bottom seal meets the vertical seal at the miter point, both seals should be fabricated integrally. Follow EM 1110-2-2107 Paragraph 16.2.7 for all seals presets.

Make all the seals adjustable (± 7/16 inch) and replaceable to allow for future maintenance and replacement. Provide UNS S32205 stainless steel for all hardware and shims. Nuts must be bronze self-Locking, hexagon regular-height, (non-metallic insert) per ASME B18.16.6 and ASTM F467.

Lock washers must be used.

1.8.1.6 Framing

The geometry of the structural members must be designed to optimize the water flow in order to reduce operating forces required during opening of the sector gate under reversed head. Refer to EM 1110-2-2107 Paragraph

16.2.3.1 for details/geometry where applicable. Panel or plate framing may be used in lieu of truss framing.

SECTION 01 10 00 Page 13

1.8.1.7 Pintles and Hinges

Fabricate the pintle and hinge assembly (hinge bracket, bushing, and pin) so it can be use with existing pintle support casting and hinge bracket casting, respectively. Refer to as-built drawings provided in Attachment C, for informational use only. Embedded metals in FRP are allowed for these applications. Ensure that alloys and fabrication methods chosen are able to withstand salt-water immersion corrosion and that no dissimilar metals are used which may result in galvanic corrosion. Alloys chosen must be suitable without the use of cathodic protection. The split pintle bushing embedded in the gate must allow removal and replacement without structural modification of the gate components, e.g. it must be installed by means of a press fit or through-bolt. Consideration must be taken over the 100 year service life of these gates that the pintles may need to be replaced several times, and will need to be done with only disconnecting the top hinge and machinery connection and jacking up the gate in place.

1.8.1.8 Gate Stops

Rubber bumpers must be provided to prevent damage to the gate by it being forced against the wall of the recess and at the center of the lock where the two gates meet. Bumpers should be placed on the center line of the respective to structural members. Recess bumpers mounted on the gate must align with the respective existing accompanying bumper located on the face of recess wall. Make all the bumpers adjustable using shims as necessary to properly make contact with companion bumper and replaceable to allow for future maintenance and replacement. All hardware must be UNS S32205 stainless steel. Provide rubber bumpers specifically for a marine environment.

1.8.1.9 Fender System

Design and fabricate the fenders from a thermoplastic matrix reinforced with chopped fiberglass filaments and embedded continuous FRP reinforcing bars. The thermoset FRP fender supporting frame including wales must be structurally continuous across a minimum of two spans and provide adequate creep resistance to prevent loosening of attachments over time and, at a minimum, meet the requirements of FDOT Specifications Section 973-5. The location of the new FRP fender system must match the existing one. At a minimum, the dimensions of the new FRP fender system (wales, caution fender, and spacer-blocks) must match the existing, while providing at least the same energy absorption requirements as the existing fender system. There is no known information on the existing fenders, however the same size/configuration may be provided. A material test may be used to determine the rubber composition and durometer. Fenders must be attached to the framing utilizing UNS S32205 stainless steel bolted fasteners (bolts, nuts, and washers) to facilitate the removal and replacement of damaged components and slotted holes to accommodate thermal expansion.

Nuts must be bronze self-Locking, hexagon regular-height, (non-metallic insert) per ASME B18.16.6 and ASTM F467. All hardware must be recessed.

Provide black wales unless otherwise shown in the Plans. "Caution Fenders" must be manufactured in yellow with black caution stripes along their entire length (12 feet). Black caution stripes (1 foot wide at 45 degree angle spaced at 1 foot) must be made of self-adhesive, weather-resistant, retroreflective tape conforming to ASTM D4956.

1.8.1.10 Jacking Supports

Provide a minimum of four jacking pads on the bottom of each gate as

SECTION 01 10 00 Page 14 lifting supports so that the full weight of the gate can be supported by the pads while maintaining the gate in a stable position. A jacking plan must be submitted that includes complete instructions and the sequence to be followed when performing maintenance (e.g., pintle inspection and gate removal).

1.8.1.11 Lifting Points

The design must accommodate no less than four lifting lugs or openings on each gate to facilitate vertical installation and future removal from the lock (considering the total weight of the gate to include marine life and silt). Locate the lifting lugs or openings (considering the center of gravity) so that the gate is level to within +/- 1-inch when lifted. Do not exceed a total gate weight of 183 kips including all appurtenances.

Design lifting lugs or openings in accordance with ASME BTH-1, Category B.

1.8.1.12 Walkways

Each gate must have an upper walkway with guardrails. The upper walkway and guardrails must be designed and fabricated from FRP. The walkway assemblies must be removable for routine maintenance and be provided on all sides of the top of the sector gate, similar to the existing. Walk height must match existing lock wall height and have mechanism to accommodate slight vertical misalignments with the wall such as a hinged ramp. The framing of the platform must be fabricated from pultruded structural profiles in accordance with ASCE 74-23 and assembled using Type 316 stainless steel bolted connections. Nuts must be bronze self-Locking, hexagon regular-height, (non-metallic insert) per ASME B18.16.6 and ASTM F467. The structural members, connections, and floor/deck plate must be designed to support a 100 psf (with applicable load factors) vertical live load applied over the entire surface. With a 150 psf unfactored service load, limit maximum deflection to L/180, where "L" is the unsupported length in inches. The walkway must be 4 feet wide and provide a non-slip FRP deck/floor surface primarily of grating type which does not allow ponding of water. Solid plates must be provided at the hinge and miter location when the gate is in the closed position as depicted in EM 1110-2-2107 Plate 16.6. The walkway and guardrail color must be gray in color. Design the the FRP grating and railing in accordance with Sections 06 82 14 FIBERGLASS REINFORCED PLASTIC (FRP) GRATING and 06 82 14

FIBERGLASS REINFORCED PLASTIC (FRP) PIPE AND TUBE RAILINGS.

1.8.1.13 Manatee Protection

All openings on the channel face and any exposed area that may potentially come in contact with a manatee must be screened to prevent a manatee from entering. The screen system must be made of FRP grating and removable to allow for future maintenance and replacement. Grates must be arranged such that a 6 inch sphere cannot pass through, and may be installed diagonally, horizontally, or vertically. The design loads must represent the maximum differential head, assuming the openings are blocked by debris. Where the design allows, provide a removable section for personnel access from the concrete floor (channel side) to the interior of the sector gate with minimum dimensions of 3 feet by 4 feet.

Refer to Attachment G for further information.

1.8.2 Mechanical Design

Comply with EM 1110-2-2610 and EM 1110-2-3200 .

SECTION 01 10 00 Page 15

1.8.2.1 Design Forces

The mechanical equipment is capable of exerting a maximum 150 ft-kips on the gates. The existing pintles were designed to see a maximum load of 485 kips . The existing hinges were designed to see a maximum load of 280 kips .

If the new gate is lighter than the existing gate, the new components only need to support the design forces calculated.

1.8.2.2 Gate Bottom Seals

Provide rubber seals that are fluorocarbon-clad of the molded type only.

Refer to Paragraph RUBBER SEALS within Section 35 20 16.39 HYDRAULIC SECTOR GATES for further requirements.

1.8.2.3 Lower Pintle Assembly

The pintle assembly consists of a pintle support (anchor), pintle socket seal retainer ring assembly, pintle, and split pintle bushing which are integral components of each gate. The existing pintle support at the lock will be reused for which the new pintle fabricated under this contract will be pressed into.

Refer to Section 35 20 16.39 HYDRAULIC SECTOR GATES for further requirements.

Include replacement of the two seals located inside the pintle casting which mate to the pintle neck. Refer to Detail C of as-built drawing #32 within Attachment C.

Fabricate the pintle neck with a sleeve which will allow for easier transportation for machining to tolerance once the existing pintle is removed and the bore can be measured, which will be performed by others when the gate is installed. Ensure the sleeve is oversized from the dimensions shown in the as-builts.

The pintle must be compatible with grease which meets Environmentally Acceptable Lubricant (EAL) requirements. Refer to EM 1110-2-1424 Lubricants and Hydraulic Fluids, chapter 13, and related appendices.

Protect grease supply lines from damage by mounting in structural tubes, using flexible hose connections where needed, and equipping all exposed piping and hose with structural guards to protect from debris. Grease lines must be installed by the fabricator and fittings must be above the high water level and reachable by maintenance personnel during routine maintenance.

1.8.2.4 Upper Hinge

The hinge assembly consists of hinge bracket support frame, hinge bracket support, hinge bracket, and hinge pin. The existing hinge bracket support frame and hinge bracket support will be reused.

Refer to Section 35 20 16.39 HYDRAULIC SECTOR GATES for further requirements.

Use the same dimensions of the hinge and bushing as shown on the reference drawings in Attachment C.

The hinge must be compatible with grease which meets Environmentally

SECTION 01 10 00 Page 16

Acceptable Lubricant (EAL) requirements. Refer to EM 1110-2-1424 Lubricants and Hydraulic Fluids, chapter 13, and related appendices.

1.8.2.5 Machinery

The operating machinery for the lock consists of drums, wire ropes, sheaves, hydraulic power unit (electric motor, hydraulic motor, hydraulic pump), reduction gears, limit switches, and other associated mechanical components. In summary, the gates operate by way of tension on two sets of wire ropes which open and close the gates. The ropes are connected to the gates above the waterline.

1.8.2.5.1 Wire Rope Cable Guide Track

With the skin plate face of the gate having curvature, as the wire rope operates it lays against the face in what is defined as a 'cable guide track' on the bridging plans. This curved track wears over time as the rope contacts it and so the track must be removeable and replaceable. Use a commercially available off the shelf metal component which can be easily purchased on the open market in the future, such a C-channel made of weathering steel. Coatings are not allowed as they will wear off. Nuts for stainless bolts must be bronze self-Locking, hexagon regular-height, (non-metallic insert) per ASME B18.16.6 and ASTM F467.

1.8.2.5.2 Limit Switches

The existing limit switches are mounted to the concrete lock wall. When plates attached to the gate contact the limit switches, the machinery either goes into a slower speed or stops. These gate design must have provisions for actuating the switches.

1.9 TECHNICAL SUPPORT DURING INSTALLATION SUPPORT

Provide technical support during installation. Support effort is expected to begin in January 2028 and continuing through April 2028.

1.9.1 Meetings

Participate in teleconference meetings. The intent of the meetings is to provide an exchange between the installation contractor, Government, fabricator, and designers. In general, teleconference meetings will be conducted as needed and are considered deliverables.

1.9.2 Technical Input/Recommendations

Provide technical advice in connection with the design, plans, specifications, and Government installation. Respond to requests for additional technical assistance as requested by the Government. The purpose of this task is to provide technical support that falls outside the scope of the other EDC tasks defined herein. The scope of the work within this task is expected to be for minor efforts. The designer's input/recommendations must include the appropriate contract document references/citations with detailed descriptions, summaries, interpretations, and supplemental sketches/details. Technical input/recommendations may include minor design, engineering, and/or drafting efforts, if necessary. Submit to the Government any electronic file created in support of the deliverables cited herein. Technical input/recommendations required due to errors or omissions in the gate design and fabrication will not be considered for compensation. Design

SECTION 01 10 00 Page 17 work products, such as drawings, plates, figures, tables, and sketches prepared to illustrate details and results of an technical input/recommendation may require electronic submittals and/or design authentication at the discretion of the Government, to be accepted by the Government.

PART 2 PRODUCTS (NOT USED)

PART 3 EXECUTION (NOT USED)

Attachment A Bridging Plans

Attachment B Site Photos

Attachment C As-Built Drawings

Attachment D Design Loads

Attachment E Delivery Location

Attachment F Barge Hydrographic Survey

Attachment G Manatee Protection System

-- End of Section --

SECTION 01 10 00 Page 18

Canaveral Lock Sector Gate Replacement Appendix D

Amendment 001

Load Combinations, Design Loads, and Additional Considerations

This section is intended to assist the designer with the load combinations and design loading conditions. Currently, there are no U.S. Army Corps of Engineer (USACE) Engineering Manuals (EM) that provide guidance for the design of FRP hydraulic composite structures using load and resistance factor design (LRFD) approach. For this reason, EM 1110-2-2107, Design of Hydraulic Steel Structures (specifically for the design of hydraulic steel structures), was consulted as the basis to formulate the minimum load combinations for sector gates. Furthermore, it was decided to use allowable stress design (ASD), since current industry standards for the design of vacuum infusion process (VIP) structures are performed using ASD. This decision was made with the input of internal and external Subject Matter Experts (SMEs) in the field of composites materials and hydraulic structures.

In consultation with the project’s hydraulic engineer (CESAJ EN-WH), potential relative sea level trends were considered; however, since the intent of this project is solely to replace the existing gates (of the same size), additional hydrostatic forces due to potential sea level rise were not evaluated. Nonetheless, according to ER 1100-2-8162, the local mean sea level change in FL is estimated to be 0-3 mm/year, which will translate to 11.8 inches over the 100-year service life. In this case, serviceability requirements are expected to produce a more robust gate design than the predicted future effect of sea level change would entail. All water surface elevations are referenced to the North America Vertical Datum of 1988 (NAVD88).

Hydrostatic loads consist of hydrostatic pressure on the gate considering both upper and lower pools. Hydraulic loading on sector gates is produced from direct heads and reverse heads. A direct head is a differential head across the gate with the highest water elevation on the convex side of the skin plate. A reverse head is a differential head across the gate with the highest water surface on the concave side of the skin plate.

Loads Definitions

i. Dead load (D): Includes the total weight of the structure and its permanent attachments and fixed equipment. Dead load is computed based on the nominal cross-section of the members and weight of all permanent attachments (e.g., fender system), platforms, appurtenances, fasteners, and any coating system. Weight of the coating system is based on the specified thickness of the coating system used. Uplift pressures acting on the submerged portion of the gate (resulting from the corresponding water elevations) must be considered when calculating the net vertical load (sum of all dead loads minus the upward buoyancy forces).

ii. Gravity loads (G): Consist of mud (including silt), debris, and atmospheric ice. All of these loads are highly site dependent. Both mud and debris are more likely on navigation gates and spillway gates that have tailwater present on the gate much of the time. EM 1110-2- 2610 Mechanical and Electrical Design for Lock and Dam Operating Equipment, 2013 (EM 2610), Section 7-6.e.2 specifies a unit weight of 125 pcf for silt. Assume a 1-inch thick silt layer on all areas where silt may accumulate (regardless of drainage).

Canaveral Lock Sector Gate Replacement Appendix D

iii. Live load (L): Live loads are vertical load from personnel, equipment, vehicles, or temporary storage on operating surfaces and walkways. The walkway (including all structural members, connections, and gratings) must be designed to support a 100 psf unfactored vertical live load applied over the entire surface. For the design of the gate structure, an assumed load of 100 plf should be applied over the entire walkway length.

iv. Wind load (W): Wind loads (other than for critical structures) were calculated using criteria for category II structures. Wind loads are small when compared to hydrostatic loads and only affect gate reactions when the gate is in a closed position. Winds load must be applied as a uniformly distributed load, according to ASCE 7-22, to all exposed portions of the structure that extend above the corresponding water elevation, where the effect/direction of W adds to the principal load effect.

v. Barge impact (BI): Barge impact load can occur from navigation incidents (vessels entering or exiting the lock) or from aberrant barges during storm events. The load is applied at any point on the horizontal frame and at any panel point on the channel-side end frame where barge impact is possible while the gates are in both open and closed positions. These loads need not to be applied to the design of the face skin plate/panel. If damage occurs under barge impact loads, it must be confined to a local damage and by no means result in failure of the entire structure.

vi. Earthquake (EQ): Refer to EM 1110-2-2107 Section 4.4 for earthquake loading and consider as applicable.

vii. Operational loads (Q): Operating loads (acting through the wire rope) are treated as reactions to all opposing forces including, dead, gravity, hydrostatic, hydrodynamic, and friction. This load will be the maximum load that can be exerted by the operating machinery (obtained by the project's mechanical engineer). This assumes a gate jam that prevents movement.

viii. Pintle and Hinge Friction (Ft): During opening or closing of gates, friction loads exist around the surface of the pintle and the hinge between the bushing and the ball. These friction loads result in a friction moment Ft about the pintle and the hinge that must be considered in design.

o The friction moment is a function of a coefficient of friction, the reaction forces component R that acts normal to the surface of the pintle and hinge, and the radiuses of the pintle and hinge.

o A coefficient of friction of 0.3 shall be used. This is a reasonable value that applies for any bushing material that may be slightly worn or improperly maintained.

ix. Bottom Seal Friction (Fs): Loads exist along the bottom of the gate because of friction between the bottom seal and the bottom-seal plate when the gate is opening or closing. The

Canaveral Lock Sector Gate Replacement Appendix D

Amendment 001 friction force is equal to the preset force in the seal plus product of the coefficient of friction and normal force between the sill plates and the bottom seal.

o Friction Coefficient. For rubber seals, a coefficient of friction of 0.5 is recommended. Seals that have Teflon rubbing surfaces provide a lower coefficient of friction and are recommended for serviceability. However, wear of the Teflon is a concern, and applying a lower coefficient of friction for design purposes is not recommended.

o Pre-Set Forces. Initially, the seals on a sector gate are set with approximately 0 to 1/32” of clearance. A design pre-compression of 0.25” accounts for gate sag, hinge and pintle wear, and variations in gate temperature between submerged members and non-submerged members. Refer to EM 1110-2-2107 Chapter 10 for the determination of seal friction forces.

x. Maximum hydrostatic loading (Hspr): Design water levels that create the maximum hydrostatic loading caused by a differential head that is geometrically and hydrologically possible. 10-year return period. Some considerations:

o The maximum hydrostatic loading may occur at water levels that are not necessarily the largest possible differential head.

o Usually, the maximum hydrostatic load is limited by the height of the structure and other factors. But the maximum hydrostatic load may be from water levels that exceed the top of a structure.

o In some cases, hydrostatic loading may be experienced from differential head across a structure in either direction.

o Determination of the maximum differential head condition should be made in…