05 50 15 Amendment 0002.pdf

LD5A, LD8 and LD10 Anchorage Replacement W912ES21B0010

SECTION TABLE OF CONTENTS

DIVISION 05 - METALS

SECTION 05 50 15

CIVIL WORKS FABRICATIONS

PART 1 GENERAL

1.1 REFERENCES

1.2 SUBMITTALS

1.3 SAFTEY

1.4 DELIVERY, STORAGE, AND HANDLING

1.4.1 General

1.5 SUBMITTAL REQUIREMENTS

1.5.1 Materials Orders

1.5.2 Materials List

1.5.3 Material Tests Reports

PART 2 PRODUCTS

2.1 STANDARD METAL ARTICLES

2.1.1 Structural Steel Plates

2.1.2 Structural Steel Angle

2.1.3 Hollow Structural Section (HSS)

2.1.4 Ladder Rungs

2.1.5 Lock Wall Armor

2.1.6 Bolts, Nuts and Washers

2.1.7 Connecting Pins

2.1.7.1 Tolerances

2.1.8 Anchorage Bar Adjustment Rings

2.1.9 Eyebolts

2.1.10 Steel Studs for Recess Seat Angles

2.1.11 Steel Castings

2.2 MISCELLANEOUS ITEMS

2.2.1 Bonding Agent Compound

2.3 RECESS SEAT ANGLES

2.3.1 Welded Shear Stud Connectors

2.3.2 Welding of Structural Steel

2.3.3 Tests, Inspections, And Verifications

2.3.4 Inspection of Structural Steel Welding

2.3.5 Structural Steel Welding Repairs

2.3.6 Shop Assembly and Field Work

2.4 UPSTREAM RECESS ANCHORAGE CHECK POSTS

PART 3 EXECUTION

3.1 FINISHES

3.1.1 Painting

3.2 TESTS

3.2.1 Workmanship

3.2.2 Production Welding

3.3 Recess Seat Angles

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3.4 SAFETY PROVISIONS.

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SECTION 05 50 15 Page 2

SECTION 05 50 15

CIVIL WORKS FABRICATIONS

PART 1 GENERAL

This section covers fabrication of recess seat angles, connecting pins, steel spacers, trench lid supports, corner protection, support braces, and miscellaneous items. For fabrication of the anchorage frames, see SECTION

05 59 20 - FABRICATION OF HYDRAULIC STEEL STRUCTURES.

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 NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI B4.1 (1967; R1974) ANSI Standard Limits and Fits

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2020) Structural Welding Code - Steel

AWS Z49.1 (2012) Safety in Welding and Cutting and Allied Processes

ASTM INTERNATIONAL (ASTM)

ASTM A27/A27M (2020) Standard Specification for Steel Castings, Carbon, for General Application

ASTM A29/A29M (2016) Standard Specification for General Requirements for Steel Bars, Carbon and Alloy, Hot-Wrought

ASTM A36/A36M (2019) Standard Specification for Carbon Structural Steel

ASTM A325 (2014) Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength

ASTM A490 (2014a) Standard Specification for Structural Bolts, Alloy Steel, Heat Treated, 150 ksi Minimum Tensile Strength

ASTM A500/A500M (2020) Standard Specification for Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and Shapes

ASTM A563 (2015) Standard Specification for Carbon and Alloy Steel Nuts

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ASTM A572/A572M (2018) Standard Specification for High-Strength Low-Alloy Columbium-Vanadium Structural Steel

ASTM A709/A709M (2018) Standard Specification for Structural Steel for Bridges

ASTM A992/A992M (2020) Standard Specification for Structural Steel Shapes

ASTM F436/F436M (2019) Standard Specification for Hardened Steel Washers Inch and Metric Dimensions

U.S. ARMY CORPS OF ENGINEERS (USACE)

EM 385-1-1 (2014) Safety and Health Requirements Manual

AMERICAN IRON AND STEEL INSTITUTE (AISI)

AISI 1030 AISI 1030 Carbon Steel

AISI 4340 H AISI Structural Alloy Steel

AISI/SAE 4140 AISI Medium Carbon, Chromium-Molybdenum Alloy Steel

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-02 Shop Drawings

Detail Drawings; G

Detail drawings for metalwork and machine work shall be submitted and approved prior to start of fabrication. Drawings shall indicate the sequence of fabrication and assembly.

Materials Orders

Materials List

Structural Steel Welding Repairs; G

SD-06 Test Reports

Tests, Inspections, And Verifications

Material Tests Reports

1.3 SAFTEY

Safe welding practices and safety precautions during welding must conform to AWS Z49.1 .

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1.4 DELIVERY, STORAGE, AND HANDLING

1.4.1 General

Perform delivery, handling, and storage of materials and fabricated items in conformance with the recommendations of the manufacturer and approved by the Contracting Officer. Damaged materials shall be repaired by the Contractor at the direction of the Contracting Officer.

1.5 SUBMITTAL REQUIREMENTS

1.5.1 Materials Orders

Copies of purchase orders, mill orders, shop orders and work orders for materials shall be submitted prior to the use of the materials in the work.

1.5.2 Materials List

Materials List for fabricated items shall be submitted at the time of the submittal of detail drawings.

1.5.3 Material Tests Reports

Certified materials test reports for all materials shall be submitted with all materials delivered to the site.

PART 2 PRODUCTS

2.1 STANDARD METAL ARTICLES

Standard metal articles shall conform to the respective specifications and other designated requirements. Sizes shall be as specified or shown.

Where material requirements are not specified, materials furnished shall be suitable for the intended use and shall be subject to Government Approval.

2.1.1 Structural Steel Plates

Miscellaneous structural steel plate shall be ASTM A36/A36M. Steel plate for steel spacer plate and keeper plates shall be ASTM A709/A709M , conforming to the grade requirements shown on the drawings.

2.1.2 Structural Steel Angle

Structural steel angle shall be ASTM A36/A36M or ASTM A992/A992M .

2.1.3 Hollow Structural Section (HSS)

Structural steel hollow structural sections shall be ASTM A500/A500M Grade C.

2.1.4 Ladder Rungs

Fabricate ladder rungs from steel rods in accordance with the details and shall be galvanized after fabrication.

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2.1.5 Lock Wall Armor

Fabricate lock wall armor tees and preformed corner protection plates from steel conforming to ASTM A36/A36M or ASTM A572/A572M . Tees may be commercially rolled sections or may be fabricated from steel plates provided they have a nominal weight of not less than 42.0 kg/m 28.2 pounds/foot and conform essentially to details shown. Conform installation to details shown. Erect tees and preformed plates true to line and grade.

The continuous edges of exposed faces must not have a vertical or horizontal distortion from a straight line greater than 2 mm/m 0.025 inch/foot of length. Distortion for any single section must not exceed 36 mm 1.4 inches. Where there is a warp in the installed tees or preformed plates greater than 2 mm 1/16 inch, install an extra anchor at the proper location to draw the section into position. Counter sink bolt heads on exposed faces and fit so that they are flush with the finished surfaces.

Make joints between abutting sections square and saw or otherwise made smooth and regular the butting ends.

2.1.6 Bolts, Nuts and Washers

Bolts shall be ASTM A490, with ASTM A563, grade DH, heavy hex nuts.

Structural washers shall conform to ASTM F436/F436M . Gudgeon Link Bolts shall conform to the requirements of ASTM A325.

2.1.7 Connecting Pins

Connecting pins include the anchorage bar pins.

The anchorage bar pins shall be fabricated from material conforming to AISI 4340 H . Minimum required yield strength is 68 ksi and a minimum required ultimate strength of 108 ksi.

2.1.7.1 Tolerances

Tolerances between anchorage pins and anchorage frame pin plates shall conform to the requirements from ANSI B4.1 as shown on the drawings.

Contractor to submit Certificate of Fit Compliance before assembly.

2.1.8 Anchorage Bar Adjustment Rings

The anchorage bar adjustment rings shall be fabricated from material conforming to AISI/SAE 4140 (normalized).

2.1.9 Eyebolts

The eyebolts shall be fabricated from material conforming to AISI 1030 .

Minimum required yield strength is 63 ksi and a minimum required ultimate strength of 76 ksi.

2.1.10 Steel Studs for Recess Seat Angles

Studs shall be ASTM A29/A29M

2.1.11 Steel Castings

ASTM A27/A27M, Grade N-1, Class 2.

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2.2 MISCELLANEOUS ITEMS

2.2.1 Bonding Agent Compound

Steel plating in contact with concrete, as indicated on the plans, shall be coated with a bonding agent. Bonding agent sha1l be moisture-tolerant, epoxy modified, and a cementitious product specifically formulated as a bonding agent and anti-corrosion coating. Follow the manufacturer's written instructions and recommendations for preparation and application.

2.3 RECESS SEAT ANGLES

Recess Seat Angles shall be fabricated of rolled steel angle, ASTM A36/A36M, or ASTM A992/A992M , and steel plate, ASTM A36/A36M or ASTM A572/A572M . Detail drawings shall be submitted and approved prior to work beginning. Materials shall be straight before being laid off or worked. Perform straightening, if necessary, by methods that will not impair the metal. Sharp kinks or bends will be cause for rejection of the material. Material with welds will not be accepted except where welding is definitely specified, indicated or otherwise approved. Shearing shall be accurate and all portions of the work neatly finished. Corners shall be square and true unless otherwise shown. Structural steel may be cut by mechanically guided or hand-guided torches, provided an accurate profile with a surface that is smooth and free from cracks and notches is obtained. Prepare surfaces and edges in accordance with AWS D1.1/D1.1M , Subsection 3.2. Where structural steel is not to be welded, chipping or grinding will not be required except as necessary to remove slag and sharp edges of mechanically guided or hand-guided cuts not exposed to view.

Chip, grind or machine to sound metal hand-guided cuts which are to be exposed or visible.

2.3.1 Welded Shear Stud Connectors

Welded shear stud connectors shall be ASTM A29/A29M, Type B and welded in accordance with AWS D1.1/D1.1M .

2.3.2 Welding of Structural Steel

a. Welding Process - Perform welding of structural steel by an electric arc welding process using a method which excludes the atmosphere from the molten metal and conforms to the applicable provisions of AWS D1.1/D1.1M . Minimize residual stresses, distortion and shrinkage from welding. For field work, temporary enclosures shall be utilized to prevent wind, rain, and extreme elements from interfering with welding operations and results.

b. Welding Technique

1. Filler Metal - The electrode, electrode-flux combination and grade of weld metal shall conform to the appropriate AWS specification for the base metal and welding process being used or be as shown where a specific choice of AWS specification allowables is required. Include the AWS designation of the electrodes to be used in the schedule of welding procedures. Use only low hydrogen electrodes for manual shielded metal-arc welding regardless of the thickness of the steel. Use a controlled temperature storage oven at the job site as prescribed by AWS D1.1/D1.1M , Subsection 5.3.2 to maintain low moisture of low hydrogen electrodes.

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2. Preheat and Interpass Temperature - Perform preheating as required by AWS D1.1/D1.1M , Subsection 3.5 or as otherwise specified except that the temperature of the base metal shall be at least 70 degrees F. Slowly and uniformly preheat the weldments by approved means to the prescribed temperature, held at that temperature until the welding is completed and then permitted to cool slowly in still air.

c. Workmanship - Perform welding workmanship in accordance with AWS D1.1/D1.1M , Section 3 and other applicable requirements of these specifications.

1. Preparation of Base Metal - Prior to welding inspect surfaces to be welded to ensure compliance with AWS D1.1/D1.1M , Subsection 5.15.

2. Temporary Welds - Make temporary welds, required for fabrication and erection, under the controlled conditions prescribed for permanent work. Make temporary welds using low-hydrogen welding electrodes and by welders qualified for permanent work as specified in these specifications. Conduct preheating for temporary welds as required by AWS D1.1/D1.1M for permanent welds except that the minimum temperature shall be 120 degrees F in any case. In making temporary welds, arcs shall not be struck in other than weld locations. Remove each temporary weld and grind flush with adjacent surfaces after serving its purpose.

3. Tack Welds - Subject tack welds that are to be incorporated into the permanent work to the same quality requirements as the permanent welds; clean and thoroughly fuse them with permanent welds. Perform preheating as specified above for temporary welds. Multiple-pass tack welds shall have cascaded ends. Remove defective tack welds before permanent welding.

2.3.3 Tests, Inspections, And Verifications

Perform material tests and analyses certified by an approved laboratory to demonstrate that materials are in conformity with the specifications.

These tests and analyses shall be performed and certified at the Contractor's expense. Perform tests, inspections, and verifications conforming to the requirements of the particular sections of these specifications for the respective items of work unless otherwise specified or authorized. Conduct tests in the presence of the Contracting Officer if so required. Furnish specimens and samples for additional independent tests and analyses upon request by the Contracting Officer. Properly label specimens and samples and prepare for shipment. Submit certified test reports for materials with all materials delivered to the site.

2.3.4 Inspection of Structural Steel Welding

Welding shall be subject to inspection to determine conformance with the requirements of AWS D1.1/D1.1M and the approved welding procedures and provisions stated in other sections of these specifications. All welds shall be visually examined by the Contractor's Inspector. For all visual examination of completed welds clean and carefully examine for insufficient throat or leg sizes, cracks, undercutting, overlap, excessive convexity or reinforcement and other surface defects to ensure compliance with the requirements of AWS D1.1/D1.1M , Section 6, subsection 6.9, Part C.

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2.3.5 Structural Steel Welding Repairs

Repair defective welds in the structural steel welding repairs in accordance with AWS D1.1/D1.1M , Subsection 3.7. Remove defective weld metal to sound metal by use of air carbon-arc or oxygen gouging.

Thoroughly clean surfaces before welding. Retest welds that have been repaired by the same methods used in the original inspection. Except for the repair of members cut to remove test coupons and found to have acceptable welds costs of repairs and retesting will be borne by the Contractor. Submit welding repair plans for steel, prior to making repairs.

2.3.6 Shop Assembly and Field Work

Fabrication and assembly of sub components shall be accomplished in the shop where practical. Shop assembly shall be accomplished in an indoor, climate controlled shop. For field work, temporary enclosures shall be utilized to prevent wind, rain, and extreme elements from interfering with welding operations and results.

2.4 UPSTREAM RECESS ANCHORAGE CHECK POSTS

The upstream recess anchorage check posts (Landwall and Intermediate Wall) that will be removed during the concrete demolition will not be reinstalled. After removal the check posts shall be salvaged and shall remain property of the Government.

PART 3 EXECUTION

3.1 FINISHES

3.1.1 Painting

Steel items that are not designated as galvanized on the drawings shall be blasted and painted in accordance with SECTION 09 97 13.00 40 STEEL

COATINGS.

3.2 TESTS

3.2.1 Workmanship

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

3.2.2 Production Welding

Perform production welding conforming to the requirements of AWS D1.1/D1.1M as applicable.

3.3 Recess Seat Angles

The recess seal angles shall be cast in with the new concrete and installed as shown on the drawings. The Contractor shall determine the extent of necessary replacement based on new and existing concrete excavation. New recess seal angles shall be spliced by welding to the existing recess seat angles. New recess seal angles shall contain bevel joints at corners, as applicable.

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3.4 SAFETY PROVISIONS.

The Contractor shall comply with all applicable provisions of Corps of Engineers Safety Manual EM 385-1-1 .

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2.4 UPSTREAM RECESS ANCHORAGE CHECK POSTS