TSpecs_-_Cable_Assemblies_2-3-2016_Rev_3.pdf

Nashville District

GUNTERSVILLE MAIN LOCK

WILSON MAIN LOCK

& KENTUCKY LOCK CABLE ASSEMBLIES.

Tennessee River

Technical Specifications

January 2016

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Cable Assemblies GUN/L, WIL/L and KY/L

SECTION TABLE OF CONTENTS

DIVISION 35 - WATERWAY AND MARINE CONSTRUCTION

SECTION 35 01 71

ANCHOR CABLE ASSEMBLIES

PART 1 GENERAL

1.1 SCOPE

1.2 PART DESCRIPTION AND QUANTITY

1.2.1 Guntersville Main Lock

1.2.1.1 Spare set of Cable (Optional Items)

1.2.2 Wilson Main Lock

1.2.2.1 Spare set of Cable (Optional Items)

1.2.3 Kentucky Lock

1.2.3.1 Spare Set of Cable Assembly

1.3 DIMENSION VERIFICATION

1.4 REFERENCES

1.5 SUBMITTALS

1.6 DELIVERY AND HANDLING

1.6.1 General

1.6.2 Inspection on Delivery

1.6.3 Time and Place of Delivery

1.7 WARRANTY

PART 2 PRODUCTS

2.1 PINS AND NUTS

2.2 END COUPLINGS

2.3 BOLTS, NUTS AND WASHERS

2.4 WIRE ROPE AND SOCKETS

2.4.1 Type of Wire Rope

2.4.2 Pre-Stretching

2.4.3 Wire Strength and Ductility

2.4.4 Pre-forming

2.4.5 Stress Relief "(Wrapping Test)"

2.4.6 Galvanizing

2.4.7 Strand Pitch Length

2.4.8 Core Strand Wires

2.4.9 End Terminations

2.4.10 Tension Testing

2.4.11 Attaching and Proof Loading Terminations

2.5 WIRE ROPE PLASTIC IMPREGNATION

2.6 LUBRICATION

2.7 2.4 CORROSION RESISTANT COATING

2.7.1 2.4.1 General

2.7.2 2.4.2 Cleaning

2.7.3 2.4.2 Coating

PART 3 EXECUTION

3.1 EXAMINATION

3.1.1 Quality Assurance Inspections

3.2 ATTACHING SOCKETS

SECTION 35 01 71 Page 1 Feb 03, 2016

3.3 UN-REELING WIRE ROPE

-- End of Section Table of Contents --

SECTION 35 01 71 Page 2 Feb 03, 2016

SECTION 35 01 71

ANCHOR CABLE ASSEMBLIES

PART 1 GENERAL

1.1 SCOPE

The work shall consist of furnishing materials, labor and equipment necessary to fabricate, assemble, supply and deliver the anchor cable assemblies and hardware for Guntersville Main Lock, Wilson Main Lock and Kentucky Lock. All cable assemblies shall be in strict accordance with specifications for each project location.

1.2 PART DESCRIPTION AND QUANTITY

Contractor shall provide the following items.

1.2.1 Guntersville Main Lock

See contract drawing 64N426r4 - UPSTREAM ANCHORAGE CHAIN & CABLE DETAILS for mark numbers (MK) and part description.

MARK NUMBER(MK) DESCRIPTION QUANTITY NOTE

MK-2 Pin and Nut 2 See Par. 2.1 - Pin & Nuts

MK-3 Pin 2 See Par. 2.1 - Pin & Nuts

MK-4 Pin 6 See Par. 2.1 Pin & Nuts

MK-5 End Coupling 2 See Par. 2.2 - End Coupling

MK-6 Anchor Cable (99'-0")

1 See Par. 2.4 - Wire Ropes and Sockets

MK-7 Anchor Cable (150'-0")

1 See Par. 2.4 - Wire Ropes and Sockets

MK-9 Lock Bolt 6 See Par. 2.3 - Bolts, Nuts and Washers

MK-10 Anchor Cable (86'- 6")

1 See Par. 2.4 - Wire Ropes and Sockets

MK-11 Anchor Cable (137'-6")

1 See Par. 2.4 - Wire Ropes and Sockets

SECTION 35 01 71 Page 3 Feb 03, 2016

1.2.1.1 Spare set of Cable (Optional Items)

Contractor shall also provide the following anchor cables for Guntersville Lock. All cables shall be furnished with sockets and socket attachment.

MK-6: Anchor cable. Required: 1 MK-7: Anchor cable. Required: 1 MK-10: Anchor cable. Required: 1 MK-11: Anchor cable. Required: 1

1.2.2 Wilson Main Lock

See contract drawing 64N428r4 - UPSTREAM ANCHORAGE CHAIN & CABLE DETAILS for mark numbers (MK) and part description.

MARK NUMBER(MK) DESCRIPTION QUANTITY NOTE

MK-2 Pin and Nut 2 See Par. 2.1 - Pin & Nuts

MK-4 Pin 2 See Par. 2.1 Pin & Nuts

MK-5 End Coupling 2 See Par. 2.2 - End Coupling

MK-6 Anchor Cable (138'-0")

1 See Par. 2.4 - Wire Ropes and Sockets

MK-7 Anchor Cable (134'-0")

1 See Par. 2.4 - Wire Ropes and Sockets

MK-8 Anchor Cable (223'-6")

1 See Par. 2.4 - Wire Ropes and Sockets

MK-9 Anchor Cable (219'-6")

1 See Par. 2.4 - Wire Ropes and Sockets

MK-14 Pin 6 See Par. 2.1 Pin & Nuts

MK-16 Lock Bolt 6 See Par. 2.3 - Bolts, Nuts and Washers

1.2.2.1 Spare set of Cable (Optional Items)

Contractor shall also provide the following anchor cables for Wilson Lock.

All cables shall be furnished with sockets and socket attachment.

MK-6: Anchor cable. Required: 1 MK-7: Anchor cable. Required: 1 MK-8: Anchor cable. Required: 1 MK-9: Anchor cable. Required: 1

SECTION 35 01 71 Page 4 Feb 03, 2016

1.2.3 Kentucky Lock

See contract drawing 64N433r2 - UPSTREAM ANCHORAGE CHAIN & CABLE DETAILS for mark numbers (MK) and part description.

MARK NUMBER(MK) DESCRIPTION QUANTITY NOTE

MK-1 Anchor Cable (171'-3")

1 See Par. 2.4 - Wire Ropes and Sockets

MK-2 Anchor Cable (218'-0")

1 See Par. 2.4 - Wire Ropes and Sockets

MK-3 Anchor Cable (267'-3")

1 See Par. 2.4 - Wire Ropes and Sockets

MK-4 Anchor Cable (330'-0")

1 See Par. 2.4 - Wire Ropes and Sockets

MK-6 End Coupling 2 See Par. 2.2 - End Coupling

MK-8 Pin and Nut 2 See Par. 2.1 - Pin & Nuts

MK-9 Pin 2 See Par. 2.1 - Pin & Nuts

MK-11 Washers 40

MK-12 Pins 6 See Par. 2.1 - Pin & Nuts

MK-13 Lock Bolt 6 See Par. 2.3 - Bolts, Nuts and Washers

1.2.3.1 Spare Set of Cable Assembly

Contractor shall also provide a spare set of anchor cables and all other components listed above for Kentucky Lock.

1.3 DIMENSION VERIFICATION

The Contractor shall become familiar with details of the work, verify dimensions and materials, and advise the Contracting Officer's Representative (COR) of any discrepancy before performing any work. The Contractor shall correct any dimension discrepancy and submit the shop drawings for approval.

1.4 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.

SECTION 35 01 71 Page 5 Feb 03, 2016

AMERICAN IRON AND STEEL INSTITUTE (AISI)

AISI 4140 Medium Carbon Steel Alloy Bars

ASTM INTERNATIONAL (ASTM)

ASTM A1023/A1023M (2015) Standard Specification for Stranded Carbon Steel Wire Ropes for General Purposes

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

ASTM A148/A148M (2014) Standard Specification for Steel Castings, High Strength, for Structural Purposes

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

ASTM A193/A193M (2015) Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service and Other Special Purpose Applications

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

ASTM A449 (2014) Standard Specification for Hex Cap Screws, Bolts, and Studs, Steel, Heat Treated, 120/105/90 ksi Minimum Tensile Strength, General Use

ASTM A572/A572M (2015) Standard Specification for High-Strength Low-Alloy Columbium-Vanadium Structural Steel

ASTM A668/A668M (2015) Standard Specification for Steel Forgings, Carbon and Alloy, for General Industrial Use

ASTM A709/A709M (2013a) Standard Specification for Structural Steel for Bridges

ASTM B117 (2011) Standard Practice for Operating Salt Spray (Fog) Apparatus

SOCIETY FOR PROTECTIVE COATINGS (SSPC)

SSPC SP 10/NACE No. 2 (2007) Near-White Blast Cleaning

U.S. GENERAL SERVICES ADMINISTRATION (GSA)

FS RR-W-410 (Rev G) Wire Rope and Strand

SECTION 35 01 71 Page 6 Feb 03, 2016

WIRE ROPE TECHNICAL BOARD (WRTB)

WRTB (2005) Wire Rope Users Manual

1.5 SUBMITTALS

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

submittals not having a "G" designation are for information only.

SD-02 Shop Drawings

SD-03 Product Data

Type of Wire Rope; G End Terminations; G Lubrication; G End Termination Attachment Method; G

SD-06 Test Reports

Tension Testing; G Attaching and Proof Loading Terminations; G Wire Strength and Ductility; G Pre-forming; G Stress Relief "(Wrapping Test)"; G Zinc Coating; G Corrosion Resistant Coating; G

SD-07 Certificates

Warranty Tension Testing Equipment; G Packaging details; G

1.6 DELIVERY AND HANDLING

1.6.1 General

Wind the wire ropes on spools in the same direction as they were bent during manufacturing. Cover the spools for protection from rain, snow, and/or road spatter during shipping.

1.6.2 Inspection on Delivery

Unless otherwise noted, the Contracting Officer's Representative (COR) will inspect the wire ropes and other equipment at the contractor shop or fabricator shop prior to delivery. Upon completion of the inspection, furnish the COR with a written report of the results. The equipment shall be packed in a manner acceptable to preserve the condition of the equipment as it left the fabricator's shop. The packaging shall clearly identify the contents and weight of the package. Packaging details shall be submitted for approval. Material found to be defective shall be replaced with sound material without additional expense to the Government.

1.6.3 Time and Place of Delivery

Delivery shall be made between Monday-Thursday, from 7:00AM to 3:30PM at the locations below. Arrangements shall be made with the below point of contact not less than five (5) working days prior to delivery:

SECTION 35 01 71 Page 7 Feb 03, 2016

Delivery items for Guntersville Lock to the following location:

Guntersville Lock 3780 Guntersville Dam Road Grant, AL 35747-9731 Attn: Ronnie Henson 256-582-3263

Delivery items for Wilson Lock to the following location:

Wilson Lock 704 S Wilson Dam Road Florence, AL 35630-2010 Attn: Gerald Choat 256-764-5223

Delivery items for Kentucky Lock to the following location:

Kentucky Lock 265 Kentucky Lock Road Grand Rivers, KY 40245-9706 Attn: Caleb Skinner 270-362-4226

1.7 WARRANTY

Submit signed copies or the manufacturer's warranty of a 1 year warranty for all materials under this section.

PART 2 PRODUCTS

2.1 PINS AND NUTS

Pins and nuts shall be in accordance with AISI 4140 with Brinell Hardness of 240BHN - 280 BHN or ASTM A668/A668M, Class J.

2.2 END COUPLINGS

ASTM A572/A572M or ASTM A709/A709M, galvanized steel.

2.3 BOLTS, NUTS AND WASHERS

Bolts, nuts and washers shall be galvanized steel. Furnish bolts with nuts, washers, bronze cotter key as required on the contract drawings. Bolts shall be in accordance with ASTM A325, ASTM A449 or ASTM A193/A193M, Gr.

B7. All holes for cotter key shall be done by the contractor.

2.4 WIRE ROPE AND SOCKETS

Provide wire rope and sockets which are the standard product of a manufacturer regularly engaged in the manufacture of wire rope, and that essentially duplicate products having been in satisfactory use for at least 5 years prior to bid opening. Furnish wire ropes with sockets. Each wire rope must be of the length indicated on contract drawings. Splicing will not be allowed. Wire rope shall have the minimum breaking strength of 722 lbs.

SECTION 35 01 71 Page 8 Feb 03, 2016

2.4.1 Type of Wire Rope

Wire ropes shall meet the requirements of the ASTM A1023/A1023M - Standard Specification for Stranded Carbon Steel Wire Ropes for General Purposes, drawn galvanized steel, and shall be of 2.75 inch diameter of 6x36 IWRC (Independent wire rope core) Classification, warrington-seale, right or left regular lay, pre-formed, extra improved plow steel (EIPS) steel wire rope with the breaking strength of 361 tons. The rope shall be shipped on reels with diameters not less than 25 times the rope diameter, and with suitable protection for the rope. Provide the wire rope product data that include the plastic impregnation for approval.

2.4.2 Pre-Stretching

Pre-stretching is not required to prevent separation of the plastic from the rope and/or fracturing the plastic coating during pre-stretching operations.

2.4.3 Wire Strength and Ductility

Perform testing in accordance with FS RR-W-410 to verify wire strength and ductility. Submit test results.

2.4.4 Pre-forming

Provide pre-formed wire rope, and perform testing in accordance with FS RR-W-410 to verify pre-forming. Submit test results.

2.4.5 Stress Relief "(Wrapping Test)"

Stress relieve the wire rope, and perform testing in accordance with FS RR-W-410 to verify stress relief. Submit test results.

2.4.6 Galvanizing

The wire rope must be woven from drawn galvanized wire. That is, the wires galvanized prior to their last drawing operation. The wire rope must have the same accepted industry standards for nominal strength as it would, had it not been galvanized. The manufacturer must perform testing in accordance with FS RR-W-410 to verify the zinc coating has been applied at the required rate.

Galvanizing / zinc coating of bolts, nuts, washers and other steel equipment shall be in accordance with ASTM A123/A123M or ASTM A153/A153M.

Re-galvanizing any coated surfaces that are damaged prior to acceptance by the COR.

2.4.7 Strand Pitch Length

Not be less than 4-1/2 times the nominal rope diameter.

2.4.8 Core Strand Wires

The number of wires in the core strand must be equal to or greater than the number of wires in the other strands. Use the same material as the wires in the other strands, or use a material with a lower tensile strength.

SECTION 35 01 71 Page 9 Feb 03, 2016

2.4.9 End Terminations

Submit product data for approval. The wire rope end terminations must be an open spelter socket type with poured zinc or epoxy resin. Spelter sockets shall be forged steel (ASTM A668/A668M), cast steel (ASTM A148/A148M ) or structural steel (ASTM A572/A572M, Gr. 50). Other materials may be acceptable to allow welding of the lifting attachment in Detail A of contract drawings. Lifting attachment shall be done by the contractor. End terminations without lifting attachment shall be Muncy open spelter sockets, R-115 or approved equal.

2.4.10 Tension Testing

Submit rope tension test report. Perform a tension test to verify all wire ropes meet the accepted industry standards for nominal strength. Perform the test using suitable tension testing equipment and by qualified personnel. Submit certification of rope tension testing device. Cut the rope samples to no less than 3 feet of length. The test will not be considered valid if the failure occurs less than 2 inches from either socket or holding mechanism. Relative speed between the machine heads must not exceed 1 inch per minute.

2.4.11 Attaching and Proof Loading Terminations

The manufacturer must attach the end terminations. The end termination attachment method must be submitted for approval. After their attachment, proof load the wire ropes at 40 percent of nominal strength of the rope.

Submit proof load of terminations test report and measured rope lengths.

2.5 WIRE ROPE PLASTIC IMPREGNATION

Wire rope shall be impregnated with a dense, waterproof plastic that effectively withstands abrasion and abusive treatment. Each individual strand is separated from all the others by the inner plastic filler. This design provides a tight , interlocking bond between the inner plastic filler and the outer plastic jacket.

2.6 LUBRICATION

Lubricate the wire ropes at the manufacturing facility. Apply the lubricant with equipment capable of forcing the lubricant between the rope wires, including the center strand. Apply lubrication prior to plastic impregnation.

2.7 2.4 CORROSION RESISTANT COATING

2.7.1 2.4.1 General

All items shall be coated by the contractor except components whose operation, assembly, or disassembly would be affected by coating application. Wire rope, galvanized bolts, nuts and washers shall not be coated.

2.7.2 2.4.2 Cleaning

Remove all loose rust, dirt, moisture, grease or other contaminants from surface.

SECTION 35 01 71 Page 10 Feb 03, 2016

2.7.3 2.4.2 Coating

Corrosion resistant coating shall be accomplished through zinc electro-plating. Surface preparation before coating application shall be SSPC SP 10/NACE No. 2. Coating shall be a minimum 0.001" to 0.0015" of electrodeposited Zinc, apply yellow Dichromate passivate and an application of colorless Ultra-Seal. One (1) pin and one (nut) shall be tested in a salt spray test in accordance with ASTM B117for a minimum of 14 days. The tested components shall show no signs of corrosion. The costs of such testing will be borne by the Contractor. Contractor shall provide a report of testing to the C.O.R.

The Contractor shall submit for approval the name of an independent commercial testing agency, names of individuals qualified and proposed to perform the salt spray test (such as resumes including education, training, etc.).

PART 3 EXECUTION

3.1 EXAMINATION

3.1.1 Quality Assurance Inspections

The fabricator's facilities shall be open, during normal business hours, to the Contracting Officer's Representative (C.O.R.) for the purpose of inspection of work, completed and in progress, on this contract. The tension test shall be performed in the presence of the C.O.R. unless waived in writing.

Failure of any parts to pass the requirements specified will be cause for rejection. Contractor shall replace the rejected parts without additional cost to the Government.

3.2 ATTACHING SOCKETS

Attach the end terminations to the wire rope as indicated and the recommendations of WRTB.

3.3 UN-REELING WIRE ROPE

Attach the wire rope(s) to spools or pulleys. Wind the wire rope under adequate tension and guide the each end of the rope(s) to its proper location. Wind the wire rope in the same direction it was bent during its manufacture. Ensure that no twists or loops occur.

-- End of Section --

SECTION 35 01 71 Page 11 Feb 03, 2016

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1.7 WARRANTY

Submittal Register