W912P518T0075_TSpecs_BAR_miter_gate_strut_AM4Sheet.pdf

Miter Gate Strut Replacement Barkley Lock W912P518T0075 Amendment 0004 Lyon County, Kentucky

SECTION TABLE OF CONTENTS

DIVISION 05 - METALS

SECTION 05 50 38

MITER GATE STRUT

PART 1 GENERAL

1.1 SCOPE

1.2 REFERENCES

1.3 SUBMITTALS

1.4 QUALITY ASSURANCE

1.4.1 Detail Drawings

1.4.2 As-built Drawings

1.4.3 Welding Qualifications

1.5 MATERIALS

1.6 ACCESS TO WORK

1.7 PREPARATION FOR SHIPMENT

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Structural steel

2.1.2 Cast Steel

2.1.3 Steel Pipe

2.1.4 Bolts, Turn Bolts and Screws

2.1.5 Forging Steel

2.1.6 Aluminum Bronze

2.1.7 Other Materials

2.2 FABRICATION

2.2.1 Structural Fabrication

2.2.1.1 Structural Steel Fabrication

2.2.2 Welding

2.2.2.1 Welding of Structural Steel

2.2.2.1.1 Welding Procedures for Structural Steel

2.2.2.1.2 Welding Process

2.2.2.1.3 Welding Technique

2.2.2.1.3.1 Filler Metal

2.2.2.1.3.2 Preheat and Interpass Temperature

2.2.2.1.3.3 Stress-Relief Heat Treatment

2.2.2.1.4 Workmanship

2.2.2.1.4.1 Preparation of Base Metal

2.2.2.1.4.2 Temporary Welds

2.2.2.1.4.3 Tack Welds

2.2.2.2 Welding of Steel Castings

2.2.3 Bolted Connections

2.2.3.1 Bolted Structural Steel Connections

2.2.4 Castings

2.2.4.1 Types of Patterns

2.2.4.2 Pattern Materials

2.2.5 Machine Work

2.2.5.1 Finished Surfaces

SECTION 05 50 38 Page 1

2.2.5.2 Unfinished Surfaces

2.2.5.3 Pin Holes

2.2.5.4 Shafting

2.2.6 Miscellaneous Provisions

2.2.6.1 Lubrication

2.2.7 Shop Assembly

2.3 TESTS, INSPECTION AND VERIFICATIONS

2.3.1 Inspection of Structural Steel Welding

2.3.1.1 Visual Examination

2.3.1.2 Testing Agency

2.3.1.3 Examination Procedures

2.3.1.3.1 Ultrasonic Testing

2.3.1.3.2 Magnetic Particle Inspection

2.3.1.3.3 Dye Penetrant Inspection

2.3.1.4 Welds to be Subject to Nondestructive Testing

2.3.1.5 Test Coupons

2.3.2 Acceptability of Welds

2.3.3 Structural Steel Welding Repairs

PART 3 EXECUTION

3.1 INSTALLATION

3.1.1 Alignment and Setting

3.2 PROTECTION OF FINISHED WORK

3.2.1 Machined Surfaces

3.2.2 Lubrication After Assembly

3.3 CLEANING AND PAINTING

3.4 WARRANTY

3.5 DELIVERY, STORAGE, AND HANDLING

-- End of Section Table of Contents --

SECTION 05 50 38 Page 2

SECTION 05 50 38

MITER GATE STRUT

PART 1 GENERAL

1.1 SCOPE

The work covered by this section consists of furnishing all labor, materials and equipment, and performing all work necessary and required to complete the miter gate strut assemblies as specified herein and on the drawings. All work shall be performed in strict accordance with this section of the specifications and the applicable drawings, and shall be subject to the terms and conditions of the contract. Contractor shall also deliver the equipment to Barkley Lock Project. Installation shall be performed by others.

Quantities on the contract drawings are for four (4) complete miter gate strut assemblies.

a. Base contract: provide two (2) complete miter gate strut assemblies.

b. Option 1: provide two (2) complete miter gate strut assemblies.

1.2 REFERENCES

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

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2010; Errata 2011) Structural Welding Code - Steel

ASME INTERNATIONAL (ASME)

ASME B4.1 (1967; R 2009) Preferred Limits and Fits for Cylindrical Parts

ASME B46.1 (2009) Surface Texture, Surface Roughness, Waviness and Lay

ASTM INTERNATIONAL (ASTM)

ASTM A106/A106M (2014) Standard Specification for Seamless Carbon Steel Pipe for High-Temperature Service

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

ASTM A153/A153M (2016) Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel

SECTION 05 50 38 Page 3

Hardware

ASTM A193/A193M (2016) Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service and Other Special Purpose Applications

ASTM A194/A194M (2017a) Standard Specification for Carbon Steel, Alloy Steel, and Stainless Steel Nuts for Bolts for High-Pressure or High-Temperature Service, or Both

ASTM A27/A27M (2017) Standard Specification for Steel Castings, Carbon, for General Application

ASTM A350/A350M (2017) Standard Specification for Carbon and Low-Alloy Steel Forgings, Requiring Notch Toughness Testing for Piping Components

ASTM A36/A36M (2014) Standard Specification for Carbon Structural Steel

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 A514/A514M (2014) Standard Specification for High-Yield-Strength, Quenched and Tempered Alloy Steel Plate, Suitable for Welding

ASTM A53/A53M (2012) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

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

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

ASTM A576 (2017) Standard Specification for Steel Bars, Carbon, Hot-Wrought, Special Quality

ASTM A668/A668M (2017) Standard Specification for Steel Forgings, Carbon and Alloy, for General Industrial Use

ASTM B505/B505M (2014) Standard Specification for Copper-Base Alloy Continuous Castings

ASTM E165/E165M (2012) Standard Practice for Liquid Penetrant Examination for General Industry

ASTM E709 (2015) Standard Guide for Magnetic Particle Examination

SECTION 05 50 38 Page 4

ASTM F3125/F3125M (2015a) Standard Specification for High Strength Structural Bolts, Steel and Alloy Steel, Heat Treated, 120 ksi (830 MPa) and 150 ksi (1040 MPa) Minimum Tensile Strength, Inch and Metric Dimensions

ASTM F436/F436M (2016) Standard Specification for Hardened Steel Washers Inch and Metric Dimensions

1.3 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.

SD-01 Pre-Fabrication Submittals

Welding Of Structural Steel; G

Structural Steel Welding Repairs; G

SD-02 Shop Drawings

Detail Drawings; G

Drafting shall be executed by computer assistance in .dwg format and shall not have any attached files on submitted copies.

Drawings shall also have "true" scale. These drawings shall be completely detailed and shall be prepared using AutoCAD.

Reproduction of the contract drawings with notations and changes as necessary for the Contractor's shopwork will be acceptable.

Drawings shall be made in a manner to give clear permanent reproductions. Drawings shall be identified by serial number and descriptive titles indicating their application to the contract and they shall be signed by a responsible representative of the Contractor.

Submit detail drawings for approval prior to ordering materials.

SD-03 Product Data

Lubricant; G

SD-06 Test Reports

NDT Reports; G, ECD

SD-07 Certificates

Welding Qualifications; G

SD-08 Manufacturer's Instructions

Delivery/Shipping Plan; G

SECTION 05 50 38 Page 5

1.4 QUALITY ASSURANCE

1.4.1 Detail Drawings

Submit detail drawings for metalwork and machine work, prior to fabrication, include within the detail drawings catalog cuts, templates, fabrication and assembly details and type, grade and class of material as appropriate. Indicate methods of protecting the work during shipping, storage, field assembly, and installation.

Provide material data with the detail drawings. Material data shall clearly indicate the ASTM standards, grade, yield schedule, tensile strength, schedule, etc. as applicable. At the minimum, material data for pins, bushings, steel pipe, turned bolts, and steel castings shall be provided.

1.4.2 As-built Drawings

Provide the as-built drawings in accordance with Section 01 78 00 at the completion of project.

1.4.3 Welding Qualifications

Prior to welding, submit certification for each welder stating the type of welding and positions qualified for, the code and procedure qualified under, date qualified, and the firm and individual certifying the qualification tests. If the qualification date of the welding operator is more than one-year old, accompany the welding operator's qualification certificate with a current certificate by the welder attesting to the fact that he has been engaged in welding since the date of certification, with no break in welding service greater than 6 months.

Conform to all requirements specified in AWS D1.1/D1.1M.

1.5 MATERIALS

Materials used in this work shall be new, manufactured within the time period not to exceed one year prior to delivery, and shall be of kind, composition, and physical properties best adapted to their several purposes in accordance with best engineering practice. Where the characteristics of any material are not explicitly specified, approved material meeting the requirements of the appropriate specifications of the American Society for Testing Materials or other recognized standard shall be employed.

Incidental fittings, fixtures, accessories, and supplies shall be of approved manufacture and of standard first-grade quality.

1.6 ACCESS TO WORK

The Contracting Officer, assistants, and other agents of the Corps shall at all times have full and unrestricted access for inspection to all places of manufacture where equipment or materials are being made or prepared for use under this contract.

Contractor shall notify the COR at least 15 calendar days prior to the painting and delivery so that Government personnel can make the shop visits. Unless otherwise approved bye the COR, the Government personnel shall inspect the miter gate strut assembly prior to delivery.

SECTION 05 50 38 Page 6

1.7 PREPARATION FOR SHIPMENT

The Contractor shall prepare all materials and articles for shipment in such manner as to facilitate handling and to protect them from any type of damage in transit, and he shall be responsible for and make good any and all damage due to improper preparation or loading for shipment. Boxes and crates shall be marked and have a packing list enclosed showing the parts contained therein. The castings, pipe, flanges, and bushings shall be shipped as assemblies.

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Structural steel

ASTM A36/A36M, ASTM A572/A572M, GR 50 as shown on contract drawings.

2.1.2 Cast Steel

ASTM A148/A148M Grade 80-50, ASTM A27/A27M, GR 70-36 as shown on the contract drawings.

Machined, fabricated, or forged parts of materials with equivalent or better mechanical properties and weldability will be accepted in lieu of cast steel parts. Submit detail drawings for approval prior to ordering materials.

2.1.3 Steel Pipe

ASTM A53/A53M, ASTM A106/A106M seamless steel pipe, Grade B, Sch. 160 with the dimension as shown on the contract drawings. Pipe nominal wall thickness is 1". Welded steel pipe shall not be acceptable.

2.1.4 Bolts, Turn Bolts and Screws

ASTM A193/A193M, GR B6, ASTM A449, type 3, ASTM F3125/F3125M. Furnish bolts, turn bolts and screws with nuts and washers as needed. Nuts shall be in accordance with ASTM A194/A194M or ASTM A563. Washers shall be in accordance with ASTM F436/F436M.

All keeper plates shall be furnished with screws and washers. Bolts, turn bolts, crews, nuts and washers shall be hot-dipped galvanized in accordance with ASTM A153/A153M.

2.1.5 Forging Steel

ASTM A668/A668M with the grade as shown on the contract drawings. Unless otherwise approve by the Contracting Officer's Representative (COR), the use of other materials for pins shall not be accepted.

Contractor shall be grease fittings for all pins.

2.1.6 Aluminum Bronze

ASTM B505/B505M, UNS 95400.

SECTION 05 50 38 Page 7

2.1.7 Other Materials

a. Slip-on Flange: ASTM A350/A350M, GR LF2

b. Wedge: ASTM A576, SAE 1040

2.2 FABRICATION

2.2.1 Structural Fabrication

Material must 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. Make bends using approved dies, press brakes or bending rolls. Where heating is required, take precautions to avoid overheating the metal and allow it to cool in a manner that will not impair the original properties of the metal. Proposed flame cutting of material, other than structural steel, is subject to approval and must be indicated on detail drawings. Shearing shall be accurate and all portions of the work neatly finished. Make corners square and true unless otherwise shown. Fillet re-entrant cuts to a minimum radius of 3/4 inch unless otherwise approved. Provide finished members free of twists, bends and open joints. Tighten bolts, nuts and screws.

2.2.1.1 Structural Steel Fabrication

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, Subclause 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.

2.2.2 Welding

2.2.2.1 Welding of Structural Steel

2.2.2.1.1 Welding Procedures for Structural Steel

Prequalify welding procedures for structural steel as described in AWS D1.1/D1.1M, Subclause 3.1 or qualify by tests as prescribed in AWS D1.1/D1.1M, Clause 4. Properly documented evidence of compliance with all requirements of these specifications for previous qualification tests establish a welding procedure as prequalified. For welding procedures qualified by tests, the test welding and specimen testing will be witnessed and the test report document signed by the Contracting Officer. Approval of any welding procedure will not relieve the responsibility for producing a finished structure meeting all requirements of these specifications. The Contractor will be directed or authorized to make any changes in previously approved welding procedures that are deemed necessary or desirable by the Contractor Officer.

a. Submit a complete schedule of welding procedures for each steel structure to be welded prior to commencing fabrication. Provide the schedule in conformance with the requirements specified in the provisions AWS D1.1/D1.1M, Clauses 2, 3, 4, 6, 7 and applicable portions of Clause 8.

SECTION 05 50 38 Page 8

b. Provide within the schedule detailed procedure specifications and tables or diagrams showing the procedures to be used for each required joint. Include in the welding procedures filler metal, preheat, interpass temperature and stress-relief heat treatment requirements.

Clearly identify each welding procedure as being prequalified or required to be qualified by tests.

c. Show types and locations of welds designated or in the specifications to receive nondestructive testing in the welding procedures.

2.2.2.1.2 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.

2.2.2.1.3 Welding Technique

2.2.2.1.3.1 Filler Metal

Provide the electrode, electrode-flux combination and grade of weld metal conforming 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, Subclause 3.5 to maintain low moisture of low hydrogen electrodes.

2.2.2.1.3.2 Preheat and Interpass Temperature

Perform preheating as required by AWS D1.1/D1.1M, Subclause 3.5 or as otherwise specified except that the temperature of the base metal must 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.

2.2.2.1.3.3 Stress-Relief Heat Treatment

Where stress relief heat treatment is specified or shown, perform in accordance with the requirements of AWS D1.1/D1.1M, Subclause 5.8 unless otherwise authorized or directed.

2.2.2.1.4 Workmanship

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

2.2.2.1.4.1 Preparation of Base Metal

Prior to welding inspect surfaces to be welded to ensure compliance with AWS D1.1/D1.1M, Subclause 3.2.

SECTION 05 50 38 Page 9

2.2.2.1.4.2 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 must be 120 degrees F in any case. In making temporary welds, do not strike arcs in other than weld locations.

Remove each temporary weld and grind flush with adjacent surfaces after serving its purpose.

2.2.2.1.4.3 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 must have cascaded ends. Remove defective tack welds before permanent welding.

2.2.2.2 Welding of Steel Castings

Remove unsound material from the surfaces of steel castings, to be incorporated into welded connections, by chipping, machining, air-arc gouging or grinding. Do not weld major connections designed for transfer of stresses if the temperature of the casting is lower than 100 degrees F.

Preheat castings containing over 0.35 percent carbon or over 0.75 percent manganese to a temperature not to exceed 450 degrees F and conduct welding while the castings are maintained at a temperature above 350 degrees F.

Welding will not be permitted on castings containing carbon in excess of

0.45 percent except on written authorization. Castings requiring welding repairs after the first annealing and castings involving welding fabrication must be stress-relieved annealed prior to receiving final machining unless otherwise permitted.

2.2.3 Bolted Connections

2.2.3.1 Bolted Structural Steel Connections

Provide bolts, nuts and washers of the type specified or indicated. Equip all nuts with washers. Equip each bolt with one nut and two flat washers.

Use beveled washers where bearing faces have a slope of more than 1:20 with respect to a plane normal to the bolt axis.

a. Accurately locate bolt holes, smooth, perpendicular to the member and cylindrical.

b. Drill or subdrill holes for regular bolts and ream in the shop and not more than 1/16 inch larger than the diameter of the bolt.

c. Match-ream or drill holes for fitted bolts in the shop. Remove burrs resulting from reaming. Keep bolt threads entirely outside of the holes. The body diameter of bolts must have tolerances as recommended by ASME B4.1for the class of fit specified. Place fitted bolts in reamed holes by selective assembly to provide an LN-2 fit.

d. Holes for high strength bolts must not have diameters more than 1/16 inch larger than bolt diameters. If the thickness of the material is not greater than the diameter of the bolts, the holes may be punched.

SECTION 05 50 38 Page 10

If the thickness of the material is greater than the diameter of the bolts the holes may be drilled full size or subpunched or subdrilled at least 1/8 inch smaller than the diameter of the bolts and then reamed to full size. Poor matching of holes will be cause for rejection.

Drifting occurring during assembly cannot distort the metal or enlarge the holes. Reaming to a larger diameter of the next standard size bolt will be allowed for slight mismatching.

2.2.4 Castings

Each casting and castings weighing more than 500 required pounds must bear cast or stamped heat numbers. Deviations from the dimensions of castings shown must not exceed amounts that will impair the strength of castings by more than 10 percent as computed from the dimensions shown. Dimensions of castings shown on approved detail drawings are finished dimensions.

Castings that are warped or otherwise distorted or that are oversize to an extent that will interfere with proper fit with other parts of the machinery or structure will be rejected. The structure of metal in castings must be homogeneous and free from excessive nonmetallic inclusions. Excessive segregation of impurities or alloys at critical points in castings will be cause for rejection. Do not make repairs to castings prior to approval. Minor surface imperfections not affecting the strength of casting may be welded in the "green" if approved. Surface imperfections will be considered minor when the depth of the cavity prepared for welding is the lesser of 20 percent of the actual wall thickness or 1 inch. Defects other than minor surface imperfections may be welded only when specifically authorized in accordance with the following requirements:

a. The defects have been entirely removed and are judged not to affect the strength, use or machineability of the castings when properly welded and stress relieved.

b. The proposed welding procedure, stress relief and method of examination of the repair work have been submitted and approved.

2.2.4.1 Types of Patterns

Patterns for cast components shall be developed by the Contractor and shall become their property. The following types of patterns shall be acceptable.

a. Solid or Single Piece Pattern

b. Split Pattern

c. Gated Pattern

d. Loose Piece Pattern

e. Sweep Pattern

f. Match Plate Pattern

g. Multipiece Pattern

2.2.4.2 Pattern Materials

The pattern materials shall be determined by the Contractor. Wood, metal, plaster, wax, foam or plastic shall be acceptable for pattern materials.

2.2.5 Machine Work

Tolerances, allowances and gauges for metal fits between plain, non-threaded, cylindrical parts conform to ASME B4.1 for the class of fit shown or required unless otherwise shown on approved detail drawings.

SECTION 05 50 38 Page 11

Where fits are not shown they will be suitable as approved. Tolerances for machine-finished surfaces designated by non-decimal dimensions must be within 1/64 inch. Sufficient machining stock will be allowed on placing pads to ensure true surfaces of solid material. Provide finished contact or bearing surfaces true and exact to secure full contact. Polish journal surfaces and finish all surfaces with sufficient smoothness and accuracy to ensure proper operation when assembled. Accurately machine parts entering any machine and all like parts be interchangeable except that parts assembled together for drilling or reaming of holes or machining will not be required to be interchangeable with like parts. Accurately locate all drilled holes bolts.

2.2.5.1 Finished Surfaces

Provide surface finishes, indicated or specified, in accordance with ASME B46.1. Values of required roughness heights are arithmetical average deviations expressed in microinches. These values are maximum. Lesser degrees will be satisfactory unless otherwise indicated. Compliance with surface requirements is determined by sense of feel and 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 must be consistent with the general type of finish specified by roughness height. Where the finish is not indicated or specified use that which is most suitable for the particular surface, provide the class of fit required and be indicated on the detail drawings by a symbol which conforms to ASME B46.1 when machine finishing is provided. Flaws such as scratches, ridges, holes, peaks, cracks or checks which will make the part unsuitable for the intended use will be cause for rejection.

2.2.5.2 Unfinished Surfaces

Lay out all work to secure proper matching of adjoining unfinished surfaces unless otherwise directed. Where there is a large discrepancy between adjoining unfinished surfaces chip and grind smooth or machine to secure proper alignment. Unfinished surfaces must be true to the lines and dimensions shown and be chipped or ground free of all projections and rough spots. Fill in depressions or holes not affecting the strength or usefulness of the parts in an approved manner.

2.2.5.3 Pin Holes

Pin holes are to be bored true to gauges, smooth, straight and at right angles to the axis of the member. Do the boring after the member is securely fastened in position.

2.2.5.4 Shafting

Turn or grind shafting with hot-rolled or cold-rolled steel, as required, unless otherwise specified or authorized. Provide fillets where changes in section occur. Cold-finished shafting may be used where keyseating is the only machine work required.

2.2.6 Miscellaneous Provisions

2.2.6.1 Lubrication

Provide the arrangement and details for lubrication as indicated.

Thoroughly clean and lubricate, with an appropriate Lubricant, all bearing surfaces before erection or assembly. Prior to use of the lubricant

SECTION 05 50 38 Page 12 submit for approval product data supporting its use in the assembly that includes the following lubricating properties as they apply, temperature range, protection against corrosion, ability to remain in bearing, ability to seal out contaminants, cooling and friction. Contractor shall provide grease fittings for all pins.

2.2.7 Shop Assembly

Assemble each machinery and structural unit furnished in the shop to determine the correctness of the fabrication and matching of the component parts unless otherwise specified. Do not exceed those tolerances shown.

Closely check each unit assembled to ensure that all necessary clearances have been provided and that binding does not occur in any moving part.

Assembly in the shop must be in the same position as final installation in the field unless otherwise specified. Perform assembly and disassembly work in the presence of the Contracting Officer unless waived in writing.

Immediately remedy errors or defects disclosed by the Contractor without cost to the Government.

2.3 TESTS, INSPECTION 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.

2.3.1 Inspection of Structural Steel Welding

Nondestructive testing (NDT) of all welds will be required. When doubt exists as to the soundness of any material part, such part may be subjected to any form of supplemental nondestructive testing determined by the Contracting Officer's Representative. Supplemental examination of any joint or coupon cut from any location in any joint may be required when doubt as to the soundness cannot be resolved by nondestructive testing. The cost of supplemental investigation shall be born by the government. Any defects will be cause for rejection; replace and retest of rejected parts shall be at the Contractor's expense. Fillet welds shall be inspected by magnetic particle testing or liquid penetrant testing. Use ultrasonic testing for other type of welds. Provide NDT reports for approval.

2.3.1.1 Visual Examination

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, Clause 6, Subclause 6.9, Part C.

2.3.1.2 Testing Agency

The nondestructive testing of welds and the evaluation of tests as to the acceptability of the welds must be performed by a testing agency adequately

SECTION 05 50 38 Page 13 equipped and competent to perform such services or by the Contractor using suitable equipment and qualified personnel. In either case, written approval of the examination procedures is required and perform the examination tests in the presence of the Contracting Officer. The evaluation of tests are subject to the approval and all records become the property of the Government.

2.3.1.3 Examination Procedures

Conform to the following requirements.

2.3.1.3.1 Ultrasonic Testing

Make, evaluate and report ultrasonic testing of welds in conform to the requirements of AWS D1.1/D1.1M, Clause 6, Part C. Provide ultrasonic equipment capable of making a permanent record of the test indications.

Make a record of each weld tested.

2.3.1.3.2 Magnetic Particle Inspection

Conform magnetic particle inspection of welds to the applicable provisions of ASTM E709.

2.3.1.3.3 Dye Penetrant Inspection

Perform dye penetrant inspection of welds conforming to the applicable provisions of ASTM E165/E165M.

2.3.1.4 Welds to be Subject to Nondestructive Testing

Unless otherwise approved by the COR, all welds shall have NTD testing.

2.3.1.5 Test Coupons

Should tests of any two coupons cut from the work of any welder show strengths less than that specified for the base metal it will be considered evidence of negligence or incompetence and such welder will be removed from the work. When coupons are removed from any part of a structure, repair the members cut in a neat manner with joints of the proper type to develop the full strength of the members. Peen repaired joints as approved or directed to relieve residual stress. The expense for removing and testing coupons, repairing cut members and the nondestructive testing of repairs is borne by the Government or the Contractor in accordance with the Contract Clauses INSPECTION AND ACCEPTANCE.

2.3.2 Acceptability of Welds

Welds will be unacceptable if shown to have defects prohibited by AWS D1.1/D1.1M, or possess any degree of incomplete fusion, inadequate penetration or undercutting.

2.3.3 Structural Steel Welding Repairs

Repair defective welds in the structural steel welding repairs in accordance with AWS D1.1/D1.1M, Subclause 3.7. Remove defective weld metal to sound metal by use of air carbon-arc or oxygen gouging. Do not use oxygen gouging on ASTM A514/A514M steel. 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

SECTION 05 50 38 Page 14 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.

PART 3 EXECUTION

3.1 INSTALLATION

Thoroughly clean all parts to be installed. Remove packing compounds, rust, dirt, grit and other foreign matter. Clean holes and grooves for lubrication. Examine enclosed chambers or passages to make sure that they are free from damaging materials. Do not use pipe wrenches, cold chisels or other tools likely to cause damage to the surfaces of rods, nuts or other parts used for assembling and tightening parts. Tighten bolts and screws firmly and uniformly but take care not to overstress the threads.

When a half nut is used for locking a full nut place the half nut first followed by the full nut. Lubricate threads of all bolts except high strength bolts, nuts and screws with an appropriate lubricant before assembly. Coat threads of corrosion-resisting steel bolts and nuts with an approved antigalling compound. Driving and drifting bolts or keys will not be permitted. Bushings shall be assembled in the Contractor's shop. Pin installation and the final miter gate strut installation shall be done in the field by others.

3.1.1 Alignment and Setting

Accurately align each machinery or structural unit by the use of 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 must be true within the respective tolerances required. Set true machines to the elevations shown.

3.2 PROTECTION OF FINISHED WORK

3.2.1 Machined Surfaces

Thoroughly clean foreign matter off machined surfaces. Protect all finished surfaces. Oil and wrap unassembled pins, grease fittings, and bolts with moisture resistant paper or protect them by other approved means. Wash finished surfaces of ferrous metals to be in bolted contact, with an approved rust inhibitor and coat them with an approved rust resisting compound for temporary protection during fabrication, shipping and storage periods. Paint finished surfaces of metals which will be exposed after installation, except corrosion resisting steel or nonferrous metals as specified.

3.2.2 Lubrication After Assembly

Greasing the bushings shall be done in the field by others.

3.3 CLEANING AND PAINTING

For Cleaning and Painting, see Section 09 97 02 PAINTING: HYDRAULIC

STRUCTURES.

3.4 WARRANTY

All strut equipment and material furnished shall be warranted for 12 months after delivery.

SECTION 05 50 38 Page 15

3.5 DELIVERY, STORAGE, AND HANDLING

Notify the COR at least 14 calendar days in advance of delivery of the structures. Shipping of the structures shall be at the Contractor's expense. The structures shall be arranged on the delivery vehicles such that no damage occurs during shipping. All sling lifting lugs shall be directed up. Submit a Delivery/Shipping Plan showing orientation and locations of structures on the delivery vehicles prior to shipment for Government approval. Submit drawings providing descriptions of methods of delivering the completed structural units, including details for support during shipment to prevent distortion or other damages, and orientation and location of the structure on transport equipment.

Contractor shall contact the Facilities Manager below at least 14 calendar days prior to the delivery date to set up the delivery date and location.

Delivery will be made from Monday thru Thursday, 0600 - 1630 except Federal Holidays. Cost of shipping shall be included in the contract. Government shall provide the crane /forklift and crane operator as required to unload the miter gate strut assemblies off the Contractor's delivery truck.

Barkley Lock POC Caleb Skinner 758 Barkley Dam Road Grand Rivers, KY 42045-9802 Phone: 270-362-4226 Email: John.C.Skinner@usace.army.mil

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SECTION 05 50 38 Page 16

2.2.2.2 Welding of Steel Castings

2.2.7 Shop Assembly