05 50 14 STRUCTURAL METAL FABRICATIONS.pdf

Culvert Valve Strut Arm Assemblies Wilson Lock W912P520Q0029, Amendment 001 Lauderdale County, Alabama

SECTION TABLE OF CONTENTS

DIVISION 05 - METALS

SECTION 05 50 14

STRUCTURAL METAL FABRICATIONS

PART 1 GENERAL

1.1 SCOPE

1.1.1 New Items

1.1.2 Government Furnished Items

1.1.3 Spare Items

1.1.4 For Reference

1.2 PRICE AND PAYMENT PROCEDURES

1.2.1 Payment

1.2.2 Unit of Measure

1.3 PERIOD OF PERFORMANCE

1.4 REFERENCES

1.5 SUBMITTALS

1.6 QUALITY ASSURANCE

1.6.1 Shop Drawings

1.6.2 Welding Qualifications

1.7 MATERIALS

1.8 ACCESS TO WORK

1.9 PROJECT SITE SECURITY AND AT/OPSEC PROCEDURES

1.9.1 General

1.9.2 Escorts

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Upper Valve Strut Assembly

2.1.1.1 Intermediate Strut End (MK 64W315-4)

2.1.1.2 Upper Strut Body (MK 64W315-5)

2.1.1.3 Upper Strut End (MK 64W315-6)

2.1.1.4 Intermediate Bushing (MK 64W315-9)

2.1.1.5 Intermediate Strut Pin (MK 64W315-14)

2.1.1.6 Upper Strut Pin (MK 64W315-15), Pin Nuts, Washers, and Lock

Bolt

2.1.1.7 Guide Screws (MK 64W315-17)

2.1.1.8 Intermediate Grease Seal (MK64W315-19)

2.1.1.9 Upper Grease Seal (MK64W315-20)

2.1.1.10 Collar (MK 64N315-25)

2.1.1.11 Intermediate Bearing Bushing (MK 64N316-5)

2.1.2 Fasteners and other Miscellaneous Items

2.2 FABRICATION

2.2.1 General

2.2.2 Structural Fabrication

2.2.2.1 Dimensional Tolerances for Structural Work

2.2.2.2 Structural Steel Fabrication

2.2.3 Welding

2.2.3.1 Welding of Structural Steel

SECTION 05 50 14 Page 1

2.2.3.1.1 Welding Procedures

2.2.3.1.2 Welding Process

2.2.3.1.3 Welding Technique

2.2.3.1.3.1 Filler Metal

2.2.3.1.3.2 Preheat and Interpass Temperature

2.2.3.1.3.3 Stress-Relief Heat Treatment

2.2.3.1.4 Workmanship

2.2.3.1.4.1 Preparation of Base Metal

2.2.3.1.4.2 Temporary Welds

2.2.3.1.4.3 Tack Welds

2.2.4 Machine Work

2.2.4.1 Finished Surfaces

2.2.4.2 Unfinished Surfaces

2.2.4.3 Pin Holes

2.2.5 Miscellaneous Provisions

2.2.5.1 Lubrication

2.2.6 Shop Assembly

2.3 TESTS, INSPECTIONS, AND VERIFICATIONS

2.3.1 Inspection of Structural Steel Welding

2.3.1.1 Visual Examination

2.3.1.2 Nondestructive Testing

2.3.1.2.1 Testing Agency

2.3.1.2.2 Examination Procedures

2.3.1.2.2.1 Ultrasonic Testing

2.3.1.2.2.2 Magnetic Particle Inspection

2.3.1.2.2.3 Dye Penetrant Inspection

2.3.1.2.3 Welds to be Subject to Nondestructive Testing

2.3.1.3 Test Coupons

2.3.1.4 Supplemental Examination

2.3.2 Welding Repair Plan

PART 3 EXECUTION

3.1 TRANSPORTATION OF FABRICATED PARTS

3.2 WORKMANSHIP

3.2.1 Weighing

3.3 ASSEMBLY

3.4 CLEANING AND PAINTING

3.5 AS-BUILT DRAWINGS

3.6 COATING

3.7 PROTECTION OF FINISHED WORK

3.7.1 Machined Surfaces

3.7.2 Lubrication After Assembly

3.8 DELIVERY

3.9 WARRANTY

3.10 SHOP INSPECTION

3.11 SHIPMENT

-- End of Section Table of Contents --

SECTION 05 50 14 Page 2

SECTION 05 50 14

STRUCTURAL METAL FABRICATIONS

PART 1 GENERAL

1.1 SCOPE

1.1.1 New Items

The work covered by this section consists of furnishing all labor, materials and equipment for the construction, assembly, and delivery of four (4) culvert valve upper strut arm assemblies at the Wilson Lock Project as specified herein and on the contract drawings. All work shall be performed in strict accordance with this specification and the applicable drawings, and shall be subject to the terms and conditions of the contract.

Installation shall be performed by the lock personnel at a later time.

Quantities shown on the contract drawings and below are for all four (4) complete upper strut arm assemblies. Four (4) complete upper strut arm assemblies shall be required under this contract. Each upper strut arm assembly shall include, but not be limited to the following items:

a. MK 64W315-4 Intermediate Strut End, required: 4

b. MK 64W315-5 Upper Strut Body, required: 4

c. MK 64W315-6 Upper Strut End, required: 4

d. MK 64W315-9 Intermediate Strut Bushing, required: 8

e. MK 64W315-14 Intermediate Strut Pin, required: 4

f. MK 64W315-15 Upper Strut Pin, required: 4. Furnish with pin nuts (64W315-21), washers (64W315-23) and lock bolts (64W315-27).

g. MK 64W315-17 Guide Screw, required: 4

h. MK 64W315-19 Intermediate Grease Seals, required: 8

i. MK 64W315-20 Upper Grease Seals, required: 8

j. MK 64W315-25 Collar, required: 4

k. MK 64W316-25 Intermediate Bearing Bushing, required: 8

l. Provide dowels (64W315-26), brass plugs (64W315-27 & 64W315-28), brass cap screws (64W315-29), dowels (64W316-16) and other necessary accessories for the complete upper strut arm assemblies.

1.1.2 Government Furnished Items

The following items are not included in this contract. These parts have already been fabricated, and will be used for the final assembly at the contractor's shop. The contractor shall pick-up and transport these items, which are necessary for the upper strut assembly, from the Tennessee River Operation Center (TROC) to their shop for assembly. Government personnel will load the existing parts to the Contractor's truck. See Paragraph 3.10 "SHIPMENT" for POC and location of TROC.

a. MK 64W315-7, Spindle: Steel Forging, required: 4, ASTM A668/A668M, Class K.

b. MK 64W315-10, Spindle Bushing: Aluminum Bronze, required: 4, ASTM B148 Alloy C95400.

c. MK 64W315-11, Upper Bushing: Aluminum Bronze, required: 8, ASTM B148 Alloy C95400.

SECTION 05 50 14 Page 3

d. MK 64W315-12, Outer Spring: Spring Steel, required: 4,

e. MK 64W315-16, Inner Spring: Spring Steel, required: 4,

f. MK 64W315-24, Spindle Nut: Steel Forging, required: 4, ASTM A668/A668M, Class H.

1.1.3 Spare Items

The following items will be used as spare parts for future use of the Government. These items will remain at TROC, and will not be shipped to the contractors for assembly.

a. MK 64W315-12, Outer Spring: Spring Steel, quantity: 1

b. MK 64W315-16, Inner Spring: Spring Steel, quantity: 1

1.1.4 For Reference

Items on the contract drawings that are not included in the above paragraphs are provided for reference. They will not be provided by the Contractor.

1.2 PRICE AND PAYMENT PROCEDURES

1.2.1 Payment

Payment will be made for costs associated with providing all four (4) culvert valve strut assemblies which includes all materials, equipment, and labor required to fabricate and deliver the strut assemblies in accordance with Section 05 50 14 STRUCTURAL METAL FABRICATIONS, Section 09 97 02 PAINTING: HYDRAULIC STRUCTURES and contract drawings. Shop drawing development, spare parts as applicable, and shipping shall be incidental to this payment. Payment shall be made one time at the completion of the project.

1.2.2 Unit of Measure

Unit of measure: Job.

1.3 PERIOD OF PERFORMANCE

The period of performance is 365 calendar days after the contract is awarded.

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.

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME B18.8.2 (1995) Taper Pins, Dowel Pins, Straight Pins, Grooved Pins and Spring Pins.

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2015; Errata 1 2015; Errata 2 2016) Structural Welding Code - Steel

SECTION 05 50 14 Page 4

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 A193/A193M (2019) Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service and Other Special Purpose Applications

ASTM A194/A194M (2018) Standard Specification for Carbon Steel, Alloy Steel, and Stainless Steel Nuts for Bolts for High-Pressure or High-Temperature Service, or Both

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 A53/A53M (2018) 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 A668/A668M (2017) Standard Specification for Steel Forgings, Carbon and Alloy, for General Industrial Use

ASTM B148 (2014) Standard Specification for Aluminum-Bronze Sand Castings

ASTM A123/A123M (2017) Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products

ASTM E165/E165M (2018) Standard Practice for Liquid Penetrant Examination for General Industry

ASTM E709 (2015) Standard Guide for Magnetic Particle Examination

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

SOCIETY FOR PROTECTIVE COATINGS (SSPC)

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

SECTION 05 50 14 Page 5

1.5 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 for review and approval:

SD-01 Preconstruction Submittals

Shop Drawings; G, ECD-E

SD-02 Shop DrawingsWelding Procedures

SD-03 Product Data

SD-06 Test Reports

NDT Report; G

Salt Spray Test Report; G, ECD-E

SD-07 Certificates

Welding Qualifications; G

Independent Commercial Testing Agency; G, ECD-E

SD-08 Manufacturer's Instructions

Welding Repair Plan; G

SD-11 Closeout Submittals

As-Built Drawings; G

1.6 QUALITY ASSURANCE

1.6.1 Shop Drawings

Submit Shop drawings for metalwork and machine work, prior to fabrication, include within the detail drawings catalog cuts, templates, fabrication and assembly details and quantities, type, grade and class of material as appropriate. Each component shall be detailed separately. Components can share the same drawing; however, each component shall be detailed separately. In addition to the details described above the drawings shall include but are not limited to all significant dimensions, machining tolerances, and surface finishes.In addition, product data of items in Part 2 - Products shall be submitted as applicable for review and approval.

Elements of fabricated items inadvertently omitted on contract drawings shall be detailed by the fabricator and indicated on the shop drawings.

Contractor shall not purchase materials and make fabrication until shop drawings are reviewed and approved. Indicate methods of protecting the work during shipping, storage, field assembly, and installation.

1.6.2 Welding Qualifications

Prior to welding, submit certification for each welder stating the type of welding and positions qualified for, the code and procedure qualified

SECTION 05 50 14 Page 6 under, date qualified, and the firm and individual certifying the qualification tests. If the qualification date of the welder or welding operator is more than 6 months 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.

1.7 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 purposes in accordance with best engineering practice. Where the characteristics of any material are not explicitly specified, approved materials 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 quality and standard first-grade quality.

1.8 ACCESS TO WORK

The Contracting Officer, assistants, and other agents of the Government 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.

1.9 PROJECT SITE SECURITY AND AT/OPSEC PROCEDURES

1.9.1 General

The entire Project area is not open to the public. Depending upon the level of security threat, some Project areas may or may not be open to the Contractor and Contractor employees. Guidance and forms for project site security requirements are available on the Nashville District Public Website:

http://www.lrn.usace.army.mil/BusinessWithUs/ContractSecurityRequirements.aspx

1.9.2 Escorts

All Contractor employees, including subcontractor employees who are not in possession of the appropriate security clearance or access privileges, will be escorted in areas where they may be exposed to classified and/or sensitive materials and/or sensitive or restricted areas.

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Upper Valve Strut Assembly

2.1.1.1 Intermediate Strut End (MK 64W315-4)

The intermediate strut end for the strut assembly shall be ASTM A668/A668M Class E of the outline, size, and construction shown on the contract drawings. The intermediate strut end shall have a surface finish of 125.

This surface finish is only necessary for when this component come into

SECTION 05 50 14 Page 7 contact with another component. Otherwise, the "as-forged" condition of the steel is adequate.

2.1.1.2 Upper Strut Body (MK 64W315-5)

The upper strut body shall be Seamless Steel Pipe ASTM A53/A53M, Grade B of the outline, size, and construction shown on the drawings. Wall thickness will be 0.625" (min.) and 0.650" (max.). Welded steel shall not be accepted. Submit product data with the detail drawings that shows the thickness and pipe type for approval prior to purchase. Any request to use alternate material shall be submitted to the Government for approval.

2.1.1.3 Upper Strut End (MK 64W315-6)

The upper strut end for the strut assembly shall be ASTM A668/A668M Class E of the outline, size, and construction shown on the drawings. The upper strut end shall have a surface finish of 125. This surface finish is only necessary for when this component come into contact with another component.

Otherwise, the "as-forged" condition of the steel is adequate.

2.1.1.4 Intermediate Bushing (MK 64W315-9)

The intermediate bushing of the strut assembly shall be Aluminum Bronze ASTM B148 C95400 of the outline, size, and construction shown on the drawings. The intermediate bushing shall have a surface finish of 32.

2.1.1.5 Intermediate Strut Pin (MK 64W315-14)

The intermediate strut pin shall be ASTM A668/A668M Class J with zinc electro-plating as specified in paragraph Coating, and drilled and tapped for lubrication. The intermediate strut pin shall have a surface finish of 32.

2.1.1.6 Upper Strut Pin (MK 64W315-15), Pin Nuts, Washers, and Lock Bolt

The upper strut pin shall be ASTM A668/A668M Class J with zinc electro-plating (see Par. Coating for details), and drilled and tapped for lubrication. The upper strut pin shall have a surface finish of 32.

Pin Nuts (MK 64W315-21): The pin nut shall be ASTM A668/A668M Class E with zinc electro-plating (see Par. Coating for details).

Guide Screw and Lock bolts (64W315-27): Stainless steel bolts ASTM A193/A193M, Grade B8 with stainless nut ASTM A194/A194M Grade 8, and stainless steel lock washer (SS304). All stainless steel hardware that comes into contact with non-stainless steel structure shall be provided with 1/8" thick flat insulating washers and 1/32" thick insulating sleeve.

Insulating washers, sleeve, and plates shall be made from G-10 material with the compressive strength 65 ksi.

2.1.1.7 Guide Screws (MK 64W315-17)

The guide screws shall be made of ASTM A193/A193M Grade B6 of the outline, size, and construction shown on the drawings.

2.1.1.8 Intermediate Grease Seal (MK64W315-19)

The intermediate grease seals shall be manufacturers standard rubber.

SECTION 05 50 14 Page 8

2.1.1.9 Upper Grease Seal (MK64W315-20)

The upper grease seals shall be manufacturers standard rubber.

2.1.1.10 Collar (MK 64N315-25)

The collar shall be ASTM A668/A668M Class E and Seamless Steel Pipe ASTM A53/A53M Schedule 40, Grade B of the outline, size, and construction shown on the drawings. The collar shall have a surface finish of 125. This surface finish is only necessary for when this component come into contact with another component. Otherwise, the "as-forged" condition of the steel is adequate.

2.1.1.11 Intermediate Bearing Bushing (MK 64N316-5)

The intermediate bearing bushing of the strut assembly shall be Aluminum Bronze ASTM B148 C95400 of the outline, size, and construction shown on the drawings. The intermediate bearing bushing shall have a surface finish of 32.

2.1.2 Fasteners and other Miscellaneous Items

All fasteners (bolts, nuts, screws, etc.) will be galvanized in accordance with ASTM A123/A123M.

a. Bolts ASTM F3125/F3125M, CL 325.

b. Nuts ASTM A563

c. Screws ASTM A449

d. Lock washers / washers: ASTM A36. Provide galvanized steel lock washers / washer as applicable.

e. Dowel Pins: ASME B18.8.2 galvanized

f. Brass Plugs and Cap Screws: ASTM B249/249M

2.2 FABRICATION

2.2.1 General

The work shall be manufactured in strict accordance with this specification and with the accompanying drawings except those changed that are explicitly approved by the Contracting Officer to accommodate manufacturer's standard equipment or the Contractor's shop practices.

2.2.2 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 are 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 must 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.

SECTION 05 50 14 Page 9

2.2.2.1 Dimensional Tolerances for Structural Work

Measure dimensions using an approved calibrated steel tape of approximately the same temperature as the material being measured. The overall dimensions of an assembled structural unit must be within the tolerances indicated on the drawings or as specified in the particular section of these specifications for the item of work. Where tolerances are not specified in other sections of these specifications or shown, an allowable variation of 1/32 inch is permissible in the overall length of component members with both ends milled; component members without milled ends must not deviate from the dimensions shown by more than 1/16 inch for members 30 feet or less in length, and by more than 1/8 inch for members over 30 feet in length.

2.2.2.2 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, Prequalification of WPSs Clause. 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.

2.2.3 Welding

2.2.3.1 Welding of Structural Steel

2.2.3.1.1 Welding Procedures

Use prequalied welding procedures for structural steel as described in AWS D1.1/D1.1M, Subsection 3.1 or qualify by tests as prescribed in AWS D1.1/D1.1M, Section 4. For welding procedures qualified by tests, the coupon welding and specimen testing will be witnessed and the test report document signed by the Contracting Officer. Approval of any welding procedure does not relieve the Contractor of 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 Contracting 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 of AWS D1.1/D1.1M

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.

SECTION 05 50 14 Page 10

2.2.3.1.2 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.

2.2.3.1.3 Welding Technique

2.2.3.1.3.1 Filler Metal

Provide the electrode, electrode-flux combination and grade of filler 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. Use a controlled temperature storage oven at the job site as prescribed by AWS D1.1/D1.1M, Subsection 3.5 to maintain low moisture of low hydrogen electrodes.

2.2.3.1.3.2 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 must be at least 70 degrees F. Slowly and uniformly preheat the joint area 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.

2.2.3.1.3.3 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, Subsection 5.8 unless otherwise authorized or directed.

2.2.3.1.4 Workmanship

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

2.2.3.1.4.1 Preparation of Base Metal

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

2.2.3.1.4.2 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.

2.2.3.1.4.3 Tack Welds

Tack welds that are to be incorporated into the permanent work are to exhibit the same quality requirements as the permanent welds; clean and

SECTION 05 50 14 Page 11 thoroughly fuse them with permanent welds. Perform preheating as specified above for temporary welds. Provide cascaded ends on multiple-pass tack welds. Remove defective tack welds before permanent welding.

2.2.4 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.

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 bolt holes.

2.2.4.1 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 make the part unsuitable for the intended use will be cause for rejection.

2.2.4.2 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.

2.2.4.3 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 Miscellaneous Provisions

2.2.5.1 Lubrication

Provide the arrangement and details for lubrication as indicated.

SECTION 05 50 14 Page 12

Thoroughly clean and lubricate, with an appropriate lubricant, all bearing surfaces before erection or assembly.

2.2.6 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.

2.3 TESTS, INSPECTIONS, AND VERIFICATIONS

2.3.1 Inspection of Structural Steel Welding

Nondestructive testing (NDT) of all welds will be required. NDT shall include visual examination and another form of testing such as UT, MT, or PT. Submit NDT report for approval. Supplemental examination of any joint or coupon cut from any location in any joint may also be required.

2.3.1.1 Visual Examination

To serve as a proper visual inspection, 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 AWS D1.1/D1.1M

2.3.1.2 Nondestructive Testing

When doubt exists as to the soundness of any material part, such part may be subjected to any form of nondestructive testing determined by the Contracting Officer. This may include ultrasonic, magnaflux, dye penetrant, x-ray, gamma ray or any other test that will thoroughly investigate the part in question. The cost of such investigation will be borne by the Government if the part is found to be sound and by the Contractor if the part is found to be defective. Any defects will be cause for rejection; replace and retest rejected parts at the Contractor's expense.

Perform as designated or described in the sections of these specifications, the nondestructive testing of shop and field welds covering the particular items of work.

2.3.1.2.1 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 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 performance of the examination tests must be done 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.

2.3.1.2.2 Examination Procedures

Conform to the following requirements.

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2.3.1.2.2.1 Ultrasonic Testing

Examine, evaluate and report ultrasonic testing (UT) of welds in conformance to the requirements of AWS D1.1/D1.1M, Clause 6 Part C for cyclically loaded connections. Provide ultrasonic equipment capable of making a permanent record of the test indications. Make a record of each weld tested.

2.3.1.2.2.2 Magnetic Particle Inspection

Conform magnetic particle (MT) inspection of welds to the applicable provisions of ASTM E709. Make a record of each weld tested.

2.3.1.2.2.3 Dye Penetrant Inspection

Perform dye penetrant inspection (PT) of welds conforming to the applicable provisions of ASTM E165/E165M. Make a record of each weld tested.

2.3.1.2.3 Welds to be Subject to Nondestructive Testing

All welds shall have a visual inspection and another form of NDT.

2.3.1.3 Test Coupons

The Government reserves the right to require the Contractor to remove coupons from completed work when doubt as to soundness cannot be resolved by nondestructive testing. 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.

2.3.1.4 Supplemental Examination

When the soundness of any weld is suspected of being deficient due to faulty welding or stresses that might occur during shipment or erection, the Government reserves the right to perform nondestructive supplemental examinations before final acceptance. The cost of such inspection will be borne by the Government.

2.3.2 Welding Repair Plan

Repair defective welds 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. 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.

PART 3 EXECUTION

3.1 TRANSPORTATION OF FABRICATED PARTS

Currently, the strut spindle, spindle nut, outer and inner springs, spindle bushing, and upper bushing have been fabricated and are located at the Tennessee River Operation Center (TROC). The contractor shall transport these items from TROC and bring them back to their shop to assemble the complete strut assembly. The contractor shall notify the lockmaster one

SECTION 05 50 14 Page 14 week prior to pick-up of the existing culvert valve machinery parts.

Before fabrication of any new part, the Contractor shall measure and verify that the dimensions of the fabricated parts match the government drawings.

The government shall be notified immediately if any discrepancy is found.

3.2 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.

3.2.1 Weighing

After fabrication and before assembly, each component of the Upper Strut Assembly shall be weighed, and the contractor shall provide the Government with the weights of each component. The weight shall be listed below each respective item's detail in the as-built drawings.

3.3 ASSEMBLY

The contractor shall assemble the entire upper strut arm assembly as shown on the government drawings. The contractor shall turn the spindle nut on the spindle where the distance between the upper strut pin and the first thread on the spindle is approximately 4 feet and 1 inch. Failure to do so will result in a rejection of the assembly. Any additional expense resulting from improper assembly shall be incurred by the Contractor.

3.4 CLEANING AND PAINTING

See Section 09 07 02 PAINTING: HYDRAULIC STRUCTURES.

3.5 AS-BUILT DRAWINGS

Upon completion of the work under this contract, the Contractor shall furnish a complete set of As-Built drawings in both PDF and DWG/DGN format.

As-built drawings shall include sufficient detail of each component. These details shall include but are not limited to all significant dimensions, quantities, grade, class and type of material.

3.6 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. Two samples shall be tested in a salt spray test in accordance with ASTM B 117 for a minimum of 14 days. The tested components shall show no signs of corrosion. Submit the salt spray test report along with the two sample for approval. 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.).

SECTION 05 50 14 Page 15

3.7 PROTECTION OF FINISHED WORK

3.7.1 Machined Surfaces

Thoroughly clean foreign matter off machined surfaces. Protect all finished surfaces. Oil and wrap unassembled pins 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.

3.7.2 Lubrication After Assembly

After assembly fill all lubricating systems with the appropriate lubricant and apply additional lubricant at intervals as required to maintain the equipment in satisfactory condition until acceptance of the work.

3.8 DELIVERY

The Contractor shall deliver the entire assembled upper strut assembly as directed herein and on the contract drawings. Thoroughly clean all parts prior to delivery for project personnel. The Contractor shall be responsible for and make good any and all damage due to improper preparation or loading for shipment. All damage shall be repaired or replaced by the Contractor with no additional cost to the Government. Any boxes or crates used for shipping shall be marked and have a packing list enclosed showing the parts contained therein.

3.9 WARRANTY

All strut equipment and material furnished shall be warranted for 24 months after delivery or 12 months after installation and the assembly is in operation.

3.10 SHOP INSPECTION

Government personnel shall inspect all assemblies at the fabricator's shop prior to delivery unless waived by the COR. Waiving of tests or shop inspection will not relieve the Contractor of responsibility for any fault in operation, workmanship or material that occurs before the completion of the contract or guarantee.

Please contact the Contracting Officer's Representative (COR) at least four

(4) weeks prior to delivery so that shop inspection can be arranged.

3.11 SHIPMENT

Contractor shall contact the lockmaster below two weeks prior to the delivery date. Delivery will be made from Monday to Thursday, 0800 to 1600 hours 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 strut assembly.

Wilson Lock POC Gerald Choat 704 South Wilson Dam Road Florence, AL 35630

SECTION 05 50 14 Page 16

Phone: (256) 764-5223 Email: Gerald.D.Choat@usace.army.mil

Government shall provide the crane /forklift and crane operator as required to unload the strut assemblies off the Contractor's delivery truck.

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SECTION 05 50 14 Page 17

2.1.2 Fasteners and other Miscellaneous Items

2.2.6 Shop Assembly

2.3.1.2.3 Welds to be Subject to Nondestructive Testing

2.3.2 Welding Repair Plan