05_59_13.pdf

SECTI ON TABLE OF CONTENTS

DI VI SI ON 05 - METALS

SECTI ON 05 59 13

FABRI CATI ON OF ROLLER GATE BULKHEAD AND BULKHEAD LI FTI NG BEAMS

PART 1 GENERAL

1. 1 REFERENCES

1. 2 SYSTEM DESCRI PTI ON

1. 2. 1 Wel d Tr acki ng Log Templ at e

1. 2. 2 Wel d Tr acki ng Log

1. 2. 3 Wel di ng Pr ocedur e Speci f i cat i ons ( WPS)

1. 2. 4 Fr act ur e Cr i t i cal Member s ( FCM)

1. 2. 4. 1 Wel di ng Pr ocesses

1. 2. 4. 2 Consumabl e Requi r ement s

1. 2. 4. 3 Wel di ng Pr ocedur e Speci f i cat i ons ( WPS)

1. 2. 4. 4 Cer t i f i cat i on and Qual i f i cat i on

1. 2. 4. 5 Mat er i al Handl i ng

1. 2. 4. 6 Tack Wel ds and Tempor ar y Wel ds

1. 2. 4. 7 Wel di ng Pr ocesses

1. 2. 4. 8 Wel d I nspect i on

1. 2. 4. 9 Repai r Wel di ng

1. 3 SUBMI TTALS

1. 4 QUALI TY ASSURANCE

1. 4. 1 Qual i f i cat i on of Wel der s and Wel di ng Oper at or s

1. 4. 2 I nspect or Qual i f i cat i ons

1. 4. 3 Qual i f i cat i on of St r uct ur al St eel Fabr i cat or

1. 4. 4 Test i ng by t he Gover nment

1. 4. 5 Shop Dr awi ngs

1. 5 Li f t i ng Beam Load Test i ng

1. 6 DELI VERY, STORAGE, AND HANDLI NG

PART 2 PRODUCTS

2. 1 FABRI CATI ON

2. 1. 1 St r uct ur al Fabr i cat i on

2. 1. 1. 1 Di mensi onal Tol er ances f or St r uct ur al Wor k

2. 1. 1. 2 St r uct ur al St eel Fabr i cat i on

2. 1. 2 Assembl y

2. 1. 3 Di ssi mi l ar Met al s

2. 1. 4 Mat er i al s Di sposi t i on Recor d

2. 1. 5 Wel ded Connect i ons

2. 1. 5. 1 Wel di ng Pr ocedur e

2. 1. 5. 2 Wel der Per f or mance Qual i f i cat i on of Wel der s and Wel di ng

Operators

2. 1. 5. 3 Wel di ng Pr ocess

2. 1. 5. 4 Wel di ng Techni que

2. 1. 5. 4. 1 Fi l l er Met al

2. 1. 5. 4. 2 Pr eheat and I nt er pass Temper at ur e

2. 1. 5. 5 Wor kmanshi p

2. 1. 5. 5. 1 Pr epar at i on of Base Met al

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2. 1. 5. 5. 2 Tack and Tempor ar y Wel ds

2. 1. 5. 5. 3 Wel d Access Hol es

2. 1. 5. 5. 4 Wel d Backi ng Removal

2. 1. 5. 5. 5 Wel d Backi ng Mat er i al Ot her Than St eel

2. 1. 6 Bol t ed Connect i ons

2. 1. 6. 1 Bol t s, Nut s, and Washer s

2. 1. 6. 2 Bol t Hol es

2. 1. 6. 3 Rot at i onal - Capaci t y Test s f or Pr et ensi oned and Sl i p

Cr i t i cal Joi nt s

2. 1. 7 Machi ne Wor k

2. 1. 7. 1 Fi ni shed Sur f aces

2. 1. 7. 2 Unf i ni shed Sur f aces

2. 1. 8 Pi n Hol es

2. 1. 9 Shaf t i ng

2. 1. 10 Lubr i cat i on

2. 1. 11 Mi scel l aneous Pr ovi s i ons

2. 1. 11. 1 Wel dment s

2. 1. 11. 2 Dr ai n Hol es

2. 1. 11. 3 Seal Wel ds

2. 1. 12 Shop Assembl y

2. 1. 12. 1 Bul khead Shop Test St ack

2. 1. 12. 2 Li f t i ng Beam Bal anci ng Pl an

2. 1. 13 Seal s

2. 1. 13. 1 Rubber Seal s

2. 1. 14 React i on Rol l er s

2. 1. 15 Sheaves

2. 1. 16 St r uct ur al St eel

2. 1. 17 St eel Cast i ng, Hi gh St r engt h

2. 1. 18 St eel Cast i ng

2. 1. 19 For gi ngs

2. 1. 20 Br onze

2. 1. 21 Spr i ngs

2. 1. 22 Rol l er Pi ns

2. 1. 23 Non- Fer r ous Cap Scr ews

2. 1. 24 Li f t i ng Beam Rol l er Bushi ng

2. 2 CERTI FI ED TEST REPORTS

2. 2. 1 Gener al

2. 2. 2 Nondest r uct i ve Test i ng

2. 2. 3 I nspect i on of St r uct ur al St eel Wel di ng

2. 2. 3. 1 Vi sual Exami nat i on

2. 2. 3. 2 Nondest r uct i ve Exami nat i on

2. 2. 3. 2. 1 Test i ng Agency

2. 2. 3. 2. 2 Exami nat i on Pr ocedur e and Ext ent

2. 2. 3. 2. 3 Accept abi l i t y of Wel ds

2. 2. 3. 2. 4 Exami nat i on Pr ocedur es

2. 2. 3. 2. 4. 1 Ul t r asoni c Test i ng ( UT)

2. 2. 3. 2. 4. 2 Radi ogr aphi c Test i ng ( RT)

2. 2. 3. 2. 4. 3 Magnet i c Par t i c l e I nspect i on ( MT)

2. 2. 3. 2. 4. 4 Dye Penet r ant I nspect i on ( PT)

2. 2. 4 Wel ds t o be Subj ect t o Nondest r uct i ve Exami nat i on

2. 2. 4. 1 St r uct ur al St eel Non- Fr act ur e Cr i t i cal Member s

2. 2. 4. 2 St r uct ur al St eel Non- Fr act ur e Cr i t i cal Member Fi l l et Wel ds and Par t i al Penet r at i on Wel ds

2. 2. 4. 3 St r uct ur al St eel Fr act ur e Cr i t i cal Member Wel ds

2. 2. 5 Test Coupons

2. 2. 6 Suppl ement al Exami nat i on

2. 2. 7 St r uct ur al St eel Wel di ng Repai r s

2. 2. 8 Cont r ol Di mensi ons

2. 2. 9 Li f t i ng Beam Oper at i on

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PART 3 EXECUTI ON

3. 1 I NSTALLATI ON

3. 1. 1 Cl eani ng

3. 1. 2 Al i gnment and Set t i ng

3. 2 PROTECTI ON OF FI NI SHED WORK

3. 3 PAI NTI NG

3. 4 EXI STI NG BULKHEAD AND LI FTI NG BEAM REMOVAL

3. 5 SCRAP SALE PROCEDURE

ATTACHMENTS:

PQR

- - End of Sect i on Tabl e of Cont ent s - -

SECTI ON 05 59 13 Page 3

SECTI ON 05 59 13

FABRI CATI ON OF ROLLER GATE BULKHEAD AND BULKHEAD LI FTI NG BEAMS

PART 1 GENERAL

1. 1 REFERENCES

The publ i cat i ons l i s t ed bel ow f or m a par t of t hi s speci f i cat i on t o t he ext ent r ef er enced. The publ i cat i ons ar e r ef er r ed t o wi t hi n t he t ext by t he basi c desi gnat i on onl y.

AMERI CAN SOCI ETY FOR NONDESTRUCTI VE TESTI NG ( ASNT)

ASNT SNT- TC- 1A ( 2014) Recommended Pr act i ce f or Per sonnel Qual i f i cat i on and Cer t i f i cat i on i n Nondest r uct i ve Test i ng

AMERI CAN WELDI NG SOCI ETY ( AWS)

AWS D1. 5M/ D1. 5 ( 2015) Br i dge Wel di ng Code

AWS QC1 ( 2007) St andar d f or AWS Cer t i f i cat i on of Wel di ng I nspect or s

ASTM I NTERNATI ONAL ( ASTM)

ASTM A27 ( 1991) St eel Cast i ngs, Car bon, f or Gener al Applications

ASTM A 148/ A 148M ( 2002) St eel Cast i ngs, Hi gh St r engt h, f or St r uct ur al Pur poses

ASTM A227 ( 1999) St eel Wi r e, Col d- Dr awn f or Mechani cal Spr i ngs

ASTM A 276 ( 2002) St ai nl ess St eel Bar s and Shapes

ASTM A325 ( 2010; E 2013) St andar d Speci f i cat i on f or St r uct ur al Bol t s, St eel , Heat Tr eat ed, 120/ 105 ksi Mi ni mum Tensi l e St r engt h

ASTM A490 ( 2012) St andar d Speci f i cat i on f or St r uct ur al Bol t s, Al l oy St eel , Heat Tr eat ed, 150 ksi Mi ni mum Tensi l e St r engt h

ASTM A563 ( 2007a; R2014) St andar d Speci f i cat i on f or Car bon and Al l oy St eel Nut s

ASTM A 668/ A 668M ( 2002) St eel For gi ngs, Car bon and Al l oy, f or Gener al I ndust r i al Use

ASTM A689 ( 2013) St andar d Speci f i cat i on f or Car bon and Al l oy St eel Bar s f or Spr i ngs

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ASTM A 709/ A 709M ( 2017) St andar d Speci f i cat i on f or St r uct ur al St eel f or Br i dges

ASTM B 148 ( 1997; R 2009) St andar d Speci f i cat i on f or Al umi num- Br onze Sand Cast i ngs

ASTM B505 ( 2002) Copper - Base Al l oy Cont i nuous Castings

ASTM C 412 ( 1999) Concr et e Dr ai n Ti l e

ASTM D 395 ( 2001) Rubber Pr oper t y - Compr essi on Set

ASTM D 471 ( 1998e1) Rubber Pr oper t y - Ef f ect of Liquids

ASTM D 573 ( 1999) Rubber - Det er i or at i on i n an Ai r Oven

ASTM D1187/ D1187M ( 1997; R 2002e1) Asphal t - Base Emul si ons f or Use as Pr ot ect i ve Coat i ngs f or Met al

ASTM D 2240 ( 2002a) Rubber Pr oper t y - Dur omet er Hardness

ASTM E165/ E165M ( 2012) St andar d Pr act i ce f or Li qui d Penet r ant Exami nat i on f or Gener al I ndust r y

ASTM E709 ( 2014) St andar d Gui de f or Magnet i c Par t i c l e Exami nat i on

ASTM F436 ( 2011) Har dened St eel Washer s

ASTM F 468 ( 2001a) Nonf er r ous Bol t s, Hex Cap Scr ews, and St uds f or Gener al Use

ASME I NTERNATI ONAL ( ASME)

ASME B4. 1 ( 1967; R 2009) Pr ef er r ed Li mi t s and Fi t s f or Cyl i ndr i cal Par t s

ASME B46. 1 ( 2009) Sur f ace Text ur e, Sur f ace Roughness, Wavi ness and Lay

U. S. ARMY CORPS OF ENGI NEERS ( USACE)

EM 385- 1- 1 ( 2008; Er r at a 2011) Saf et y and Heal t h Requi r ement s Manual

MASTER PAI NTERS I NSTI TUTE ( MPI )

MPI 79 ( Jan 2003) Al kyd Ant i - Cor r osi ve Met al Primer

1. 2 SYSTEM DESCRI PTI ON

Pr ovi de a det ai l ed Wor k Pl an f or f abr i cat i on, i ncl udi ng descr i pt i ons of shop f aci l i t i es, equi pment , number of per sonnel , and r el at ed i nf or mat i on pr i or t o t he Pr e- f abr i cat i on Conf er ence, and pr ocedur es f or saf e conduct

SECTI ON 05 59 13 Page 5 of t he wor k, car ef ul r emoval and di sposi t i on of mat er i al s, pr ot ect i on of pr oper t y t hat i s t o r emai n undi st ur bed, and coor di nat i on wi t h ot her wor k i n pr ogr ess. I ncl ude i n t he pr ocedur es a det ai l ed descr i pt i on of t he met hods and equi pment t o be used f or each oper at i on, and t he sequence of oper at i ons. Whi l e on gover nement pr oper t y al l i t ems shal l be i n accor dance with EM 385- 1- 1. The Wor k Pl an shal l i ncl ude t he r ecommended measur i ng syst em f or ensur i ng di mensi onal t ol er ances. The f abr i cat i on of t he f ol l owi ng l i s t ed st r uct ur es under t hi s cont r act shal l be per f or med accor di ng t o t hi s sect i on of t he speci f i cat i ons:

1. Lock and Dam 25 Rol l er Gat e Bul kheads ( Wi nf i el d, MO)

2. Lock and Dam 25 Rol l er Gat e Bul khead Li f t i ng Beam ( Wi nf i el d, MO)

3. Lock and Dam 25 Tai nt er Gat e Bul khead Li f t i ng Beam ( Wi nf i el d, MO)

4. Lock and Dam 24 Tai nt er Gat e Bul khead Li f t i ng Beam ( Cl ar ksvi l l e, MO)

a. Mat er i al wi t h wel ds wi l l not be accept ed unl ess t he wel di ng i s speci f i ed or i ndi cat ed on t he dr awi ngs or ot her wi se appr oved. Wel di ng shal l not be st ar t ed unt i l wel di ng pr ocedur es, i nspect or s, nondest r uct i ve t est i ng per sonnel , wel der s, wel di ng oper at or s, and t acker s have been qual i f i ed and appr oved. Each Cont r act or per f or mi ng wel di ng shal l mai nt ai n r ecor ds of t he t est r esul t s obt ai ned i n wel di ng pr ocedur e, and wel der , wel di ng oper at or , and t acker per f or mance qualifications.

b. As i t i s used i n t hese speci f i cat i ons, " The Engi neer " r ef er s t o t he Di st r i ct engi neer of r ecor d. The AWS D1. 5M/ D1. 5 def i ni t i on of " The Engi neer " as speci f i ed i n AWS D1. 5M/ D1. 5 sect i on 1. 1. 3 shal l r ef er t o t he Di st r i ct engi neer of r ecor d i n l i eu of t he st at e br i dge engi neer as speci f i ed i n sect i on 1. 1. 3 of AWS D1. 5M/ D1. 5.

c. Schedul e a Pr ef abr i cat i on Conf er ence as soon as possi bl e af t er Not i ce t o Pr oceed and pr i or t o any f abr i cat i on. The Pr ef abr i cat i on Conf er ence shal l i ncl ude, at a mi ni mum, t he Pr i me Cont r act or , Fabr i cat or , t he Fabr i cat or ' s pr i mar y QC r epr esent at i ve, t he COR, t he GQAR, and t he Engi neer of r ecor d f or t he st r uct ur e or st r uct ur es bei ng f abr i cat ed. The Pr ef abr i cat i on Conf er ence shal l occur ei t her at t he Fabr i cat i on Faci l i t i es or a s i mi l ar l ocat i on as deemed appr opr i at e.

1. 2. 1 Wel d Tr acki ng Log Templ at e

Submi t f or appr oval a wel d t r acki ng l og t empl at e, a mi ni mum of 30 days pr i or t o commencement of f abr i cat i on, t o i dent i f y al l necessar y component s t o be addr essed i n t he t r acki ng of al l wel ds f or t he st r uct ur es i n quest i on. A wel d- t r acki ng l og wi l l be devel oped and mai nt ai ned as descr i bed i n t he f ol l owi ng par agr aphs.

1. 2. 2 Wel d Tr acki ng Log

Submi t a l og capabl e of i ndi v i dual l y i dent i f y i ng and t r acki ng ever y wel d on t he pr oj ect . Member i dent i f i cat i on shal l f ol l ow t he number i ng scheme shown on t he shop dr awi ngs. The l og shal l i ncl ude t he member t o be wel ded, member t ype ( FCM and Non- FCM) , t ype of wel d i ncl udi ng t empor ar y and t ack wel ds, wel di ng posi t i on, appl i cabl e WPS r ef er ence, AWS j oi nt pr epar at i on desi gnat i on, name or st ampi ng desi gnat i on of wel der , wel di ng oper at or or t acker , dat e and t i me of compl et i on of wel di ng and/ or t acki ng, name and dat e of CWI vi sual i nspect i on, NDT t est i ng per f or med, i ncl udi ng t he t ype of i nspect i on, dat e( s) of i nspect i on, i nspect or name, and t he accept ance cr i t er i a used, descr i pt i on of def ect s f ound and r eason f or

SECTI ON 05 59 13 Page 6 non- compl i ance, cor r ect i ve act i on t aken, or whet her t he wel d i s accept abl e. Wel d i dent i f i cat i on on t he shop dr awi ng shal l mat ch wel d t r acki ng l og i dent i f i cat i on. A compl et ed l og shal l be bound t oget her f or each st r uct ur e and t wo copi es shal l be submi t t ed t o t he Cont r act i ng Of f i cer i mmedi at el y upon compl et i on of t he f abr i cat i on of each st r uct ur e.

Dr af t copi es of NDT t est i ng shal l be f ur ni shed t o t he Cont r act i ng Of f i cer upon r equest and shal l be avai l abl e on t he shop f l oor dur i ng any inspection.

1. 2. 3 Wel di ng Pr ocedur e Speci f i cat i ons ( WPS)

Submi t a Wel di ng Pr ocedur e Speci f i cat i on ( WPS) , wi t h at t ached PQR and suppor t i ng t est document at i on on f or ms si mi l ar or equi val ent t o t he sampl e f or ms i n AWS D1. 5M/ D1. 5, Annex I I I , f or each wel d, i ncl udi ng pr equal i f i ed wel ds, i n accor dance wi t h par agr aph Wel ded Connect i ons appr oved bef or e f abr i cat i on i s commenced. Wel di ng Pr ocedur e Speci f i cat i ons shal l be i ndi v i dual l y i dent i f i ed and shal l be r ef er enced on t he shop dr awi ngs. I n case of conf l i c t bet ween t hi s speci f i cat i on and AWS D1. 5M/ D1. 5 as appl i cabl e, t hi s speci f i cat i on gover ns.

1. 2. 4 Fr act ur e Cr i t i cal Member s ( FCM)

FCM ar e shown on t he Cont r act Dr awi ngs and i ncl ude al l at t achment s and connect i ons t o t hese member s as def i ned i n AWS D1. 5M/ D1. 5. Al l mat er i al s t o be wel ded shal l be ASTM A 709/ A 709M, gr ade as speci f i ed or shown on t he dr awi ngs, usi ng ki l l ed f i ne- gr ai n mi l l pr act i ce, unl ess ot her wi se shown or speci f i ed. Mi l l r epai r s of base met al ar e pr ohi bi t ed. Toughness shal l meet t he r equi r ement s of ASTM A 709/ A 709M, Tabl e 11, f or Zone 2, unl ess ot her wi se i ndi cat ed or speci f i ed. Al l mat er i al s used f or t he const r uct i on of f r act ur e cr i t i cal component s shal l meet t he r equi r ement s of sect i on 10 of ASTM A 709/ A 709M and shal l i ncl ude mi l l cer t i f i cat i on showi ng t hat t he mat er i al meet s t he necessar y t oughness r equi r ement s.

Wel di ng f or f r act ur e cr i t i cal member s shal l meet al l r equi r ement s of AWS D1. 5M/ D1. 5 Sect i on 12, i ncl udi ng:

1. 2. 4. 1 Wel di ng Pr ocesses

Al l pr ocedur es shal l be qual i f i ed as r equi r ed.

1. 2. 4. 2 Consumabl e Requi r ement s

Al l wel di ng consumabl es shal l be heat or l ot - t est ed by t he manuf act ur er t o det er mi ne conf or mance wi t h t he r equi r ement s of t he Fr act ur e Cont r ol Pl an ( FCP) . Except i ons ar e not al l owed. Toughness t est r esul t s shal l meet t he val ues speci f i ed i n Tabl e 12. 1 of AWS D1. 5M/ D1. 5. Submi t a Fr act ur e Cont r ol Pl an ( FCP) f or wel di ng on al l Fr act ur e Cr i t i cal Member s ( FCM) i n accor dance wi t h AWS D1. 5M/ D1. 5, Sect i on 12. Submi t wel di ng Pr ocedur es, qual i f i cat i ons, and cer t i f i cat i ons showi ng compl i ance wi t h FCP requirements.

1. 2. 4. 3 Wel di ng Pr ocedur e Speci f i cat i ons ( WPS)

Pr equal i f y or qual i f y al l pr ocedur es, i ncl udi ng r epai r wel ds, by t est as r equi r ed and document ed i n t he WPS and Pr ocedur e gui del i nes of

AWS D1. 5M/ D1. 5.

1. 2. 4. 4 Cer t i f i cat i on and Qual i f i cat i on

Wel der s and wel di ng oper at or s shal l meet t he appl i cabl e r equi r ement s of

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AWS D1. 5M/ D1. 5.

1. 2. 4. 5 Mat er i al Handl i ng

Mat er i al handl i ng and pr epar at i on, i ncl udi ng t her mal cut t i ng, pr epar at i on of base met al , and st r ai ght eni ng, cur vi ng, camber i ng shal l meet t he appl i cabl e r equi r ement s.

1. 2. 4. 6 Tack Wel ds and Tempor ar y Wel ds

Locat e al l wel ds wi t hi n t he j oi nt and meet t he r equi r ement s of AWS D1. 5M/ D1. 5, Tabl e 12. 2. Tempor ar y wel ds on FCM ar e not per mi t t ed.

1. 2. 4. 7 Wel di ng Pr ocesses

Wel di ng pr ocesses, i ncl udi ng pr eheat , i nt er pass t emper at ur es, and post wel d t her mal t r eat ment shal l meet t he appl i cabl e r equi r ement s.

1. 2. 4. 8 Wel d I nspect i on

Document t he Qual i t y Cont r ol i nspect i on pr ogr am i n t he FCP. Qual i f y al l i nspect or s and NDT t echni c i ans as r equi r ed. I nspect i on pr ocedur es and document at i on ar e as speci f i ed i n t he appl i cabl e sect i ons of AWS D1. 5M/ D1. 5.

St r i ct l y adher e t o cool i ng t i mes.

1. 2. 4. 9 Repai r Wel di ng

Cl assi f y r epai r wel ds as " cr i t i cal r epai r s" or " non- cr i t i cal r epai r s" f or al l r epai r wel di ng. Wel di ng Repai r pl ans f or st eel shal l be submi t t ed and appr oved pr i or t o conduct i ng r epai r s. Wel di ng r epai r pl ans shal l addr ess wel d r epai r s wi t hi n t he wel d as wel l as wel d r epai r s f or base met al di scont i nui t i es. Repai r pr ocedur es shal l f ol l ow t he mi ni mum pr ovi s i ons unl ess speci f i ed ot her wi se. Repai r pr ocedur es must be qual i f i ed and appr oved and subj ect t o t he same QA/ QC i nspect i on r equi r ement s as ot her wel ds. Mi ni mum pr eheat f or r epai r wel di ng shal l be as def i ned i n AWS D1. 5M/ D1. 5 sect i on 12. 17. 6. Al l wel d r epai r s t o f r act ur e cr i t i cal member s shal l be consi der ed cr i t i cal wel ds i n accor dance wi t h AWS D1. 5M/ D1. 5Sect i on 12. 17. 3 and shal l be appr oved by t he engi neer of record.

1. 3 SUBMITTALS

Gover nment appr oval i s r equi r ed f or submi t t al s wi t h a " G" desi gnat i on;

submi t t al s not havi ng a " G" desi gnat i on ar e f or i nf or mat i on onl y. When used, a desi gnat i on f ol l owi ng t he " G" desi gnat i on i dent i f i es t he of f i ce t hat wi l l r evi ew t he submi t t al f or t he Gover nment . Submi t t he f ol l owi ng i n accor dance wi t h Sect i on 01 33 00 SUBMI TTAL PROCEDURES:

SD- 01 Pr econst r uct i on Submi t t al s

Wel di ng Pr ocedur e Speci f i cat i ons ( WPS) ; G, EC- DS Fr act ur e Cont r ol Pl an ( FCP) ; G, EC- DS Wel d Tr acki ng Log Templ at e; G, EC- DS Load Test i ng Pl an; G, EC- DS Li f t i ng Beam Bal anci ng Pl an; G, EC- DS

SD- 02 Shop Dr awi ngs

Shop Dr awi ngs; G, EC- DS

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Assembl y; G, EC- DS Wel di ng Repai r s - Non- Fr act ur e Cr i t i cal Member s; G, EC- DS Wel di ng Repai r s - Fr act ur e Cr i t i cal Member s; G, EC- DS Del i ver y/ Shi ppi ng Pl an; G, EC- DS

SD- 03 Pr oduct Dat a

Mat er i al s Di sposi t i on Recor d

The Cont r act or shal l f ur ni sh t he Gover nment t hr ee copi es of al l pur chase and mi l l or der s, shop or der s f or mat er i al s and wor k or der s, i ncl udi ng al l new or der s pl aced by Cont r act or s and ol d or der s ext ended f or each suppl i er . The Cont r act or , at t he t i me of submi t t al of shop dr awi ngs, shal l f ur ni sh a l i s t desi gnat i ng t he mat er i al t o be used f or each i t em.

SD- 06 Test Repor t s

Cer t i f i ed Test Repor t s; G, EC- DS Wel d Tr acki ng Log; G, EC- DS Wi t ness Poi nt s Li f t i ng Beam Load Test i ng; G, EC- DS

SD- 07 Cer t i f i cat es

Wor k Pl an; G, EC- DS Qual i f i cat i on of Wel der s and Wel di ng Oper at or s; G, EC- DS I nspect or Qual i f i cat i ons; G, EC- DS Qual i f i cat i on of St r uct ur al St eel Fabr i cat or ; G, EC- DS

SD- 09 Manuf act ur er ' s Fi el d Repor t s

Cont r ol Di mensi ons; G, EC- DS

1. 4 QUALI TY ASSURANCE

Est abl i sh Wi t ness Poi nt s f or t he I ni t i al QA I nspect i on, I nt er medi at e QA I nspect i ons, and Fi nal I nspect i on as f ol l ows. St ar t t he I ni t i al QA I nspect i on af t er t he Gover nment has det er mi ned t hat t her e i s subst ant i al compl et i on of component s t hat compr i se a r easonabl e sampl i ng of each si gni f i cant FCM and non- FCM det ai l s. The ext ent of compl et i on and det ai l s and t he dat e of t he I ni t i al QA I nspect i on shal l be det er mi ned at t he Pr ef abr i cat i on Conf er ence by t he Gover nment af t er di scussi on wi t h t he Cont r act or . At t hat t i me, pr oduce a det ai l ed schedul e showi ng t he pr ogr essi on of wor k and compl et i on of component s. Thi s schedul e wi l l be updat ed weekl y and pr ovi ded by e- mai l t o t he Cont r act i ng Of f i cer . Gi ve t he Cont r act i ng Of f i cer t wo weeks not i ce pr i or t o t he pr edet er mi ned dat e f or t he I ni t i al QA I nspect i on, i ncl udi ng adj ust ment s f or changes i n schedul e. I nt er medi at e QA I nspect i ons wi l l be conduct ed on an as needed basi s and at t he di scr et i on of t he Gover nment . Al l QA i nspect i ons wi l l follow AWS D1. 5M/ D1. 5 and AASHTO/ NSBA St eel Br i dge Col l abor at i on S 4. 1 - 2002 St eel Br i dge Fabr i cat i on QC/ QA Gui de Speci f i cat i on. Pr ovi de unpai nt ed component s f or each QA NDT and Vi sual I nspect i on. At t hese st ages of const r uct i on, gi ve t he Cont r act i ng Of f i cer t hr ee wor ki ng days t o i nspect t he st r uct ur e. The QA I nspect i on per i od shal l not commence unt i l af t er a mi ni mum per i od of 72 hour s af t er any wel di ng. Af t er t he Cont r act i ng Of f i cer and t he Engi neer of Recor d has i nspect ed t he st r uct ur e, make any changes r equi r ed t o t he st r uct ur e as di r ect ed by t he Cont r act i ng Of f i cer bef or e pr oceedi ng wi t h any addi t i onal wel di ng.

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Pr oceed wi t h t he const r uct i on unt i l t he next wi t ness poi nt i s r eached, unl ess i t i s wai ved i n wr i t i ng by t he Cont r act i ng Of f i cer . Each st r uct ur e f abr i cat ed i s subj ect t o a Fi nal Fabr i cat i on I nspect i on pr i or t o pai nt i ng. A Fi nal Fabr i cat i on I nspect i on shal l be conduct ed af t er t he f i r st st r uct ur e i s compl et ed. Fi nal Fabr i cat i on I nspect i ons of addi t i onal st r uct ur es shal l be schedul ed and coor di nat ed wi t h t he Cont r act i ng Of f i cer and t he Engi neer of Recor d. Gi ve t he Cont r act i ng Of f i cer a mi ni mum not i ce of t wo weeks pr i or t o t he Fi nal Fabr i cat i on I nspect i on.

1. 4. 1 Qual i f i cat i on of Wel der s and Wel di ng Oper at or s

Submi t wel der , wel di ng oper at or and t acker qual i f i cat i on cer t i f i cat i on f or each wel der , wel di ng oper at or or t ack wel der t o t he Gover nment Repr esent at i ve/ Cont r act i ng Of f i cer / Engi neer and appr oved bef or e f abr i cat i on i s commenced i n accor dance wi t h par agr aph Wel ded Connect i ons.

A CWI meet i ng t he speci f i ed qual i f i cat i ons shal l appr ove al l wel der qual i f i cat i ons. Wel der s, wel di ng oper at or s, and t ack wel der s shal l be l i mi t ed t o wel di ng pr ocedur es f or whi ch t hey ar e cer t i f i ed. Test wel ds shal l be pr epar ed, wel ded, and t est ed i n accor dance wi t h t he r equi r ement s of AWS D1. 5M/ D1. 5. Bef or e assi gni ng any wel der , wel di ng oper at or , or t acker t o wor k under t hi s cont r act , submi t t he names of t he wel der s, wel di ng oper at or s, and t acker s t o be empl oyed, and cer t i f i cat i on t hat each i ndi v i dual i s qual i f i ed as speci f i ed. The cer t i f i cat i on shal l st at e t he t ype of wel di ng and posi t i ons f or whi ch t he wel der , wel di ng oper at or , or t acker i s qual i f i ed, t he code and pr ocedur e under whi ch t he i ndi v i dual i s qual i f i ed, t he dat e qual i f i ed, and t he name of t he f i r m and per son cer t i f y i ng t he qual i f i cat i on t est s. The cer t i f i cat i on shal l be kept cur r ent f or t he dur at i on of t he cont r act . Wel der and wel di ng oper at or qual i f i cat i on t est r ecor ds shal l be submi t t ed on f or ms si mi l ar or equi val ent t o t he sampl e f or ms i n AWS D1. 5M/ D1. 5, Annex I I I . Al l wel der s per f or mi ng f r act ur e cr i t i cal wel ds under t hi s speci f i cat i on shal l be qual i f i ed accor di ng t o Sect i on 12 of AWS D1. 5M/ D1. 5. Al l wel der s per f or mi ng non f r act ur e cr i t i cal wel ds shal l be qual i f i ed accor di ng t o Sect i on 6 of AWS D1. 5M/ D1. 5. Al l qual i f i cat i ons shal l be cur r ent pr i or t o commenci ng any wor k. Submi t a l og f or each wel der showi ng t hat he/ she i s cur r ent i n t he pr ocess and pr ocedur es bei ng pr oposed f or t hi s wor k.

1. 4. 2 I nspect or Qual i f i cat i ons

Al l i nspect or s, per f or mi ng st r uct ur al st eel i nspect i on i n accor dance wi t h t hese speci f i cat i ons, shal l be qual i f i ed and cer t i f i ed i n conf or mance wi t h AWS QC1. Pr ovi de an AWS Cer t i f i ed Wel di ng I nspect or ( CWI ) as t he pr i mar y poi nt of cont act f or qual i t y cont r ol of wel di ng. When sever al CWI and NDT t echni c i ans ar e wor ki ng, one pr i mar y i ndi v i dual shal l be desi gnat ed as havi ng pr i mar y r esponsi bi l i t y f or al l qual i t y cont r ol i n accor dance wi t h AWS D1. 5M/ D1. 5 Sect i on 6. 1. 2. 2. Non- cer t i f i ed i nspect or s and cer t i f i ed associ at e wel d i nspect or s ( CAWI ) shal l not be used f or i nspect i on under t hese speci f i cat i ons. Al l per sonnel who per f or m NDT shal l be qual i f i ed i n accor dance wi t h: ASNT SNT- TC- 1A NDT Level I I or I I I . Al l per sonnel per f or mi ng NDT shal l be super vi sed by per sonnel possessi ng a Level I I I ASNT NDT cer t i f i cat i on i n accor dance wi t h AWS D1. 5M/ D1. 5 sect i on 6. 1. 3. 4 and sect i on 12. 16. 1. 2. An ASNT Level I I I may conduct t est s i f t hat per son pr ovi des document at i on of havi ng passed a Level I I pr act i cal exami nat i on wi t hi n t he l ast t hr ee ( 3) year s. Submi t copi es of cer t i f i cat es showi ng evi dence of qual i f i cat i ons or cer t i f i cat i ons f or wel di ng i nspect or s and NDT per sonnel .

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1. 4. 3 Qual i f i cat i on of St r uct ur al St eel Fabr i cat or

The f abr i cat i ng pl ant and f abr i cat or shal l be cer t i f i ed under t he AI SC ( Amer i can I nst i t ut e of St eel Const r uct i on) Qual i t y Cer t i f i cat i on Pr ogr am, and shal l be desi gnat ed an AI SC Cer t i f i ed Pl ant , Cat egor y ABR ( Cer t i f i ed Br i dge Fabr i cat or - Advanced) wi t h a Fr act ur e Cr i t i cal Endor sement ( FC) or a Cat egor y HYD ( Cer t i f i ed Hydr aul i c Fabr i cat or ) at t i me of bi d. The f abr i cat or or f abr i cat i on pl ant shal l possess f i ve 5 year s document ed exper i ence on pr oj ect s of s i mi l ar scope. Si mi l ar scope means pr oj ect s of s i mi l ar s i ze and si mi l ar amount s of wel di ng and det ai l t ypes. Submi t copi es of t he AI SC cer t i f i cat e i ndi cat i ng t hat t he f abr i cat i on pl ant meet s t he speci f i ed st r uct ur al st eel wor k cat egor y and document ed exper i ence.

The seal s and bear i ng bl ocks ar e excl uded f r om t he AI SC f abr i cat or cer t i f i cat i on r equi r ement s.

1. 4. 4 Test i ng by t he Gover nment

Mat er i al component par t s may be subj ect ed t o any f or m of nondest r uct i ve t est i ng, as di r ect ed by t he Cont r act i ng Of f i cer . Thi s may i ncl ude ul t r asoni c, magnet i c par t i al , dye penet r ant , x- r ay, gamma r ay or any ot her t est t hat wi l l t hor oughl y i nvest i gat e t he par t i n quest i on. The cost of such i nvest i gat i on wi l l be bor ne by t he Gover nment . Any def ect s wi l l be cause f or r ej ect i on and r ej ect ed mat er i al s or par t s shal l be r epl aced and r et est ed at t he Cont r act or ' s expense.

1. 4. 5 Shop Dr awi ngs

Pr epar e al l shop dr awi ngs usi ng a Regi st er ed Pr of essi onal Engi neer or under t he di r ect super vi s i on of a Regi st er ed Pr of essi onal Engi neer .

El ement s of f abr i cat ed i t ems i nadver t ent l y omi t t ed on cont r act dr awi ngs shal l be r et ur ned t o t he Engi neer of Recor d f or det ai l i ng or shal l be det ai l ed by t he f abr i cat or and so i ndi cat ed on t he shop dr awi ngs. Any and al l det ai l s devel oped by t he f abr i cat or shal l be c l ouded on t he shop dr awi ngs f or separ at e appr oval by t he Engi neer of Recor d. Any i t ems desi gned by t he Cont r act or shal l be pr epar ed and seal ed by a Regi st er ed Pr of essi onal Engi neer . No spl i ces shal l be i ncl uded i n t he st r uct ur e wi t hout appr oval of t he Engi neer of Recor d. Each wel d, r equi r ed shal l be pr ovi ded a uni que i dent i f i er t o per mi t t r acki ng on t he wel d t r acki ng l og.

Pr i or t o per f or mi ng any f abr i cat i on of t he HSS st r uct ur es l i s t ed i n par agr aph Syst em Descr i pt i on above, submi t compl et e, det ai l ed shop dr awi ngs t o t he Cont r act i ng Of f i cer and Engi neer of Recor d f or appr oval .

Shop dr awi ngs shal l show compl et e det ai l s of mat er i al s, t ol er ances, connect i ons, and pr oposed wel di ng sequences. As par t of t he shop dr awi ng submi t t al s f or al l l i f i t ng beams, t he Cont r act or shal l pr ovi de an est i mat ed amount of wei ght t hat wi l l be used t o per f or m bal anci ng as r equi r ed by sect i on 2. 1. 12. 2. Shop dr awi ngs shal l i ncl ude cat al og cut s, t empl at es, f abr i cat i on and assembl y det ai l s, and t ype, gr ade, and cl ass of mat er i al s, as appr opr i at e. Al l FCM, i ncl udi ng at t achment s t hat meet t he FCM def i ni t i on, shal l be i dent i f i ed on t he shop dr awi ngs as wel l as al l t empor ar y and t ack wel ds. Each member shal l be i dent i f i ed f ol l owi ng t he number i ng scheme shown on t he dr awi ngs. A t abl e shal l be pr ovi ded cont ai ni ng a l i s t of al l member s and a r ef er ence t o each mat er i al cer t i f i cat e and t est r epor t t hat appl i es t o t hat member . Shop dr awi ngs shal l i dent i f y wel d pr ocedur es and NDE r equi r ed f or each wel d. Any and al l spl i ces shal l be i ncl uded i n t he shop dr awi ngs and cl ouded f or engi neer appr oval .

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1. 5 Li f t i ng Beam Load Test i ng

Af t er compl et i on of f abr i cat i on and pr i or t o del i ver y t he cont r act or shal l conduct a l oad t est on t he l i f t i ng beams. The t est shal l consi st of l oad t est i ng t he hooks t o t he l oad i ndi cat ed on t he dr awi ngs. The t est shal l consi st of l oad t est i ng t he f ul l y assembl ed l i f t i ng beam t o t he l oad t est i ndi cat ed on t he dr awi ngs. Load t est i ng shal l be conduct ed i n accor dance wi t h ASME B30. 20- 2013 and ASME B30. 10- 2014. The cont r act or shal l submi t t he t est r epor t s.

The Cont r act or shal l devel op a l oad t est i ng pl an f or al l l i f t i ng beams.

The pl an shal l i ncl ude but not l i mi t ed t o t est l oadi ng conf i gur at i on, t est i ng pr ocedur es, sampl e submi t t al t est i ng r epor t , et c. The t est pl an shal l i ncl ude pr ovi s i ons f or measur i ng t hr oat openi ng of t he hook bef or e and af t er l oad t est .

I n addi t i on t o t he t est i ng r equi r ed per ASME B30. 20- 2013 and ASME B30. 10- 2014 al l wel ds shal l be 100% vi sual l y i nspect ed and magnet i c par t i c l e i nspect ed as i ndi cat ed on t he dr awi ngs or wher e v i sual i nspect i on does not pass.

1. 6 DELI VERY, STORAGE, AND HANDLI NG

Not i f y t he Cont r act i ng Of f i cer at l east 28 days i n advance of del i ver y of t he st r uct ur es. Shi ppi ng of t he st r uct ur es shal l be at t he Cont r act or ' s expense. The st r uct ur es shal l be ar r anged on t he del i ver y vehi c l es such t hat no damage occur s dur i ng shi ppi ng. Submi t a Del i ver y/ Shi ppi ng Pl an showi ng or i ent at i on and l ocat i ons of st r uct ur es on t he del i ver y vehi c l es and t he l ocat i on of t he cr ane dur i ng l oadi ng and of f l oadi ng pr i or t o shi pment f or Gover nment appr oval . Submi t dr awi ngs pr ovi di ng descr i pt i ons of met hods of del i ver i ng t he compl et ed st r uct ur al uni t s, i ncl udi ng det ai l s f or suppor t dur i ng shi pment t o pr event di st or t i on or ot her damages, or i ent at i on and l ocat i on of t he st r uct ur e on t r anspor t equi pment , and spr eader beam t o be used t o i nst al l t he r ol l er gat e bul kheads.

Al l st r uct ur es per t ai ni ng t o Lock and Dam 25 shal l be del i ver ed vi a a Cont r act or f ur ni shed bar ge t o t he pr oj ect near Mi ssi ssi ppi Ri ver mi l e 241 and Wi nf i el d, MO. Cont r act or coor di nat i on f or del i ver y shal l be t hr ough t he St . Loui s Di st r i ct Cont r act i ng Of f i cer . The r ol l er gat e bul kheads shal l be del i ver ed and i nst al l ed i n t he bul khead sl ot s upst r eam of one of t he r ol l er gat es v i a a Cont r act or f ur ni shed bar ge, cr ane, spr eader beam and t he new l i f t i ng beam. The Cont r act or f ur ni shed spr eader beam shal l be used t o connect t he cr ane l i ne t o t he l i f t i ng beam sheave connect i ons. The spr eader beam conf i gur at i on shal l al l ow f or a compl et e ver t i cal pi ck of t he new l i f t i ng beams. Af t er i nst al l at i on of t he r ol l er gat e bul kheads, t he Cont r act or shal l r emove and di spose of t he ol d 102' r ol l er gat e bul kheads and t he ol d l i f t i ng beams. The Cont r act or shal l t hen pl ace t he new l i f t i ng beams and t he st or age yar d t r ucks t o t he upst r eam por t i on of t he st or age yar d on t he upst r eam si de of t he br i dge at t he east end of t he pr oj ect per t he di r ect i on of t he Cont r act i ng of f i cer . The new st or age t r ucks shal l be pl aced on t he t r acks at t he st or age yar d by t he Cont r act or t o ensur e pr oper f i t . Any al t er at i ons t o t he t r ucks shal l be made by t he Contractor.

The l i f t i ng beam per t ai ni ng t o Lock and Dam 24 shal l be del i ver ed and pl aced vi a a Cont r act or f ur ni shed bar ge and cr ane at t he upst r eam por t i on of t he st or age yar d of Lock and Dam 24 l ocat ed on t he east end of t he pr oj ect near Mi ssi ssi ppi Ri ver mi l e 273 and Cl ar ksvi l l e, MO. Cont r act or coor di nat i on f or del i ver y shal l be t hr ough t he St . Loui s Di st r i ct

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Cont r act i ng Of f i cer . Dur i ng t he pl acement of t he l i f t i ng beam i n t he st or age yar d, t he cont r act or shal l r emove and di spose of t he l i f t i ng beam t hat i s cur r ent l y l ocat ed i n t he st or age yar d. The Cont r act or shal l pl ace t he new l i f t i ng beam i nt o t he st or age yar d on t he upst r eam si de of t he br i dge per t he di r ect i on of t he Cont r act i ng of f i cer .

PART 2 PRODUCTS

2. 1 FABRICATION

2. 1. 1 St r uct ur al Fabr i cat i on

Mat er i al shal l be st r ai ght bef or e bei ng l ai d of f or wor ked. I f st r ai ght eni ng i s necessar y, i t shal l be done by met hods t hat wi l l not i mpai r t he met al . Shar p k i nks or bends shal l be cause f or r ej ect i on of t he mat er i al . Mat er i al wi t h wel ds wi l l not be accept ed except wher e wel di ng i s def i ni t el y speci f i ed, i ndi cat ed or ot her wi se appr oved. Bends shal l be made by appr oved di es, pr ess br akes or bendi ng r ol l s. Wher e heat i ng i s r equi r ed, pr ecaut i ons shal l be t aken t o avoi d over heat i ng t he met al and i t shal l be al l owed t o cool i n a manner t hat wi l l not i mpai r t he or i gi nal pr oper t i es of t he met al . Pr oposed f l ame cut t i ng of mat er i al , ot her t han st r uct ur al st eel , shal l be subj ect t o appr oval and shal l be i ndi cat ed on det ai l dr awi ngs. Shear i ng shal l be accur at e and al l por t i ons of t he wor k shal l be neat l y f i ni shed. Cor ner s shal l be squar e and t r ue unl ess ot her wi se shown. Re- ent r ant cut s shal l be f i l l et ed r ound t o a mi ni mum r adi us of 1 i nch i n accor dance wi t h AWS D1. 5M/ D1. 5 sect i on 3. 2. 4 unl ess ot her wi se i ndi cat ed or appr oved. Fi ni shed member s shal l be f r ee of t wi st s, bends and open j oi nt s.

2. 1. 1. 1 Di mensi onal Tol er ances f or St r uct ur al Wor k

a. Measur e di mensi ons by an appr oved measur i ng syst em. Submi t t he measur i ng syst em f or appr oval wi t h t he wor k pl an ( i . e. cal i br at ed st eel t ape of appr oxi mat el y t he same t emper at ur e as t he mat er i al bei ng measur ed) . The over al l di mensi ons of an assembl ed st r uct ur al uni t shal l be wi t hi n t he t ol er ances i ndi cat ed on t he dr awi ngs or as speci f i ed f or t he i t em of wor k. Wher e t ol er ances ar e not speci f i ed i n ot her sect i ons of t hese speci f i cat i ons or shown, a var i at i on of 1/ 32 i nch i s per mi ssi bl e i n t he over al l l engt h of component member s wi t h bot h ends mi l l ed and component member s wi t hout mi l l ed ends shal l not devi at e f r om t he di mensi ons shown by not mor e t han 1/ 16 i nch f or member s 30 f eet or l ess i n l engt h and by not mor e t han 1/ 8 i nch f or member s over 30 f eet i n l engt h.

b. St r uct ur e di mensi ons i ndi cat ed ar e based on a st r uct ur e t emper at ur e of 70 degr ees F. Per f or m di mensi onal adj ust ment s t o compensat e f or act ual t emper at ur e var i at i ons dur i ng const r uct i on.

2. 1. 1. 2 St r uct ur al St eel Fabr i cat i on

St r uct ur al st eel may be cut by mechani cal l y gui ded or hand- gui ded t or ches, pr ovi ded an accur at e pr of i l e wi t h a sur f ace t hat i s smoot h and f r ee f r om cr acks and not ches i s obt ai ned. Sur f aces and edges shal l be pr epar ed i n accor dance wi t h AWS D1. 5M/ D1. 5, Subsect i on 3. 2. Hand- gui ded cut s shal l be chi pped, gr ound or machi ned t o sound met al .

2. 1. 2 Assembly

Pr ovi de Assembl y Dr awi ngs i ndi cat i ng t he sequence of f abr i cat i on and

SECTI ON 05 59 13 Page 13 assembl y and pr ovi de det ai l s f or connect i ng t he adj oi ni ng f abr i cat ed component s i n t he shop. Assembl y det ai l s shal l i dent i f y t he r equi r ed or der of assembl y and det ai l s of wi t ness poi nt s as descr i bed i n t hese specifications.

2. 1. 3 Di ssi mi l ar Met al s

Wher e di ssi mi l ar met al s ar e i n cont act , pr ot ect sur f aces wi t h a coat conf or mi ng t o MPI 79 t o pr event gal vani c or cor r osi ve act i on. Wher e al umi num i s i n cont act wi t h concr et e, pl ast er , mor t ar , masonr y, wood, or absor pt i ve mat er i al s subj ect t o wet t i ng, pr ot ect wi t h ASTM D1187/ D1187M, asphal t - base emul si on.

2. 1. 4 Mat er i al s Di sposi t i on Recor d

Submi t t hr ee copi es of al l pur chase and mi l l or der s, shop or der s f or mat er i al s and wor k or der s, i ncl udi ng al l new or der s pl aced by Cont r act or s and ol d or der s ext ended f or each suppl i er . Fur ni sh, at t he t i me of submi t t al of shop dr awi ngs, a l i s t desi gnat i ng t he mat er i al t o be used f or each i t em. Wher e mi l l t est s ar e r equi r ed, pur chase or der s shal l cont ai n t he t est s i t e addr ess and t he name of t he t est i ng agency. Fur ni sh a shi ppi ng bi l l or memor andum of each shi pment of f i ni shed pi eces or member s t o t he pr oj ect s i t e, gi v i ng t he desi gnat i on mar k and wei ght of each pi ece, t he number of pi eces, t he t ot al wei ght , and i f shi pped by r ai l i n car l oad l ot s, t he car i ni t i al and number . Submi t mat er i al r ecor ds bef or e t he begi nni ng of f abr i cat i on. Addi t i onal r equi r ement s f or t hi s submi t t al ar e l i s t ed bel ow.

2. 1. 5 Wel ded Connect i ons

2. 1. 5. 1 Wel di ng Pr ocedur e

a. Wel di ng shal l conf or m t o t he appl i cabl e pr ovi s i ons of AWS D1. 5M/ D1. 5.

Pr i or t o t he st ar t of pr oduct i on wel di ng, submi t a compl et e schedul e of wel di ng pr ocedur es f or a t ypi cal st r uct ur e. The schedul e shal l conf or m t o t he r equi r ement s speci f i ed i n t he pr ovi s i ons of AWS D1. 5M/ D1. 5. The schedul e shal l pr ovi de det ai l ed pr ocedur e speci f i cat i ons and t abl es or di agr ams showi ng t he pr ocedur es t o be used f or each r equi r ed j oi nt .

b. Submi t t o t he Gover nment Repr esent at i ve/ Cont r act i ng Of f i cer s Repr esent at i ve/ Engi neer , a Wel di ng Pr ocedur e Speci f i cat i on f or each wel d t o be made. Submi t Wel di ng Pr ocedur e Speci f i cat i ons and Pr ocedur e Qual i f i cat i on Recor ds ( PQR) t o t he Gover nment Repr esent at i ve/ Cont r act i ng Of f i cer f or appr oval bef or e f abr i cat i on i s commenced. Copi es of t he Wel di ng Pr ocedur e speci f i cat i on and t he r esul t s of t he pr ocedur e qual i f i cat i on t est f or each t ype of wel di ng whi ch r equi r es pr ocedur e qual i f i cat i on shal l be submi t t ed f or appr oval . Submi t t he WPS and PQR wi t h t he shop dr awi ngs. Each WPS shal l be pr epar ed and qual i f i ed i n accor dance wi t h t he appl i cabl e pr ovi s i ons of AWS D1. 5M/ D1. 5. Wel di ng pr ocedur es shal l show t ypes and l ocat i ons of wel ds desi gnat ed or speci f i ed t o r ecei ve nondest r uct i ve exami nat i on and i dent i f y t he wel d as FCM when appl i cabl e. A WPS i s al ways r equi r ed, even i f t he pr ocedur e i s consi der ed pr equal i f i ed i n accor dance wi t h AWS D1. 5M/ D1. 5. Pr oper l y document ed evi dence of compl i ance wi t h al l r equi r ement s of t hese speci f i cat i ons f or pr evi ous qual i f i cat i on t est s shal l est abl i sh t he wel di ng pr ocedur e as pr equal i f i ed. Each pr ocedur e shal l be c l ear l y i dent i f i ed as bei ng ei t her pr equal i f i ed or qual i f i ed by t est s. I f a PQR i s per f or med, a

SECTI ON 05 59 13 Page 14 r epr esent at i ve of t he Gover nment shal l wi t ness t he t est pl at e wel di ng and t he speci men t est i ng. Appr oval of any pr ocedur e, however , wi l l not r el i eve t he Cont r act or of t he r esponsi bi l i t y f or pr oduci ng a f i ni shed st r uct ur e meet i ng al l r equi r ement s of t hese speci f i cat i ons.

Copi es of t he WPS shal l be made avai l abl e f or r ef er ence t o t he wel der s, wel di ng oper at or s and t ack wel der s. A CWI meet i ng t he speci f i ed qual i f i cat i ons shal l appr ove al l WPS' s and PQR' s.

2. 1. 5. 2 Wel der Per f or mance Qual i f i cat i on of Wel der s and Wel di ng Oper at or s

Wel di ng oper at or s, wel der s, and t ack wel der s shal l be qual i f i ed and r equal i f i ed i f necessar y f or t he par t i cul ar t ype of wor k t o be done.

Qual i f i cat i on shal l be i n accor dance wi t h AWS D1. 5M/ D1. 5. Bef or e assi gni ng any wel der , wel di ng oper at or , or t acker t o wor k under t hi s cont r act , submi t t he names of t he wel der s, wel di ng oper at or s, and t acker s t o be empl oyed, and cer t i f i cat i on t hat each i ndi v i dual i s qual i f i ed as speci f i ed. The cer t i f i cat i on shal l st at e t he t ype of wel di ng and posi t i ons f or whi ch t he wel der , wel di ng oper at or , or t acker i s qual i f i ed, t he code and pr ocedur e under whi ch t he i ndi v i dual i s qual i f i ed, t he dat e qual i f i ed, and t he name of t he f i r m and per son cer t i f y i ng t he qual i f i cat i on t est s. Copi es of t he Per f or mance Qual i f i cat i on r ecor ds shal l be submi t t ed t o t he Gover nment Repr esent at i ve and appr oved bef or e f abr i cat i on i s commenced. Requi r e t he wel der and wel di ng oper at or s t o r epeat t he qual i f y i ng t est s when, i n t he opi ni on of t he Gover nment Repr esent at i ve/ Cont r act i ng Of f i cer ' s Repr esent at i ve/ Engi neer , t he wor k i ndi cat es a r easonabl e doubt as t o pr of i c i ency. I n such cases, t he wel der shal l be r ecer t i f i ed, as above, af t er successf ul l y passi ng t he r et est ;

ot her wi se, he/ she shal l be di squal i f i ed unt i l successf ul l y passi ng a r et est . The per i od of ef f ect i veness f or al l wel der and wel di ng oper at or per f or mance qual i f i cat i ons shal l be i n accor dance wi t h AWS D1. 5M/ D1. 5.

Keep t he cer t i f i cat i on cur r ent f or t he dur at i on of t he cont r act . Al l expenses i n connect i on wi t h qual i f i cat i on and r equal i f i cat i on shal l be bor ne by t he Cont r act or .

2. 1. 5. 3 Wel di ng Pr ocess

Wel di ng of st r uct ur al st eel shal l be by an el ect r i c ar c wel di ng pr ocess usi ng a met hod whi ch excl udes t he at mospher e f r om t he mol t en met al and shal l conf or m t o t he appl i cabl e pr ovi s i ons of AWS D1. 5M/ D1. 5 f or al l wel ds. Wel di ng shal l be such as t o mi ni mi ze r esi dual st r esses, di st or t i on and shr i nkage.

2. 1. 5. 4 Wel di ng Techni que

2. 1. 5. 4. 1 Fi l l er Met al

The el ect r ode, el ect r ode- f l ux combi nat i on and gr ade of wel d met al shal l conf or m t o t he appr opr i at e AWS speci f i cat i on f or t he base met al and wel di ng pr ocess bei ng used or shal l be as shown wher e a speci f i c choi ce of AWS speci f i cat i on al l owabl e i s r equi r ed. Wel d met al t oughness shal l meet t he r equi r ement s of AWS D1. 5M/ D1. 5, Tabl es, 4. 1, 4. 2, or 12. 1 as appl i cabl e. The AWS desi gnat i on of t he el ect r odes t o be used shal l be i ncl uded i n t he schedul e of wel di ng pr ocedur es. Onl y l ow hydr ogen el ect r odes shal l be used f or manual shi el ded met al - ar c wel di ng r egar dl ess of t he t hi ckness of t he st eel . A cont r ol l ed t emper at ur e st or age oven shal l be used at t he j ob s i t e as pr escr i bed by AWS D1. 5M/ D1. 5, Subsect i on

12. 6 t o mai nt ai n l ow moi st ur e of l ow hydr ogen el ect r odes. Cont r ol l ed t emper at ur e st or age ovens shal l be power ed at al l t i mes. FCAW f i l l er met al shal l be subj ect ed t o t he st or age and handl i ng r equi r ement s def i ned

SECTI ON 05 59 13 Page 15 in AWS D1. 5M/ D1. 5 sect i on 12. 6. 7. 4. Fi l l er met al s and pr ocesses shal l not be combi ned i n t he same j oi nt or wel d.

2. 1. 5. 4. 2 Pr eheat and I nt er pass Temper at ur e

Per f or m pr eheat i ng as r equi r ed by t he appl i cabl e pr ovi s i ons of AWS D1. 5M/ D1. 5 f or al l wel ds except t hat t he t emper at ur e of t he base met al must be at l east 70 degr ees F. Pr eheat f or f r act ur e cr i t i cal wel ds shal l be as def i ned i n Tabl e 12. 3 and i n accor dance wi t h t he PQR/ WPS. The wel dment s t o be pr eheat ed shal l be s l owl y and uni f or ml y heat ed by appr oved means t o t he pr escr i bed t emper at ur e, hel d at t hat t emper at ur e unt i l t he wel di ng i s compl et ed and t hen per mi t t ed t o cool s l owl y as r equi r ed and i n accor dance wi t h t he appr oved WPS i n or der t o pr event cr acki ng or distortion.

2. 1. 5. 5 Workmanship

Wor kmanshi p f or wel di ng shal l be i n accor dance wi t h AWS D1. 5M/ D1. 5, Sect i on 3 f or al l wel ds and ot her appl i cabl e r equi r ement s of t hese specifications.

2. 1. 5. 5. 1 Pr epar at i on of Base Met al

Pr i or t o wel di ng, i nspect sur f aces t o be wel ded t o assur e compl i ance wi t h t he appl i cabl e sect i ons of AWS D1. 5M/ D1. 5.

2. 1. 5. 5. 2 Tack and Tempor ar y Wel ds

Make t ack and t empor ar y wel ds r equi r ed f or f abr i cat i on and er ect i on i n accor dance wi t h AWS D1. 5M/ D1. 5 under t he cont r ol l ed condi t i ons pr escr i bed her ei n f or per manent wor k. Tack wel ds t hat ar e t o be i ncor por at ed i nt o t he per manent wor k ar e subj ect t o t he same qual i t y r equi r ement s as t he per manent wel ds. Cl ean and f use such t ack wel ds t hor oughl y wi t h t he per manent wel ds. Mul t i pl e- pass t ack wel ds must have cascaded ends.

Remove def ect i ve t ack wel ds bef or e per manent wel di ng. Make al l wel ds usi ng l ow- hydr ogen wel di ng el ect r odes and wi t h wel der s qual i f i ed f or per manent wor k as speci f i ed el sewher e i n t hese speci f i cat i ons. Pr eheat as r equi r ed by AWS D1. 5M/ D1. 5 f or per manent t ack wel ds except t hat t he mi ni mum t emper at ur e must be 70 degr ees F i n any case, r egar dl ess of el ect r ode used. Al l t ack wel ds whi ch wi l l be i ncor por at ed i nt o t he f i nal wel dment must be a maxi mum of 1/ 8 i nch wi t h a mi ni mum l engt h of 1 i nch l ong spaced at a maxi mum of 6 i nch on cent er . I n maki ng t empor ar y wel ds, ar c st r i kes must not be st r uck i n ot her t han wel d l ocat i ons. Each t empor ar y wel d shal l be r emoved as r equi r ed by AWS D1. 5M/ D1. 5, Subsect i on

3. 3. 8. Gr i nd out and f i l l al l ar c st r i kes st r uck out si de t he wel d zone, and i nspect i n accor dance wi t h AWS D1. 5M/ D1. 5.

2. 1. 5. 5. 3 Wel d Access Hol es

Pr ovi de wel d access hol es as shown on t he shop dr awi ngs. I f t he over si t e of i nt er sect i ng out - of - pl ane wel ds i s encount er ed, t he f abr i cat or shal l not i f y t he Cont r act i ng Of f i cer f or t he appr oval of wel d access hol e addi t i ons i n such l ocat i ons. Payment f or t he addi t i on of wel d access hol es not shown on pl ans wi l l be t he Cont r act or ' s r esponsi bi l i t y .

2. 1. 5. 5. 4 Wel d Backi ng Removal

Unl ess ot her wi se i ndi cat ed, r emove al l st eel wel d backi ng mat er i al f r om wel ded j oi nt s. Al l st eel wel d backi ng mat er i al shal l be r emoved pr i or t o

SECTI ON 05 59 13 Page 16 t est i ng. I dent i f y on t he shop dr awi ngs al l wel d backi ng mat er i al t hat cannot be r emoved.

2. 1. 5. 5. 5 Wel d Backi ng Mat er i al Ot her Than St eel

Al l wel d backi ng mat er i al , ot her t han st eel , shal l be qual i f i ed by t est i ng and shal l be i ncl uded i n submi t t ed PQR/ WPS. Var i at i on f r om appr oved wel d backi ng mat er i al wi l l not be per mi t t ed and wi l l r equi r e t he devel opment and t est i ng a new wel d pr ocedur e whi ch addr esses t he change i n backi ng material.

2. 1. 6 Bol t ed Connect i ons

Al l hi gh st r engt h connect i ons shal l be t i ght ened t o a t ensi on not l ess t han t hat gi ven bel ow f or ASTM A325 Bol t s. Ti ght eni ng shal l be done by t ur n- of - nut , di r ect t ensi on i ndi cat or , cal i br at ed wr ench, or al t er nat i ve desi gn bol t met hods.

5/ 8 i nch 19 ki ps

3/ 4 i nch 28 ki ps

7/ 8 i nch 39 ki ps

1 i nch 51 ki ps

1- 1/ 8 i nch 56 ki ps

1- 1/ 4 i nch 71 ki ps

1- 3/ 8 i nch 85 ki ps

1- 1/ 2 i nch 103 ki ps

Al l ot her connect i ons shal l be t i ght ened t o t he snug- t i ght condi t i on.