A21. Solicitation Amendment 0003 amended specifications.pdf

SUBMITTAL FORM,Jan 96 PREVIOUS EDITION IS OBSOLETE PAGE 1 OF 19 PAGES

Mel Price Lift Gate Install and Machinery Replacement

00 08 00 SD-01 Preconstruction Submittals

1.13 GAccident Prevention Program

1.17 GStatements of Required

Insurance

1.21 GWork Plan

1.21 GWork Plan

1.21 GWork Plan

1.21 GDiving Plan

1.21 GTemporary Power Plan

SD-11 Closeout Submittals

1.23 GAs-Built Contract Drawings

1.23 GAs-Built Shop Drawings

01 11 30 SD-01 Preconstruction Submittals

1.5 GEnvironmental Protection Plan

01 15 00 SD-01 Preconstruction Submittals

3.1 GAccess/Haul Road Plan

01 32 01.00 10 SD-01 Preconstruction Submittals

1.3 GProject Scheduler Qualifications

3.4.1 GInitial Project Schedule

3.6.2 GPeriodic Schedule Update

01 35 26 SD-01 Preconstruction Submittals

1.7 GAccident Prevention Plan (APP)

SD-06 Test Reports 1.4Monthly Exposure Reports 1.12Notifications and Reports

1.12.2 GAccident Reports

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(a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) (m) (n) (o) (p) (q) (r)

Amended

SUBMITTAL FORM,Jan 96 PREVIOUS EDITION IS OBSOLETE PAGE 2 OF 19 PAGES

01 35 26 1.12.3LHE Inspection Reports SD-07 Certificates

1.6.1.3Crane Operators/Riggers

1.7.3.2 GStandard Lift Plan

1.7.3.3 GCritical Lift Plan

1.7.3.4 GNaval Architecture Analysis

1.8Activity Hazard Analysis (AHA) 1.9.1Confined Space Entry Permit 1.12.4Certificate of Compliance

01 45 00.00 10 SD-01 Preconstruction Submittals

3.2 GContractor Quality Control (CQC)

Plan SD-06 Test Reports

3.9.2Verification Statement 01 78 00 SD-03 Product Data

1.5.1Warranty Management Plan 1.3Spare Parts Data

SD-08 Manufacturer’s Instructions 1.5.1Instructions

SD-10 Operation and Maintenance Data

3.4 GOperation and Maintenance

Manuals

SD-11 Closeout Submittals

3.1 GAs-Built Drawings

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SUBMITTAL FORM,Jan 96 PREVIOUS EDITION IS OBSOLETE PAGE 3 OF 19 PAGES

01 78 00 1.5.1As-Built Record of Equipment and Materials

3.3As-Built Record of Equipment and Materials

3.2 GFinal Approved Shop Drawings

01 91 00.15 20 SD-01 Preconstruction Submittals

1.4 GCommissioning Team

3.2.4Commissioning Document 3.2.4Functional Checklist

3.2.3 G EC-DCommissioning

SD-05 Design Data

3.2.3 G EC-DFinal Operating Test

SD-06 Test Reports

3.5 G EC-DDesign Review Report

3.7 G EC-DCompleted Pre-Functional

Checklists

3.2.1 G EC-DMotor Control Center Acceptance

Tests

3.2.2 G EC-DLift Gate Control System

Acceptance Tests

3.3.4 G EC-DBond Resistance Test

3.3.5 G EC-DEquipment Continuity Test

3.2.1 G EC-DFinal Test Reports

3.2.4Startup and Acceptance Test 3.3.1Adjustable Speed Drive (ASD)

Test Plan

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SUBMITTAL FORM,Jan 96 PREVIOUS EDITION IS OBSOLETE PAGE 4 OF 19 PAGES

01 91 00.15 20 3.3.2ASD Performance Verification Tests

3.3.3ASD Endurance Test SD-07 Certificates

1.6 GCertificate Of Readiness

SD-09 Manufacturer’s Field Reports

3.4.1 G EC-DASD and PLC/HMI Training

Documentation

SD-10 Operation and Maintenance Data

3.3Inspection Log SD-11 Closeout Submittals

3.9 G EC-DFinal Commissioning Report

02 41 00 SD-01 Preconstruction Submittals

1.2.2 GEC-DSDemolition Plan

03 30 00 SD-01 Preconstruction Submittals

1.6.3.1Concrete Curing Plan

1.6.5 G EC-DQuality Control Plan

1.6.12 G EC-GThermal Analysis and Thermal

Control Plan

1.6.6 G EC-GQuality Control Personnel

Certifications 1.6.6Quality Control Organizational

Chart

1.6.8 G EC-GLaboratory Accreditation

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SUBMITTAL FORM,Jan 96 PREVIOUS EDITION IS OBSOLETE PAGE 5 OF 19 PAGES

03 30 00 1.6.2.1 G EC-DForm Removal Schedule 3.5.7Maturity Method Data

1.6.9 G EC-DSill Anchor Pull Testing Plan

1.6.10 G EC-DDowel Pull Testing Plan

1.6.11 G EC-DSill Anchor Post-Tensioning Plan

2.4Concrete Placement Plan 2.4Concrete Placement Plan

G, EC-D&G

SD-02 Shop Drawings

1.6.2.1 G EC-DFormwork Shop Drawings

1.6.2.2 G EC-DReinforcing Steel Shop Drawings

SD-03 Product Data

2.1 G EC-DFormwork Materials

2.3.1 G EC-GCementitious Materials

2.5.1 G EC-GConcrete Curing Materials

2.7 G EC-DReinforcement

2.8.1 G EC-DSill Extension Threaded Anchors

2.8.3 G EC-DSill Extension Threaded Couplers

2.3.4 G EC-GAdmixtures

2.7.2 G EC-DMechanical Reinforcing Bar

Connectors 2.2.2Biodegradable Form Release

Agent

1.6.3.2 G EC-GPumping Concrete Plan

1.6.3.3 G EC-GFinishing Plan

2.5.2 G EC-DNonshrink Grout

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SUBMITTAL FORM,Jan 96 PREVIOUS EDITION IS OBSOLETE PAGE 6 OF 19 PAGES

03 30 00 2.5.4 G EC-DManufacturer's Literature

2.4.1 GBatch Plant

SD-05 Design Data

1.6.1.2 G EC-GConcrete Mix Design

1.6.1.1 G EC-DFormwork Calculations

3.7.4 G EC-GHot-Weather Placing Plan

3.7.5 G EC-GCold Weather Protection Plan

SD-06 Test Reports

1.6.1.2 G EC-GConcrete Mix Design

1.6.4.1 G EC-GFly Ash

1.6.4.2 G EC-GAggregates

3.12.2.3 G EC-GCompressive Strength Tests

3.12.2.4 G EC-GAir Content

3.12.2.1 G EC-GSlump Tests

2.3.2Water

3.3.1 G EC-DSill Anchor Pull Testing Records

3.4.5 G EC-DDowel Pull Testing Records

3.14.1 G EC-DSill Anchor Post-tensioning

Records SD-07 Certificates

2.7.1 G EC-DReinforcing Bars

1.6.6.2 G EC-GField Testing Technician and

Testing Agency SD-08 Manufacturer’s Instructions

2.5.1 G EC-GCuring Compound

05 50 14 SD-02 Shop Drawings

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SUBMITTAL FORM,Jan 96 PREVIOUS EDITION IS OBSOLETE PAGE 7 OF 19 PAGES

05 50 14 1.9 G EC-DShop Drawings SD-03 Product Data

1.5 G EC-DWelding Procedure Specifications

1.5.2 G EC-DPre-qualified Procedures

2.1.1Materials Orders and Material List

SD-05 Design Data

2.3.3 G EC-DStructural Steel Welding Repairs

SD-06 Test Reports 2.3Tests, Inspections, and

Verifications SD-07 Certificates

2.3.2.1 G EC-DWeld Inspection Log

2.3.2.2 G EC-DWeld Inspection Log

1.6 G EC-DWelder, Welding Operator, and

Tacker Qualification

1.7 G EC-DCertified Welding Inspector

1.7 G EC-DCertified Welding Inspector

2.3.2.1 G EC-DCertified Welding Inspector

1.7 G EC-DNondestructive Testing Personnel

1.7 G EC-DNondestructive Testing Personnel

2.2.3.1 G EC-DApplication Qualification for Steel

Studs 05 50 15 SD-06 Test Reports

2.1Material Test Reports 05 59 20 SD-01 Preconstruction Submittals

1.5.5 G EC-DShop Drawings

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SUBMITTAL FORM,Jan 96 PREVIOUS EDITION IS OBSOLETE PAGE 8 OF 19 PAGES

05 59 20 1.3.3 G EC-DWelding Procedure Specifications

(WPS)

1.3.4.1 G EC-DFracture Control Plan (FCP)

1.3.1 G EC-DWeld Tracking Log Template

1.3.2 G EC-DWeld Tracking Log

1.5.1 G EC-DQualification of Welders and

Welding Operators

1.5.2 G EC-DInspector Qualifications

1.5.3 G EC-DQualification of Structural Steel

Fabricator

2.2.3.2.1 G EC-DNDT Inspector Certification

2.2.7 G EC-DWelding Repairs - Non-Fracture

Critical Members

2.2.7 G EC-DWelding Repairs - Fracture

Critical Members

2.1.4.2 G EC-DPerformance Qualification

Records 2.2.3.2.4.1G EC-DUltrasonic Written Procedure

1.5.7 G EC-DFabrication Log Template

1.3.10 G EC-DNonconformance Report Form

Template

1.3.5 G EC-DStress Relieving Plan

1.3.9 G EC-DDistortion And Shrinkage Control

Plan

2.1.1.2 G EC-DDistortion And Shrinkage Control

Plan

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SUBMITTAL FORM,Jan 96 PREVIOUS EDITION IS OBSOLETE PAGE 9 OF 19 PAGES

05 59 20 1.3.8 G EC-DBolt Work Plan

1.3.6 G EC-DBolt Inspection And Tracking Log

Template

1.3.7 G EC-DBolt Inspection And Tracking Log

1.3.11 G EC-DLoad Testing Plan

SD-02 Shop Drawings

1.6 G EC-DDelivery/Shipping Plan

1.5.6 G EC-DAssembly Drawings

2.1.2 G EC-DAssembly Drawings

1.6.1 G EC-DContractor Lifting Lugs

2.1.2 G EC-DFabrication And Assembly

Sequencing Plan SD-03 Product Data

2.1.3Materials Disposition Record SD-06 Test Reports

1.5.8 G EC-DFabrication Log - Downstream

Counterweight Box #1

1.5.8 G EC-DFabrication Log - Downstream

Counterweight Box #2

1.5.8 G EC-DFabrication Log - Upstream

Counterweight Box #1

1.5.8 G EC-DFabrication Log - Upstream

Counterweight Box #2

1.5.8 G EC-DFabrication Log - Counterweight

Connection Beam #1

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SUBMITTAL FORM,Jan 96 PREVIOUS EDITION IS OBSOLETE PAGE 10 OF 19 PAGES

05 59 20 1.5.8 G EC-DFabrication Log - Counterweight Connection Beam #2

1.5.8 G EC-DFabrication Log - Counterweight

Connection Beam #3

1.5.8 G EC-DFabrication Log - Counterweight

Connection Beam #4

1.5.8 G EC-DFabrication Log - Dogging Beam

Assembly #1

1.5.8 G EC-DFabrication Log - Dogging Beam

Assembly #2

1.5.8 G EC-DFabrication Log - Dogging Beam

Assembly #3

1.5.8 G EC-DFabrication Log - Dogging Beam

Assembly #4

2.2 G EC-DCertified Test Reports

1.5Witness Points

2.1.5.5 G EC-DRepair of Mislocated or Misdrilled

Holes

2.2.4.2 G EC-DSchedule of Random Testing

2.1.5.6 G EC-DManufacturer Certified Test

Reports

2.1.5.6 G EC-DDistributor Certified Test Reports

1.3.11Load Testing Reports

SD-07 Certificates

1.3 G EC-DWork Plan

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SUBMITTAL FORM,Jan 96 PREVIOUS EDITION IS OBSOLETE PAGE 11 OF 19 PAGES

05 59 20 SD-09 Manufacturer’s Field Reports

2.2.8 G EC-DControl Dimensions

09 97 02 SD-01 Preconstruction Submittals

1.3 GSafety, Health, and

Environmental Requirements

1.3.1 GAccident Prevention Plan

1.3.1.5 GConfined Spaces Plan

1.3.1.6 GRespiratory Protection Plan

1.3.2.1 GAirborne Sampling Plan

1.3.1 GVentilation Assessment Plan

1.3.2 GMedical Surveillance Plan

1.3.3 GEnvironmental Protection Plan

1.3.3.1Waste Manifest

1.3.3.1 GWaste Disposal Plan

1.3.3.2 G EC-DContainment Plan

SD-03 Product Data

2.1 GManufacturer's Safety Data Sheet

3.1.4 G EC-DSlip-Critical Faying Surface

Primer Material Data SD-04 Samples

2.1 GProduct Samples

2.2 G EC-DSpecial Paint Formulas

2.4.3 G EC-DSolvent and Thinners

SD-06 Test Reports 3.4Inspection Reports

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SUBMITTAL FORM,Jan 96 PREVIOUS EDITION IS OBSOLETE PAGE 12 OF 19 PAGES

09 97 02 1.3.2.2Medical Status Records

1.3.2.3 G EC-CChange in Medical Status Report

1.3.2.1 G EC-CAir Monitoring Test Plan

1.3.2.1Air Monitoring Test Report

3.1.4 G EC-DSlip-Critical Faying Surface

Primer Test Report SD-07 Certificates

1.5.1 G EC-CCertified EHS Professional

1.5.2 G EC-DSSPC QP-3 Certificate

1.5.2 G EC-DAISC Sophisticated Paint

Endorsement

1.5.2 G EC-DSSPC QP 1 Certificate

1.5.3 G EC-DQualified Coating Applicator

1.5.4 G EC-DCoating Thickness Gage

Qualification 09 97 13.00 40 SD-01 Preconstruction Submittals

Part 2 G EC-DMaterial, Equipment, and Fixture Lists

1.4 G EC-DSafety Plan

SD-03 Product Data

2.1.1 G EC-DAbrasive Blasting Material

2.1.2 G EC-DSealant Compound

3.2.4 G EC-DInorganic Zinc

2.1.3.1 G EC-DInhibitive Polyamide Epoxy

2.1.3.1 G EC-DAliphatic Polyurethane

SD-04 Samples

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09 97 13.00 40 1.4Manufacturer's Standard Color Charts

3.3.2Inspection Forms SD-05 Design Data

2.1.3 G EC-DMix Designs

3.2.4 G EC-DInorganic Zinc

2.1.3.1 G EC-DInhibitive Polyamide Epoxy

2.1.3.1 G EC-DAliphatic Polyurethane

SD-06 Test Reports

3.3.1 G EC-DInspection Reports

2.1.3 G EC-DTest Reports

SD-07 Certificates

2.1.1 G EC-DAbrasive Blasting Material

2.1.2 G EC-DSealant Compound

3.2.1 G E-CDInorganic Zinc Coating

2.1.3.1 G EC-DInhibitive Polyamide Epoxy

2.1.3.1 G EC-DAliphatic Polyurethane

SD-08 Manufacturer’s Instructions

2.1.3 G EC-DProtective Coatings

SD-11 Closeout Submittals

1.6 G EC-DWarranty

26 05 00.00 40 SD-03 Product Data

2.1.1 G EC-DConduits and Raceways

2.2.1 G EC-DWire and Cable

2.2.3 G EC-DSwitches

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SUBMITTAL FORM,Jan 96 PREVIOUS EDITION IS OBSOLETE PAGE 14 OF 19 PAGES

26 05 00.00 40 2.1.7 G EC-DDry-Type Distribution Transformers

SD-06 Test Reports

3.7 G EC-DTransformer Tests

SD-08 Manufacturer’s Instructions 3.1Manufacturer's Instructions

26 05 19.10 10 SD-02 Shop Drawings

3.1.3.1 GMarking Strips

SD-03 Product Data

2.1.2 GConductors

3.1 GCable Manufacturing Data;

SD-06 Test Reports

3.2 G EC-DContinuity Test

3.2 G EC-DPhase-Rotation Tests

3.2 G EC-DInsulation Resistance Test

3.2 G EC-D600-Volt Wiring Test

26 24 19.00 40 SD-02 Shop Drawings 2.1Motor Control Center Equipment

Drawings SD-03 Product Data

2.2 G EC-DMotor Control Centers

2.4.2.1 G EC-DPanelboards

SD-06 Test Reports

2.5 G EC-DFactory Test Procedures

2.5.1.4 G EC-DFactory Test Results

SD-07 Certificates

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SUBMITTAL FORM,Jan 96 PREVIOUS EDITION IS OBSOLETE PAGE 15 OF 19 PAGES

26 24 19.00 40 2.5.1.4 G EC-DMotor Control Center Certification

1.3.2.1 G EC-DQualifications of MCC Specialist

SD-11 Closeout Submittals

3.3 G EC-DWarranty

3.3 G EC-DManufacturer's Instructions

26 28 01.00 10 SD-03 Product Data

2.4 G EC-DFault Current Analysis

2.4 G EC-DProtective Device Coordination

Study

1.4.1 G EC-DSystem Coordinator

3.2Installation

2.4.7.6.1 G EC-DArc Flash Equipment Label

Material

2.1 G EC-DDevices and Equipment

SD-04 Samples

2.4.7.6.2 G EC-DArc Flash Equipment Label

Format SD-06 Test Reports

3.3Field Testing 35 01 41.00 10 SD-01 Preconstruction Submittals

1.4.1Purchase Agreements

3.7.1 G MEInstallation and Alignment

Procedure 3.7.6Gate Position Settings on Limit

Switches

2.1.3.1 G MEEquipment Protection Plan

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SUBMITTAL FORM,Jan 96 PREVIOUS EDITION IS OBSOLETE PAGE 16 OF 19 PAGES

35 01 41.00 10 2.1.6 G MEMaterials List

2.1.6 G MEOperating Test Procedure

3.8.1 G MEErecting Engineer Qualifications

SD-02 Shop Drawings

2.1.6 G MEDetail Drawings

2.1.6Materials Orders 1.4.2Shipping Bills

2.4.3 G MEReducer Shafts

2.6.1Key Fit and Shaft Bores

SD-03 Product Data

2.1.6 G MEManufacturer's Literature and

Equipment Data 2.7Electric motors

2.5.1 G MEParallel Shaft Reducer Bearings

2.8 G MEBrakes

2.6.2 G METorque Limiting Couplings

2.6 G MECouplings

SD-05 Design Data

2.11.2 G MEContractor Designed Gearing

2.4.5 G MEParallel Shaft Reducer

Lubrication System 2.4.9Lubricating Oil for Speed

Reducers SD-06 Test Reports

2.7Electric Motors

3.7.1 G MEFinal Operating Tests

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SUBMITTAL FORM,Jan 96 PREVIOUS EDITION IS OBSOLETE PAGE 17 OF 19 PAGES

35 01 41.00 10 SD-07 Certificates

1.3.1 G MEContractor's Qualifications For

Parallel Shaft Reducer Fabrication 3.5Qualification of Welders and

Welding Operators 3.10Equipment Warranty 3.8Erecting Engineer Installation and

Operation 3.3Gear Certification

SD-08 Manufacturer’s Instructions 3.6.1Cleaning of Corrosion-Resisting

Steel

3.4 GSlip Coupling Adjustment And

Alignment SD-10 Operation and Maintenance Data

3.11 G TL-MOperations and Maintenance

(O&M) Manual

35 01 70.13 SD-01 Preconstruction Submittals

1.4.1 G EC-DWire Rope Work Plan

1.4.2 GWire Rope Safety Plan

1.3 GContractor Installation

Qualifications

3.7.1 GWire Rope Tensioning Plan

SD-02 Shop Drawings

2.1.1 G EC-DEnd Terminations

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SUBMITTAL FORM,Jan 96 PREVIOUS EDITION IS OBSOLETE PAGE 18 OF 19 PAGES

35 01 70.13 SD-06 Test Reports

2.1.2 G EC-DAttaching and Proof Loading

Terminations

2.1.1 G EC-DEnd Terminations

SD-07 Certificates 1.6Warranty

35 20 20 SD-01 Preconstruction Submittals

1.4.2 G EC-DControl System Modifications

Plan SD-02 Shop Drawings

2.4 G EC-DASD Motor Controller

2.3.1 G EC-DLimit Switches

2.3.1 G EC-DPosition Tracking Encoders

2.3.1 G EC-DSpeed Reference Encoders

2.1 G EC-DHoist Motor

SD-03 Product Data

2.1 G EC-DHoist Motor

2.3.1 G EC-DSpeed Reference Encoders

2.4.17.2Overload Relays

2.4 G EC-DASD Motor Controller

2.4.16.1 G EC-DWiring

2.6.1 G EC-DConductors

2.1.12Terminal Leads 2.4.16.2Terminal Blocks 2.1.14Motor nameplates 2.4.21Equipment and Door Nameplates

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SUBMITTAL FORM,Jan 96 PREVIOUS EDITION IS OBSOLETE PAGE 19 OF 19 PAGES

35 20 20 SD-06 Test Reports

2.9 G EC-DTests

2.9.1Motor Factory Test Results

SD-07 Certificates

1.4.1 G EC-DQualifications of ASD Engineer

1.4.2 G EC-DQualifications of Systems

Integrator SD-08 Manufacturer’s Instructions

3.4.1 G EC-DManufacturer's Instructions

SD-09 Manufacturer’s Field Reports

2.9.4 G EC-DASD Test Plan

SD-10 Operation and Maintenance Data

3.4.1Operating and Maintenance Manual

SD-11 Closeout Submittals

3.4.2 G EC-DWarranty

35 20 30 SD-01 Preconstruction Submittals

1.4.1 GUnwatering Work Plan

35 20 40 SD-01 Preconstruction Submittals

1.3.1 G EC-DExisting Counterweight Removal

Work Plan 35 20 50 SD-01 Preconstruction Submittals

1.3.1 GCounterweight Installation Work

Plan

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SECTION TABLE OF CONTENTS

DIVISION 05 - METALS

SECTION 05 59 20

FABRICATION AND ASSEMBLY OF LIFT GATE COUNTERWEIGHT BOXES,COUNTERWEIGHT

CONNECTION BEAMS, AND DOGGING BEAM ASSEMBLIES

PART 1 GENERAL

1.1 SCOPE

1.2 REFERENCES

1.3 SYSTEM DESCRIPTION

1.3.1 Weld Tracking Log Template

1.3.2 Weld Tracking Log

1.3.3 Welding Procedure Specifications (WPS)

1.3.4 Fracture Critical Members (FCM)

1.3.4.1 Fracture Control Plan (FCP)

1.3.4.2 Repair Welding

1.3.5 Stress Relieving Plan

1.3.6 Bolt Inspection and Tracking Log Template

1.3.7 Bolt Inspection and Tracking Log

1.3.8 Bolt Work Plan

1.3.9 Distortion and Shrinkage Control Plan

1.3.10 Nonconformance Reports

1.3.11 Counterweight Connection Beam Load Testing

1.4 SUBMITTALS

1.5 QUALITY ASSURANCE

1.5.1 Qualification of Welders and Welding Operators

1.5.2 Inspector Qualifications

1.5.3 Qualification of Structural Steel Fabricator

1.5.4 Testing by the Government

1.5.5 Shop Drawings

1.5.6 Assembly Drawings

1.5.7 Fabrication Log Template

1.5.8 Fabrication Log

1.6 DELIVERY, STORAGE, AND HANDLING

1.6.1 Contractor Lifting Lugs

PART 2 PRODUCTS

2.1 FABRICATION

2.1.1 Structural Fabrication

2.1.1.1 Dimensional Tolerances for Structural Work

2.1.1.2 Control of Distortion and Shrinkage

2.1.1.3 Stress Relieving

2.1.2 Assembly

2.1.3 Materials Disposition Record

2.1.4 Welded Connections

2.1.4.1 Welding Procedure

2.1.4.2 Welder Performance Qualification of Welders and Welding

Operators

2.1.4.3 Welding Process

2.1.4.4 Welding Technique

2.1.4.4.1 Filler Metal

SECTION 05 59 20 Page 1

2.1.4.4.2 Preheat and Interpass Temperature

2.1.4.5 Workmanship

2.1.4.5.1 Preparation of Base Metal

2.1.4.5.2 Tack and Temporary Welds

2.1.4.5.3 Weld Access Holes

2.1.4.5.4 Weld Backing Removal

2.1.5 Bolted Connections

2.1.5.1 Pretensioned Bolted Connections

2.1.5.2 Slip-Critical Bolted Connections

2.1.5.3 Snug-Tight Bolted Connections

2.1.5.4 Re-use of High Strength Bolts

2.1.5.5 Bolt Holes

2.1.5.6 Rotational Capacity Tests

2.1.5.7 Pre-installation Verification Tests

2.1.5.8 Quality Control Inspections

2.1.5.9 Shipping and Storage of High Strength Bolt Assemblies

2.1.6 Miscellaneous Provisions

2.1.6.1 Weldments

2.1.6.2 Drain Holes

2.1.6.3 Seal Welds

2.1.6.4 Pin Holes

2.1.7 Shop Assembly

2.2 CERTIFIED TEST REPORTS

2.2.1 General

2.2.2 Nondestructive Testing

2.2.3 Inspection of Structural Steel Welding

2.2.3.1 Visual Examination

2.2.3.2 Nondestructive Examination

2.2.3.2.1 Testing Agency

2.2.3.2.2 Examination Procedure and Extent

2.2.3.2.3 Acceptability of Welds

2.2.3.2.4 Examination Procedures

2.2.3.2.4.1 Ultrasonic Testing (UT)

2.2.3.2.4.2 Magnetic Particle Inspection (MT)

2.2.3.2.4.3 Dye Penetrant Inspection (PT)

2.2.4 Welds to be Subject to Nondestructive Examination

2.2.4.1 Structural Steel Non-Fracture Critical Members

2.2.4.2 Structural Steel Non-Fracture Critical Member Fillet Welds and Partial Penetration Groove Welds

2.2.4.3 Structural Steel Fracture Critical Member Welds

2.2.5 Test Coupons

2.2.6 Supplemental Examination

2.2.7 Structural Steel Welding Repairs

2.2.8 Control Dimensions

PART 3 EXECUTION

3.1 INSTALLATION

3.1.1 Cleaning

3.1.2 Alignment and Setting

3.2 PROTECTION OF FINISHED WORK

3.3 PAINTING

-- End of Section Table of Contents --

SECTION 05 59 20 Page 2

SECTION 05 59 20

FABRICATION AND ASSEMBLY OF LIFT GATE COUNTERWEIGHT BOXES,COUNTERWEIGHT

CONNECTION BEAMS, AND DOGGING BEAM ASSEMBLIES

PART 1 GENERAL

1.1 SCOPE

The work to be done under these specifications consists of furnishing all plant, equipment, supplies, materials, labor and performing all operations required for the fabrication and the on-site assembly of the replacement counterweight boxes, fabrication and load testing of the counterweight connection beams, and fabrication of the dogging beam assemblies. See SECTION 05 50 14 for fabrication of miscellaneous steel structures.

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 INSTITUTE OF STEEL CONSTRUCTION (AISC)

AISC 303 (2016) Code of Standard Practice for Steel Buildings and Bridges

AISC 325 (2017) Steel Construction Manual

AISC 326 (2009) Detailing for Steel Construction

AISC 360 (2016) Specification for Structural Steel Buildings

AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING (ASNT)

ANSI/ASNT CP-189 (2020) ASNT Standard for Qualification and Certification of Nondestructive Testing Personnel

AMERICAN WELDING SOCIETY (AWS)

AWS D1.5M/D1.5 (2020) Bridge Welding Code

AWS QC1 (2016) Specification for AWS Certification of Welding Inspectors

ASTM INTERNATIONAL (ASTM)

ASTM A709/A709M (2021) Standard Specification for Structural Steel for Bridges

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

ASTM E709 (2021) Standard Guide for Magnetic

SECTION 05 59 20 Page 3

Particle Testing

ASTM F3125/F3125M (2019) 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

RESEARCH COUNCIL ON STRUCTURAL CONNECTIONS (RCSC)

RCSC A348 (2020) RCSC Specification for Structural Joints Using High-strength Bolts

U.S. ARMY CORPS OF ENGINEERS (USACE)

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

1.3 SYSTEM DESCRIPTION

Submit a detailed Work Plan for fabrication and assembly of the counterweight boxes, fabrication of the counterweight connection beams and dogging beam assemblies, including descriptions of shop facilities, equipment, number of personnel, and related information prior to the Prefabrication Conference, and procedures for safe conduct of the work, careful removal and disposition of materials, protection of property that is to remain undisturbed, and coordination with other work in progress.

Include in the procedures a detailed description of the methods and equipment to be used for each operation, and the sequence of operations in accordance with EM 385-1-1 for all work that occurs on federal property.

Include the recommended measuring system for ensuring dimensional tolerances in the Work Plan.

a. Material with welds will not be accepted unless the welding is specified or indicated on the drawings or otherwise approved. Do not begin welding until welding procedures, inspectors, nondestructive testing personnel, welders, welding operators, and tackers have been qualified and approved. Each Contractor performing welding must maintain records of the test results obtained in welding procedure, and welder, welding operator, and tacker performance qualifications.

b. As it is used in these specifications, "The Engineer" refers to the District or engineer of record. The AWS D1.5M/D1.5 definition of "The Engineer" as specified in AWS D1.5M/D1.5 Application Clause refers to the District or engineer of record in lieu of the state bridge engineer as specified in the Application Clause of AWS D1.5M/D1.5.

c. Schedule a Prefabrication Conference as soon as possible after Notice to Proceed and prior to any fabrication. Include the Prime Contractor, Fabricator, the Fabricator's primary QC representative, the Contracting Officer, and the Engineer of Record for the structure or structures being fabricated in the Prefabrication Conference, at a minimum. Hold the Prefabrication Conference at either the Fabrication Facilities or a similar location as deemed appropriate.

SECTION 05 59 20 Page 4

1.3.1 Weld Tracking Log Template

Submit for approval a weld tracking log template, a minimum of 30 days prior to commencement of fabrication, to identify all necessary components to be addressed in the tracking of all welds for the structures in question. A weld tracking log will be developed and maintained as described in the following paragraphs.

1.3.2 Weld Tracking Log

Submit a log capable of individually identifying and tracking every weld on the project. Member identification must follow the numbering scheme shown on the shop drawings. Include in the log the member to be welded, member type (FCM and Non-FCM), type of weld including temporary and tack welds, welding position, applicable WPS reference, AWS joint preparation designation, name or stamping designation of welder, welding operator or tacker, date and time of completion of welding and/or tacking, name and date of CWI visual inspection, NDT testing performed, including the type of inspection, date(s) of inspection, inspector name, and the acceptance criteria used, description of defects found and reason for non-compliance, corrective action taken, or whether the weld is acceptable. Weld identification on the shop drawing must match weld tracking log identification. Bind together a completed log for each structure and submit two copies to the Contracting Officer immediately upon completion of the fabrication of each structure. Furnish draft copies of NDT testing to the Contracting Officer upon request and have a copy available on the shop floor during any inspection.

1.3.3 Welding Procedure Specifications (WPS)

Submit a Welding Procedure Specification (WPS), with supporting Procedure Qualification Records and supporting test documentation on forms similar or equivalent to the sample forms in AWS D1.5M/D1.5for each weld, including prequalified welds, in accordance with paragraph Welded Connections approved before fabrication is commenced. Individually identify each Welding Procedure Specification and reference it on the shop drawings. In case of conflict between this specification and AWS D1.5M/D1.5 as applicable, this specification governs.

1.3.4 Fracture Critical Members (FCM)

FCM are shown on the Contract Drawings and include all attachments and connections to these members as defined in AWS D1.5M/D1.5. All materials to be welded must be ASTM A709/A709M, killed steel, grade as specified or shown on the drawings. Use Grade 50 steelunless otherwise shown or specified. Mill repairs of base metal are prohibited. Unless otherwise indicated or specified, meet toughness requirements for fracture critical members in tension in accordance with ASTM A709/A709M for Zone 2. All materials used for the construction of fracture critical components must meet the applicable requirements of ASTM A709/A709M for fracture critical components. Welding for fracture critical members must meet all requirements of AWS D1.5M/D1.5 AASHTO/AWS Fracture Control Plan (FCP) for Nonredundant Members Clause.

1.3.4.1 Fracture Control Plan (FCP)

Submit a Fracture Control Plan (FCP) for welding on all Fracture Critical Members (FCM) in accordance with AWS D1.5M/D1.5, AASHTO/AWS Fracture Control Plan (FCP) for Nonredundant Members Clause. Submit welding

SECTION 05 59 20 Page 5

Procedures, qualifications, and certifications showing compliance with FCP requirements.

1.3.4.2 Repair Welding

Classify repair welds as "critical repairs" or "non-critical repairs" for all repair welding. Unless specified otherwise, follow the minimum provisions for repair procedures. Repair procedures must be qualified and approved and subject to the same QA/QC inspection requirements as other welds. Follow minimum preheat requirements, as defined in AWS D1.5M/D1.5 AASHTO/AWS Fracture Control Plan (FCP) for Nonredundant Members Clause, for repair welding. Consider all weld repairs to fracture critical members critical welds in accordance with AWS D1.5M/D1.5 AASHTO/AWS Fracture Control Plan (FCP) for Nonredundant Members Clause and must be approved by the Engineer of Record.

1.3.5 Stress Relieving Plan

Submit a Stress Relieving Plan in accordance with AWS D1.5M/D1.5 Technique Clause.

1.3.6 Bolt Inspection and Tracking Log Template

Submit for approval a Bolt Inspection and Tracking Log Template, a minimum of 30 calendar days prior to the commencement of fabrication, to identify all necessary components to be addressed in the bolt inspection and testing tracking for all bolts in the structures.

1.3.7 Bolt Inspection and Tracking Log

Submit a Bolt Inspection and Tracking Log capable of individually identifying and tracking every bolt on the structure to verify that all bolts were properly tensioned. Maintain a separate log for each individual structure. Member and connection identification must follow the numbering scheme shown on the shop drawings. Include in the log the member to be bolted, name of inspector conducting the test, date of test, documents the preinstallation verification, rotational capacity testing, recorded torque for each shift/day, and results of post installation verification testing for each bolt in each connection.

1.3.8 Bolt Work Plan

Submit a Bolt Work Plan that includes, at a minimum, a description of the equipment used to calibrate, tension and measure bolt pretension, bolt group tensioning sequences, method of match-marking and tracking of pretensioned and re-tensioned bolts, and quality control measures to ensure that bolts are pretensioned and re-tensioned in accordance with the specifications.

1.3.9 Distortion and Shrinkage Control Plan

Submit a Distortion and Shrinkage Control Plan in accordance with AWS D1.5M/D1.5 Workmanship Clause.

1.3.10 Nonconformance Reports

The Fabricator has the responsibility to ensure that all work performed complies with the Quality Control Plan and generate Nonconformance Reports (NCR) for all work deemed to not meet quality control standards. If the

SECTION 05 59 20 Page 6

Government determines that fabrication work does not comply with the QCP or that fabrication does not follow approved fabrication procedures, the Government will deem the materials as non-conforming. If the Government finds nonconforming work, the Fabricator is required to immediately correct the procedure, conduct additional tests, and submit a written nonconformance report containing data required by the Government to ensure compliance with the Quality Control Plan. Perform additional testing as required by the Government at no additional cost to the Government.

Properly document all nonconformances using a Nonconformance Report form.

Submit a Nonconformance Report Form Template prior to start of fabrication. The Nonconformance Report Form Template is to be used during fabrication to record and submit all nonconformances. Submit a Nonconformance Report on the approved form documenting any deviation from the Quality Control Plan, approved shop drawings, codes, Work Plan, and/or specifications.

At a a minimum, include the following in the Nonconformance Report:

1. Company name and address

2. Report title

3. Nonconformance Report Number

4. Date

5. Company job number

6. Piece mark

7. Owner

8. Fabricator

9. Owner's project number

10. Location

11. Detailed description of the nonconformance

12. Photo, sketch, or drawing

13. Proposed repair/disposition of the nonconformance

14. Quality Control Manager's signature and date

1.3.11 Counterweight Connection Beam Load Testing

After completion of fabrication but prior to painting, the Contractor shall conduct a load test on the counterweight connection beams. The test shall consist of load testing the beams to 230,000 lbs. Load testing shall be conducted in accordance with ASME B30.20-2013. The Contractor shall develop and submit a load testing plan. The plan shall include at a minimum, test loading configuration, testing procedures, sample submittal testing report, etc. The contractor shall submit the load testing reports.

In addition to the testing required per ASME B30.20-2013, all welds shall be 100% visually inspected, magnetic particle, and ultrasonic inspected after testing.

1.4 SUBMITTALS

Government approval is required for submittals with a "G" classification.

Submittals not having a "G" classification are for information only. When used, a code following the "G" classification identifies the office that will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Shop Drawings; G, EC-DS Welding Procedure Specifications (WPS); G, EC-DS

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Fracture Control Plan (FCP); G, EC-DS Weld Tracking Log Template; G, EC-DS Weld Tracking Log; G, EC-DS Qualification of Welders and Welding Operators; G, EC-DS Inspector Qualifications; G, EC-DS Qualification of Structural Steel Fabricator; G, EC-DS NDT Inspector Certification; G, EC-DS Welding Repairs - Non-Fracture Critical Members; G, EC-DS Welding Repairs - Fracture Critical Members; G, EC-DS Performance Qualification Records; G, EC-DS Ultrasonic Written Procedure; G, EC-DS Fabrication Log Template; G, EC-DS Nonconformance Report Form Template; G, EC-DS Stress Relieving Plan; G, EC-DS Distortion And Shrinkage Control Plan; G, EC-DS Bolt Work Plan; G, EC-DS Bolt Inspection And Tracking Log Template; G, EC-DS Bolt Inspection And Tracking Log; G, EC-DS Load Testing Plan; G, EC-DS

SD-02 Shop Drawings

Delivery/Shipping Plan; G, EC-DS Assembly Drawings; G, EC-DS Contractor Lifting Lugs; G, EC-DS Fabrication And Assembly Sequencing Plan; G, EC-DS

SD-03 Product Data

Materials Disposition Record

SD-06 Test Reports

Fabrication Log - Downstream Counterweight Box #1; G, EC-DS Fabrication Log - Downstream Counterweight Box #2; G, EC-DS Fabrication Log - Upstream Counterweight Box #1; G, EC-DS Fabrication Log - Upstream Counterweight Box #2; G, EC-DS Fabrication Log - Counterweight Connection Beam #1; G, EC-DS Fabrication Log - Counterweight Connection Beam #2; G, EC-DS Fabrication Log - Counterweight Connection Beam #3; G, EC-DS Fabrication Log - Counterweight Connection Beam #4; G, EC-DS Fabrication Log - Dogging Beam Assembly #1; G, EC-DS Fabrication Log - Dogging Beam Assembly #2; G, EC-DS Fabrication Log - Dogging Beam Assembly #3; G, EC-DS Fabrication Log - Dogging Beam Assembly #4; G, EC-DS Certified Test Reports; G, EC-DS Witness Points Repair of Mislocated or Misdrilled Holes; G, EC-DS Schedule of Random Testing; G, EC-DS Manufacturer Certified Test Reports; G, EC-DS Distributor Certified Test Reports; G, EC-DS Load Testing Reports

SD-07 Certificates

Work Plan; G, EC-DS

SD-09 Manufacturer's Field Reports

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Control Dimensions; G, EC-DS

1.5 QUALITY ASSURANCE

Establish Witness Points for the Initial QA Inspection, Intermediate QA Inspections, and Final Inspection as follows and submit a record of all witness points. Start the Initial QA Inspection after the Government has determined that there is substantial completion of components that comprise a reasonable sampling of each significant FCM and non-FCM details. Determine the extent of completion and details and the date of the Initial QA Inspection by the Government at the Prefabrication Conference after discussion with the Contractor. At that time, produce a detailed schedule showing the progression of work and completion of components. This schedule will be updated weekly and provided by e-mail to the Contracting Officer. Give the Contracting Officer two weeks notice prior to the predetermined date for the Initial QA Inspection, including adjustments for changes in schedule. Intermediate QA Inspections will be conducted on an as needed basis and at the discretion of the Government.

All QA inspections will follow AWS D1.5M/D1.5. Provide unpainted components for each QA NDT and Visual Inspection. At these stages of construction, give the Contracting Officer three working days to inspect the structure. Do not begin the QA Inspection period until a minimum period of 72 hours after any welding. After the Contracting Officer and the Engineer of Record has inspected the structure, make any changes required to the structure as directed by the Contracting Officer before proceeding with any additional welding. Proceed with the construction until the next witness point is reached, unless it is waived in writing by the Contracting Officer. Each structure fabricated is subject to a Final Fabrication Inspection prior to painting. Conduct a Final Fabrication Inspection after the first structure is completed. Schedule and coordinate with the Contracting Officer and the Engineer of Record final fabrication inspections of additional structures. Give the Contracting Officer a minimum notice of two weeks prior to the Final Fabrication Inspection.

1.5.1 Qualification of Welders and Welding Operators

Submit welder, welding operator and tacker qualification certification for each welder, welding operator or tack welder for approval before fabrication is commenced in accordance with paragraph Welded Connections.

An AWS Certified Welding Inspector (CWI) meeting the specified qualifications must approve all welder qualifications. Limit welders, welding operators, and tack welders to welding procedures for which they are certified. Prepare, weld, and test welds in accordance with the requirements of AWS D1.5M/D1.5. Before assigning any welder, welding operator, or tacker to work under this contract, submit the names and certification that each individual is qualified as specified. State the type of welding and positions for which the welder, welding operator, or tacker is qualified, the code and procedure under which the individual is qualified, the date qualified, and the name of the firm and person certifying the qualification tests on the certification. Keep the certification current for the duration of the contract. Submit welder and welding operator qualification test records on forms similar or equivalent to the sample forms in AWS D1.5M/D1.5. All welders must be qualified in accordance with the Qualification Clause of AWS D1.5M/D1.5. Welders performing fracture critical welds must meet the additional requirements of the AASHTO/AWS Fracture Control Plan (FCP) for Nonredundant Members Clause of AWS D1.5M/D1.5. Verify all qualifications are current prior to commencing any work. Submit a log for each welder showing that he/she is

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1.5.2 Inspector Qualifications

All inspectors, performing structural steel visual inspection in accordance with these specifications, must be qualified and certified in conformance with AWS QC1. Provide an AWS Certified Welding Inspector (CWI) as the primary point of contact for quality control of welding.

Designate one individual as having primary responsibility for all quality control in accordance with AWS D1.5M/D1.5 Inspection Clause when several CWI and NDT technicians are working. Do not use non-certified inspectors and certified associate weld inspectors (CAWI) for inspection under these specifications. All personnel who perform NDT must be qualified in accordance with: ANSI/ASNT CP-189 NDT Level II or III. Provide supervision by personnel possessing a Level III ASNT NDT certification for all personnel performing NDT, in accordance with AWS D1.5M/D1.5 Inspection Clause and the AASHTO/AWS Fracture Control Plan (FCP) for Nonredundant Members Clause. Submit copies of certificates showing evidence of qualifications or certifications for welding inspectors and NDT personnel.

1.5.3 Qualification of Structural Steel Fabricator

The fabricating plant and fabricator must be certified under the AISC (American Institute of Steel Construction) Quality Certification Program, and must be designated an AISC Certified Plant, Category CBR: Major Bridge Fabrication, IBR: Certified Bridge Fabricator - Intermediate, ABR:

Certified Bridge Fabricator - Advanced or HYD: Certified Metal Hydraulic Fabricator with a fracture critical endorsement (FCE) at time of bid and for the duration of the contract. The fabricator or fabrication plant must possess five 5 years documented experience on projects of similar scope.

Similar scope means projects of similar size and similar amounts of welding and detail types. Submit copies of the AISC certificate indicating that the fabrication plant meets the specified structural steelwork category and documented experience.

1.5.4 Testing by the Government

Material component parts may be subjected to any form of nondestructive testing, as directed by the Contracting Officer. This may include any test that will thoroughly investigate the part in question. The cost of such investigation will be borne by the Government. Replace and retest all defects that are cause for rejection and rejected materials or parts at the Contractor's expense. The government reserves the right to perform quality assurance at any point during fabrication.

1.5.5 Shop Drawings

Prepare all shop drawings in accordance with AISC 303, AISC 326, AISC 360, and AISC 325. Return elements of fabricated items inadvertently omitted on contract drawings to the Engineer of Record for detailing unless they are to be detailed by the fabricator and so indicated on the shop drawings. Cloud any and all details developed by the fabricator on the shop drawings for separate approval by the Engineer of Record. Any items designed by the Contractor must be prepared and sealed by a Registered Professional Engineer. All splices must be approved bythe Engineer of Record. Make all splices with complete joint penetration groove welds.Identify all field welds on the shop drawings. Provide a unique identifier to permit tracking on the weld tracking log for each weld, both shop and field welds. Prior to performing any fabrication of the

SECTION 05 59 20 Page 10 counterweight boxes, submit complete, detailed shop drawings for approval. Show complete details of materials, tolerances, connections, and proposed welding sequences on the shop drawings. Include catalog cuts, templates, fabrication and assembly details, and type, grade, and class of materials, as appropriate in the shop drawings. Identify all FCM, including attachments that meet the FCM definition, on the shop drawings as well as all temporary and tack welds. Identify each member following the numbering scheme shown on the drawings. Provide a table containing a list of all members and a reference to each material certificate and test report that applies to that member. Identify weld procedures and NDE required for each weld on shop drawings. Cloud any and all splices in the shop drawings for engineer approval.

1.5.6 Assembly…