AMENDMENT OF SOLICITATION/MODIFICATION OF CONTRACT Government... · W912EE17B0010 0002 Page 2 of 2 SECTION SF 30 BLOCK 14 CONTINUATION PAGE SUMMARY OF CHANGES . SECTION 00010 - SOLICITATION

W807PM71646998

AMENDMENT OF SOLICITATION/MODIFICATION OF CONTRACT

Except as provided herein, all terms and conditions of the document referenced in Item 9A or 10A, as heretofore changed, remains unchanged and in full force and effect.

15A. NAME AND TITLE OF SIGNER (Type or print)

30-105-04EXCEPTION TO SF 30

APPROVED BY OIRM 11-84STANDARD FORM 30 (Rev. 10-83)

Prescribed by GSA

FAR (48 CFR) 53.243

Reference Solicitation No. W912EE-17-B-0010, for FC/MR&T, Yazoo River Basin, Yazoo Backw ater, Issaquena County, Mississippi, Steele

Bayou Drainage Structure, Vertical Lift Gates Construction is amended as follow s:

SEE CONTINUATION PAGE FOR SUMMARY OF CHANGES.

1. CONTRACT ID CODE PAGE OF PAGES

J 1 2

16A. NAME AND TITLE OF CONTRACTING OFFICER (Type or print)

16C. DATE SIGNED

BY 04-Aug-2017

16B. UNITED STATES OF AMERICA15C. DATE SIGNED15B. CONTRACTOR/OFFEROR

(Signature of Contracting Officer)(Signature of person authorized to sign)

8. NAME AND ADDRESS OF CONTRACTOR (No., Street, County, State and Zip Code) X W912EE17B0010

X 9B. DATED (SEE ITEM 11)18-Jul-2017

10B. DATED (SEE ITEM 13)

9A. AMENDMENT OF SOLICITATION NO.

11. THIS ITEM ONLY APPLIES TO AMENDMENTS OF SOLICITATIONS

X The above numbered solicitation is amended as set forth in Item 14. The hour and date specified for receipt of Offer is extended, X is not extended.

Offer must acknowledge receipt of this amendment prior to the hour and date specified in the solicitation or as amended by one of the following methods:

(a) By completing Items 8 and 15, and returning copies of the amendment; (b) By acknowledging receipt of this amendment on each copy of the offer submitted;

or (c) By separate letter or telegram which includes a reference to the solicitation and amendment numbers. FAILURE OF YOUR ACKNOWLEDGMENT TO BE

RECEIVED AT THE PLACE DESIGNATED FOR THE RECEIPT OF OFFERS PRIOR TO THE HOUR AND DATE SPECIFIED MAY RESULT IN

REJECTION OF YOUR OFFER. If by virtue of this amendment you desire to change an offer already submitted, such change may be made by telegram or letter,

provided each telegram or letter makes reference to the solicitation and this amendment, and is received prior to the opening hour and date specified.

12. ACCOUNTING AND APPROPRIATION DATA (If required)

13. THIS ITEM APPLIES ONLY TO MODIFICATIONS OF CONTRACTS/ORDERS.

IT MODIFIES THE CONTRACT/ORDER NO. AS DESCRIBED IN ITEM 14.

A. THIS CHANGE ORDER IS ISSUED PURSUANT TO: (Specify authority) THE CHANGES SET FORTH IN ITEM 14 ARE MADE IN THE CONTRACT ORDER NO. IN ITEM 10A.

B. THE ABOVE NUMBERED CONTRACT/ORDER IS MODIFIED TO REFLECT THE ADMINISTRATIVE CHANGES (such as changes in paying office, appropriation date, etc.) SET FORTH IN ITEM 14, PURSUANT TO THE AUTHORITY OF FAR 43.103(B).

C. THIS SUPPLEMENTAL AGREEMENT IS ENTERED INTO PURSUANT TO AUTHORITY OF:

D. OTHER (Specify type of modification and authority)

E. IMPORTANT: Contractor is not, is required to sign this document and return copies to the issuing office.

14. DESCRIPTION OF AMENDMENT/MODIFICATION (Organized by UCF section headings, including solicitation/contract subject matter where feasible.)

10A. MOD. OF CONTRACT/ORDER NO.

0002

2. AMENDMENT/MODIFICATION NO. 5. PROJECT NO.(If applicable)

6. ISSUED BY

3. EFFECTIVE DATE

04-Aug-2017

CODE

VICKSBURG CONTRACTING OFFICE

4155 CLAY ST

VICKSBURG MS 39183-3435

W912EE 7. ADMINISTERED BY (If other than item 6)

4. REQUISITION/PURCHASE REQ. NO.

CODE

See Item 6

FACILITY CODECODE

EMAIL:TEL:

W912EE17B0010

0002

Page 2 of 2

SECTION SF 30 BLOCK 14 CONTINUATION PAGE

SUMMARY OF CHANGES

SECTION 00010 - SOLICITATION CONTRACT FORM

The following have been added by full text:

VERTICLAL LIFT GATES

SPECIFICATIONS: Section 05 59 13 and Submittal Register are revised and replaced.

Specifications revised by this amendment have the notation "Revised by Amendment 0002" at

the bottom of the page. Text added by this amendment is shown as underlined. Text deleted by

this amendment is shown as overstruck.

(End of Summary of Changes)

W912EE-17-B-0010

SECTION TABLE OF CONTENTS

DIVISION 05 - METALS

SECTION 05 59 13

FABRICATION OF HYDRAULIC STEEL STRUCTURES

PART 1 GENERAL

1.1 REFERENCES 1.2 SYSTEM DESCRIPTION 1.2.1 Weld Tracking Log Template 1.2.2 Weld Tracking Log 1.2.3 Quality Control and Material Tracking 1.2.4 Welding Procedure Specifications (WPS) 1.2.5 Fracture Critical Members (FCM) 1.2.6 NDT Written Practice 1.3 SUBMITTALS 1.4 QUALITY ASSURANCE 1.4.1 Qualification of Welders and Welding Operators 1.4.2 Inspector Qualifications 1.4.3 Qualification of Structural Steel Fabricator 1.4.4 Quality Assurance Testing by the Government 1.4.5 Shop Drawings 1.4.6 Field Verification of Dimensions 1.5 DELIVERY, STORAGE, AND HANDLING

PART 2 PRODUCTS

2.1 FABRICATION 2.1.1 Structural Fabrication 2.1.2 Assembly and Fabrication Sequencing Plan 2.1.3 Materials Disposition Record 2.1.4 Welded Connections 2.1.5 Bolted Connections 2.1.6 Miscellaneous Provisions 2.1.7 Shop Assembly

2.1.7.1 Vertical Lift Gate Section2.1.7.2 Gate Section Wheel Assemblies2.1.7.3 Seal Assemblies

2.1.8 Seals 2.2 Testing and Inspection 2.2.1 General 2.2.2 Nondestructive Testing 2.2.3 Inspection of Structural Steel Welding 2.2.4 Welds to be Subject to Nondestructive Examination 2.2.5 Test Coupons 2.2.6 Supplemental Examination 2.2.7 Structural Steel Welding Repairs 2.2.8 Control Dimensions 2.2.9 Verification of Bolted Connections

PART 3 EXECUTION

3.1 DELIVERY OF WHEEL GATE SECTIONS

SECTION 05 59 13 Page 1Revised By Amendment 0002

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3.2 REMOVAL OF EXISTING GATES 3.3 INSTALLATION 3.3.1 Gate Section 3.3.2 Cleaning 3.3.3 Alignment and Setting 3.4 TEST, INSPECTIONS, AND VERIFICATIONS 3.4.1 Inspection 3.4.2 Operation Tests 3.5 PROTECTION OF FINISHED WORK 3.6 PAINTING

-- End of Section Table of Contents --


W912EE-17-B-0010

SECTION 05 59 13

FABRICATION OF HYDRAULIC STEEL STRUCTURES

PART 1 GENERAL

1.1 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 (2010) Code of Standard Practice for Steel Buildings and Bridges

AISC 325 (2011) Steel Construction Manual

AISC 326 (2009) Detailing for Steel Construction

AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING (ASNT)

ANSI/ASNT CP-189 (2011) ASNT Standard for Qualification and Certification of Nondestructive Testing Personnel (ANSI/ASNT CP-105-2006)

ASTM INTERNATIONAL (ASTM)

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

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

ASTM A709/A709M (2015) Standard Specification for Structural Steel for Bridges

ASTM E165 (2009) Standard Test Method for Liquid Penetrant Examination

ASTM E709 (2016) Standard Guide for Magnetic Particle Examination

ASTM F436 (2011) Hardened Steel Washers

AMERICAN WELDING SOCIETY (AWS)

AWS D1.5M/D1.5 (2015) Bridge Welding Code

AWS QC1 (2007) Standard for AWS Certification of Welding Inspectors

AWS A2.4 (2012) Standard Symbols for Welding,


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Brazing and Nondestructive Examination

AWS A3.0M/A3.0 (2010) Standard Welding Terms and Definitions

RESEARCH COUNCIL ON STRUCTURAL CONNECTIONS (RCSC)

RCSC S348 (2009) RCSC Specification for Structural Joints Using ASTM A325 or A490 Bolts

U.S. ARMY CORPS OF ENGINEERS (USACE)

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

1.2 SYSTEM DESCRIPTION

Provide a detailed Work Plan for fabrication, including descriptions of shop facilities, equipment, number of personnel, and related information prior to the Pre-fabrication Conference. Update the Work Plan as conditions warrant. Provide procedures which ensure the 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 onsite work. Fabricate the following structures according to this section of the specifications:

Vertical Lift Gates

a. Material with welds will not be accepted unless the welding isspecified or indicated on the drawings or otherwise approved. Do not commence welding until welding procedures, inspectors, nondestructive testing personnel, welders, welding operators, and tackers have been qualified and approved. 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 theDistrict engineer of record.

c. Schedule a Prefabrication Conference as soon as practicable afterNotice to Proceed and prior to any fabrication. Include, at a minimum, the following personnel at the Prefabrication Conference, the Prime Contractor, Fabricator, the Fabricator's primary QC representative, the COR, the GQAR, and the Engineer of record for the structure or structures being fabricated. The Prefabrication Conference should occur either at the Fabrication Facilities or a similar location as deemed appropriate. The format of the prefabrication conference should include a review of these specifications, discussion of the fabricator's QCP, identification of roles and responsibilities including roles and responsibilities of fabrication subcontractors. Submit key welding submittals, including shop drawings, welding procedure specifications, the fracture control plan, and certified testing personnel prior to holding the Prefabrication Conference. The contractor should prepare for this meeting by reviewing plans and specifications and code concerns prior to this meeting and be prepared to discuss any issues regarding the fabrication including WPS qualification requirements and required witnessing of testing.


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Identify and discuss complicated connections that require prototyping for both welding and inspection. In addition, hold points/witness points will be established during the prefabrication conference.

1.2.1 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. Develop and maintain a weld tracking log as described in the following paragraphs.

1.2.2 Weld Tracking Log

Provide a log capable of individually identifying and tracking every weld on the project. Follow the numbering scheme shown on the shop drawings for member identification. Include the member to be welded, member type (FCM and Non-FCM), type of weld including temporary and tack welds which are not fully consumed, 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 (weld time required to designate required hold time prior to NDT), 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. Match weld identification between the shop drawings and weld tracking log. Continually maintain the weld tracking log. Ensure the weld tracking log, including draft copies of NDT testing, is available on the shop floor during any inspection. Provide a bound, completed log for each structure included in the Fabrication Record upon completion of the fabrication of each structure.

1.2.3 Quality Control and Material Tracking

Provide structural material fabricated and assembled meeting the requirements of AASHTO/NSBA Steel Bridge Collaboration "Steel Bridge Fabrication Guide Specification" and AWS welding codes, except as modified in this document.

Before the start of work, the fabricator is to supply a Quality Control Plan (QCP) to the Engineer for approval. Ensure the QCP describes the methods, equipment, and procedures utilized to ensure quality control. The Engineer will use the AASHTO/NSBA, "Steel Bridge Fabrication QC/QA Guide Specification," as the basis for approving the QCP.

Submit a Material Tracking Log Template. Identify how all material is tracked in the fabrication shop from receiving through complete assembly in the material tracking log template. Use low stress die stamps for the identification coding of material. Stamp each component with low-stress stamping to include the project number, part number, and additional required information to permit tracking of material. Use material travelers to conform with the material tracking log and quality control plan.

The contractor/fabricator has the responsibility to ensure that all work performed complies with the QCP and generate Non-Conformance Reports (NCR's)for all work deemed to not meet quality control standards. If the Government determines that fabrication work does not comply with the QCP or


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that fabrication does not follow approved fabrication procedures, the Government will deem the materials as non-conforming. If the Government finds non-conforming work, the prime contractor is required to direct the fabricator/subcontractor to immediately correct the procedure, conduct additional tests, and submit a written non-conformance report containing data required by the Government to ensure compliance with the QCP. Perform additional testing as required by the Government at no additional cost to the Government.

During each stage of fabrication of major structural components, ensure the fabricator provides and maintains material identification to establish the heat of the material from which the component is fabricated. Provide the Engineer with a list showing heat numbers referenced to the material incorporated into each component. The Engineer will reject material that loses its material identification unless the identity can be re-established to the satisfaction of the Engineer. Submit Material Test Reports or Certified Test Reports for all material used in fabrication prior to incorporation into the structure.

Provide fracture critical members with identification numbers placed on each individual piece of material that is referenced to the corresponding heat number.

Properly document all non-conformances using a Non-Conformance Report form. Submit a Non Conformance Report Form Template prior to fabrication. The Non-Conformance Report Template is to be used during fabrication to record and submit all Non-conformances. Submit a Non-Conformance Report on the approved form to the Engineer documenting any deviation from the QCP, approved shop drawings, code, Work Plan and/or specifications. Include the following in the Non-Conformance Report form:

(1) Company name and address, (2) Report title, (3) Non-conformance Report number, (4) Date, (5) Company job number, (6) Piece mark, (7) Owner of structure, (8) Contractor, (9) Owner's project number, (10) Location, (11) Detailed description of the non-conformance, (12) Photo, sketch, or drawing, (13) Proposed repair/disposition of the non-conformance, and (14) Quality Control Manager's signature and date.

1.2.4 Welding Procedure Specifications (WPS)

Submit a Welding Procedure Specification (WPS) for each weld, including prequalified welds, in accordance with paragraph Welded Connections approved before fabrication is commenced. Individually identify and reference Welding Procedure Specifications on the shop drawings. In case of conflict between this specification and AWS D1.5M/D1.5as applicable, this specification governs. The following items are not be considered ancillary items as defined in AWS D1.5 Clause 1.3.7 and are to be subjected to the same level of inspection required for primary welds under AWS D1.5:

Sacrificial anodes attached to the gate


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1.2.5 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. Utilize ASTM A709/A709M, grade as specified or shown on the drawings, using killed fine-grain mill practice, unless otherwise shown or specified for all materials to be welded or bolted to form the completed structure. Mill repairs of base metal are prohibited. Provide material with toughness in accordance with the requirements of ASTM A709/A709M, Table 10, for Zone 1, unless otherwise indicated or specified. Provide materials meeting the requirements of section 10 of ASTM A709/A709M including mill certification showing that the material meets the necessary toughness requirements for all fracture critical members. Meet all requirements of AWS D1.5M/D1.5 Clause 12, for welding fracture critical members including:

a. 12.5 Welding Processes. Qualify all welding procedures inaccordance with Clause 12.5 of AWS D1.5M/D1.5.

b. 12.6 Consumable Requirements. Heat or Lot Test all weldingconsumables by the manufacturer to determine conformance with the requirements of the Fracture Control Plan (FCP) in accordance with AWS D1.5M/D1.5 Clause 12.6. Ensure toughness test results meet the values specified in Table 12.1 of AWS D1.5M/D1.5.

c. 12.7 Welding Procedure Specifications (WPS). Ensure allprocedures, including repair welds, are prequalified or qualified by test as required and documented in the WPS and Procedure guidelines of AWS D1.5M/D1.5.

d. 12.8 Certification and Qualification. Ensure all welders andwelding operators meet the applicable requirements of AWS D1.5M/D1.5.

e. Ensure material handling and preparation, including thermalcutting, preparation of base metal, and straightening, curving, cambering meets t the applicable requirements of AWS D1.5M/D1.5.

f. 12.13 Tack Welds and Temporary Welds. Locate all welds within thejoint and ensure all welds meet the requirements of AWS D1.5M/D1.5, Table 12.2. Temporary welds on FCM are not permitted. Submit any and all temporary welding required for the fabrication or assembly of welded components (i.e. lifting aides, assembly jigs etc.) for Engineer approval prior to use.

g. Ensure all welding processes, including preheat, interpasstemperatures, and postweld thermal treatment meet the applicable requirements of AWS D1.5M/D1.5.

h. 12.16 Weld Inspection. Ensure that the Quality Control inspectionprogram is documented within the Fracture Control Plan. Qualify all inspectors and NDT technicians as required. Test all butt joints with UT and RT. Inspection procedures and documentation are as specified in the applicable sections of AWS D1.5M/D1.5. Cooling times must be strictly adhered to.

i. 12.17 Repair Welding. Repair welds must be classified as "criticalrepairs" or "non-critical repairs" for all repair welding. Ensure repair procedures follow the minimum provisions unless specified otherwise. Repair procedures must be qualified and approved and subject to the same QA/QC inspection requirements as other welds.


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Utilize minimum preheat for repair welding as defined in AWS D1.5M/D1.5 Clause 12.17.6. All weld repairs to fracture critical members are considered critical welds in accordance with AWS D1.5 Clause 12.17.3 and require approval from the engineer of record.

1.2.6 NDT Written Practice

Establish the minimum requirements for education, training, experience, examination and certification of personnel responsible for conducting nondestructive tests while in the employment of the contracted company within the Written Practice. It applies to all persons conducting nondestructive tests that are required to be certified to the provisions of ANSI/ASNT CP-189. Additionally the methods of nondestructive testing are to be outlined and described in the written practice and explanation as to how they are used in accordance with the applicable codes, standards and specifications. In addition to the written practice, submit NDT Equipment Calibration Records for all NDT equipment used by both the fabricator and any subcontractors performing NDT.

1.3 SUBMITTALS

Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submit the following in accordance with SECTION 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Quality Control Plan (QCP); G DSMaterial Tracking Log Template; G DSWelding Procedure Specifications (WPS); G DSFracture Control Plan (FCP); G DSWelding Repair Plan - Non-Fracture Critical Members; G DSWelding Repair Plan - Fracture Critical Members; G DSHeat Straightening Procedure; G DSWeld Tracking Log Template; G DSNon-Conformance Report Form Template; G DSNDT Written Practice; G DSNDT Equipment Calibration Records; G DSWork Plan; G DSQualification of Welders and Welding Operators; G DSInspector Qualifications; G DSQualification of Structural Steel Fabricator; G DSDetermination of Center of Gravity; G DSLift Plan; G DSGate Removal Plan; G DSGate Installation Plan; G DSField Measurements

SD-02 Shop Drawings

Shop Drawings; G DSAssembly and Fabrication Sequencing Plan; G DSFabrication Quality Control ReportsDelivery/Shipping Plan; G DS

SD-03 Product Data


W912EE-17-B-0010

Materials Disposition RecordAntigalling Compound; G DSFinal Weights

SD-06 Test Reports

Certified Test Reports; G DSWeld Tracking Log; G DSWitness PointsNon-Conformance Report

SD-07 Certificates

SD-09 Manufacturer's Field Reports

Control Dimensions; G DSFabrication Record; G DS

1.4 QUALITY ASSURANCE

Establish Witness Points for the Initial QA Inspection, Intermediate QA Inspections, and Final Inspection as follows. 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 at the Prefabrication Conference by the Government after discussion with the Contractor. At that time, produce a detailed schedule showing the progression of work and completion of components. This schedule is to 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. 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. After the Contracting Officer and the Engineer of Record have 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 the Final Fabrication Inspection of additional structures with the Contracting Officer and the Engineer of Record. Give the Contracting Officer a minimum notice of two weeks prior to the Final Fabrication Inspection.

1.4.1 Qualification of Welders and Welding Operators

Submit welder, welding operator and tacker qualification certification for each welder, welding operator or tack welder to the Government Representative/Contracting Officer. Engineer and approved before fabrication is commenced in accordance with paragraph Welded Connections. Submit welder and welding operator qualification test records on forms similar or equivalent to the sample forms in AWS D1.5M/D1.5. Ensure welder qualifications are approved by a CWI meeting the specified minimum qualifications of these specifications. Welders, welding operators, and tack welders are limited to welding procedures for which they are


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certified. Qualify welders performing fracture critical welds under this specification according to Clause 12 of AWS D1.5. Qualify welders performing non fracture critical welds according to Clause 5 of AWS D1.5. Ensure all qualifications are current prior to commencing any work. Submit a log for each welder showing that he/she is current in the process and procedures being proposed for this work. Test welds are to be prepared, welded, and tested 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 of the welders, welding operators, and tackers to be employed, 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. Keep the certification current for the duration of the contract.

1.4.2 Inspector Qualifications

Qualify all inspectors performing structural steel inspection in accordance with these specifications, according to the requirements of AWS QC1. Provide an AWS Certified Welding Inspector (CWI) as the primary point of contact for quality control of welding. When several CWI and NDT technicians are working, designate one primary individual as having primary responsibility for all quality control in accordance with AWS D1.5 Clause 6. The CWI who serves as the primary point of contact must provide evidence of having initially tested for certification in accordance with AWS D1.5M/D1.5 or possesses an AWS D1.5M/D1.5 endorsement. Alternately the CWI may be an SCWI to serve as this primary point of contact. Do not utilize non-certified inspectors or certified associate weld inspectors (CAWI) for inspection under these specifications. Qualify all personnel who perform NDT in accordance with: ANSI/ASNT CP-189 NDT Level II or III. Inspectors who are Level III ASNT NDT certified in accordance with AWS D1.5 Clause 6 and Clause 12 are required to supervise all personnel performing NDT. An ASNT Level III may conduct tests if that person provides documentation of having passed a Level II practical examination within the last three (3) years.

1.4.3 Qualification of Structural Steel Fabricator

The fabricating plant and fabricator shall be certified under the AISC (American Institute of Steel Construction) Quality Certification Program with one of the following certifications:

CBR: Major Bridge FabricationIBR: Certified Bridge Fabricator - IntermediateABR: Certified Bridge Fabricator - AdvancedHYD: Certified Hydraulic Steel Structures Fabricator

The fabricating plant and fabricator shall have a Fracture Critical endorsement (F) and possess five 5 years documented experience on projects of similar scope. Similar scope consists of having fabricated structures of similar size including total weight, member thicknesses and dimensions, geometry, tolerances, and handling requirements. Submit copies of the AISC certificate indicating that the fabrication plant meets the specified structural steelwork category and documented experience. The rubber seals are excluded from the AISC fabricator certification requirements.


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1.4.4 Quality Assurance 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 radiography,ultrasonic, magnetic particle, or any other test that is capable of thoroughly investigating the part in question. The cost of such investigation will be borne by the Government. Any defects will be cause for rejection and rejected materials or parts will be replaced and retested at the Contractor's expense.

1.4.5 Shop Drawings

Prior to performing any fabrication of the HSS structures listed in paragraph System Description above, submit detailed shop drawings to the Contracting Officer and Engineer of Record for approval. Show complete details of materials, tolerances, connections, and proposed welding sequences on Shop Drawings. Include catalog cuts, templates, fabrication and assembly details, and type, grade, and class of materials, as appropriate. Utilize AWS A2.4, AWS A3.0M/A3.0, AISC 303, AISC 325, and AISC 326 for shop drawing preparation.

Identify all Fracture Critical Members, including attachments that meet the FCM definition, on the shop drawings. Identify all temporary and tack welds which are not be fully consumed during final welding on the shop drawings. 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 NDT required for each weld on the shop drawings. Identify any and all splices on the shop drawings for engineer approval.

Return to the Engineer of Record any elements of fabricated items inadvertently omitted on contract drawings for detailing and design by the Engineer.. Cloud any and all details developed by the fabricator on the shop drawings for separate approval by the Engineer of Record. Prepare and seal any items designed by the Contractor utilizing the services of a Registered Professional Engineer. Do not include splices in the structure without approval from the Engineer of Record. Identify all field welds required the shop drawings. Provide a unique identifier to permit tracking on the weld tracking log for all shop and field welds.

1.4.6 Field Verification of Dimensions

To ensure proper installation of each gate, the Contractor shall take field measurements of the existing lift gates and gate slots to verify overall dimensions and tolerances shown in the drawings. All field measurements shall be submitted to the Government.

1.5 DELIVERY, STORAGE, AND HANDLING

Notify the Contracting Officer at least 28 days in advance of delivery of the structures. Store material above ground on platforms, skids, or other supports. Protect material from dirt, oil, and other foreign matter. Drain material so that water is never in constant contact with the surface. Employ handling methods that do not result in damage to components during fabrication, assembly, loading, shipment, and unloading of components. Replace damaged material with new material or repair using a procedure approved by the Engineer. Protect completed assemblies/structures from the environment. Shipping of the structures is at the Contractor's


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expense. Deliver all structures to the Steele Bayou Drainage Structure. Coordinate delivery through the Vicksburg District Contracting Officer. Arrange structures on the delivery vehicles such that no damage occurs during shipping. Direct all slings and lifting lugs up. Submit a Delivery/Shipping Plan showing orientation and locations of structures on the delivery vehicles prior to shipment for Government approval.

PART 2 PRODUCTS

2.1 FABRICATION

2.1.1 Structural Fabrication

Ensure material is straight before being laid off or worked. If straightening is necessary, utilize methods that do not impair the metal. Material with sharp kinks or bends is cause for rejection. Material with welds will not be accepted except where welding is definitely specified, indicated or otherwise approved. Make bends utilizing approved dies, press brakes or bending rolls. Cold bending of fracture critical members is prohibited. Where heating is required, avoid overheating the metal and allow the material to cool in a manner that does not impair the original properties of the metal. Proposed flame cutting of material, other than structural steel, is subject to approval. Indicate flame cutting on detail drawings. Shear and finish all portions accurately. Ensure all corners are square and true unless otherwise shown. Re-entrant cuts are to be filleted round to a minimum radius of 1 inch in accordance with AWS D1.5 Clause 3.2.4 unless otherwise indicated or approved. Ensure members are free of twists, bends and deformation. Straighten material without shearing, fracturing, stressing, or damaging the bolts, welds, or base metal. Use heat straightening methods approved by the Engineer. Replace material damaged during straightening operations with new material at no additional cost to the Government. Do not heat the metal unless allowed by the engineer, if allowed and before performing any straightening operations, submit a Heat Straightening Procedure to the engineer for review and approval. Utilize the FHWA publication "GUIDE FOR HEAT-STRAIGHTENING OF DAMAGED STEEL BRIDGE MEMBERS" for generating the Heat Straightening Procedure. Do not heat metal to temperatures greater than 1200F. The use of cutting heads for heating and straightening is not permitted. After heating and straightening, allow the metal to slowly cool to ambient before inspecting for evidence of fracture or other damage. If the Engineer determines it is not possible to straighten a member as part of an assembly, remove the bent material from the assembly, straighten, and re-assemble or replace the component as required by the Engineer. Cut steel and fabricate steel plates and splice plates for major structural components so the primary direction of rolling is parallel to the direction of the main tensile or compressive stresses. For CJP butt joint splices which are ground flush, establish the center line of the weld on the components of the piece before welding by placing low-stress stamp punch marks 1 ft back from the center line of the weld and 1 in from the edge of the plate on either side of the weld on both ends.

a. Dimensional Tolerances for Structural Work.

(1) Measure dimensions by an approved measuring system. Submitthe measuring system for approval with the Work Plan. Ensure theoverall dimensions of an assembled structural unit are within thetolerances indicated on the drawings or as specified for the itemof work. Where tolerances are not specified in other sections ofthese specifications or shown, a variation of 1/32 inch is


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permissible in the overall length of component members with both ends milled and component members without milled ends may not deviate from the dimensions shown by not more than 1/16 inchfor members 30 feet or less in length and by not more than1/8 inch for members over 30 feet in length.

(2) Structure dimensions indicated on the drawings are based on a structure temperature of 70 degrees F. The Contractor is responsible for any and all dimensional adjustments to compensate for actual temperature variations during construction. Measure tolerances of the final assembly with the structure in the orientation in which the structure is used.

b. Structural Steel Fabrication. Structural steel may be cut bymechanically guided or hand-guided torches, provided an accurate profile with a surface that is smooth and free from cracks and notches is obtained. Prepare surfaces and edges in accordance with AWS D1.5M/D1.5, Clause 3.2. Chip, grind, or machine all Hand-guided cuts to sound metal.

2.1.2 Assembly and Fabrication Sequencing Plan

Provide drawings and detailed descriptions of the fabrication sequence of all components and subassemblies. Provide drawings and detailed descriptions of the assembly of components into the final structure. Ensure the assembly and fabrication sequencing plan includes details describing fit-up, welding and bolting sequences of individual components and the completed assembly, and the required hold points necessary for weld inspection in accordance with the quality control plan or fracture control plan. The Assembly and Fabrication sequence plan will be evaluated to show that the fabricator is sequencing the work to control distortion,shrinkage, residual stresses and to meet required tolerances.

2.1.3 Materials Disposition Record

Furnish the Contracting Officer three copies of all purchase and mill orders, shop orders for materials and work orders, including all new orders placed by Contractors and old orders extended for each supplier. Furnish, at the time of submittal of shop drawings, a list designating the material to be used for each item. Furnish a shipping bill or memorandum of each shipment of finished pieces or members to the project site, giving the designation mark and weight of each piece, the number of pieces, the total weight, and if shipped by rail in carload lots, the car initial and number. Provide materials from mills, warehouses, or processors with supporting certified MTRs meeting the requirements of applicable ASTM specifications. If the MTR does not contain sufficient information, provide copies of the test results to the Engineer for review and approval before fabrication. Track all material through fabrication with the use of material traveler records. Ensure a material traveler is present on each assembled component in the fabrication shop.

2.1.4 Welded Connections

a. Welding Procedure.

(1) Conform all welding to the applicable provisions of AWS D1.5M/D1.5. Prior to the start of production welding, submit a complete schedule of welding procedures for a typical structure. Conform the schedule to the requirements specified in


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the provisions of AWS D1.5M/D1.5. Provide detailed procedure specifications and tables or diagrams showing the procedures to be used for each required joint.

(2) Submit to the Government Representative/Contracting Officers Representative/Engineer, a Welding Procedure Specifications (WPS) for each weld to be made. Submit Welding Procedure Specifications and Procedure Qualification Records (PQR) to the Government Representative/Contracting Officer and Engineer of Record for approval before fabrication is commenced. Submit all WPS with attached PQR and supporting test documentation on forms similar or equivalent to the sample forms in AWS D1.5M/D1.5. Qualify each WPS in accordance with the applicable provisions of AWS D1.5M/D1.5. Identify the weld as a fracture critical weld on each WPS as applicable. A WPS is always required, even if the procedure is considered prequalified in accordance with AWS D1.5M/D1.5. All government approved WPS will receive a Government approval stamp and copies of the stamped WPS are the only WPS allowed for use on this project. Identify each procedure clearly as being either prequalified or qualified by tests. A representative of the Government is required to witness the test plate welding and the mechanical testing for all welding procedure specifications qualified by testing. Approval of any procedure, however, does not relieve the Contractor of the responsibility for producing a finished structure meeting all requirements of these specifications. Approved WPS bearing a government stamp, mark, identifier are to be posted in work areas where welding is being performed such that a WPS is readily available for reference at all times. Ensure A CWI approves all WPS's and PQR's. Copies of approved WPS including approval stamps are to be present at all work stations where welding is occurring so that the welder, QC staff and government QA staff have access to the WPS.

(3) Welding Procedure Specifications include at a minimum the following; Indicate whether WPS is prequalified or qualified by testing, WPS ID#, Revision #, Date, Created by, Company Name, Supporting PQR#, Joint Design information (to include dimensional tolerances), Base Metal information, Shielding information, Preheat information, Type of operation, Position, Electrical Characteristics, Technique, PWHT, Joint Sketch including all code required essential variables. Include filler metal data sheets with WPS and PQR. Weld repair procedures are to be included on each WPS. All Welding Procedure Specifications for weldingASTM A709/A709M base metal to alternate base metal are required to be qualified through testing. Reduced section tensile tests and bend tests are always required when qualifying welding procedures.

b. Welding Process. Utilize an electric arc welding process using amethod which excludes the atmosphere from the molten metal for welding all structural steel. Conform to the applicable provisions of AWS D1.5M/D1.5 for all welds. Ensure all welding minimizes residual stresses, distortion, and shrinkage.

c. Welding Technique.

(1) Filler Metal - Conform the electrode, electrode-fluxcombination and grade of weld metal to the appropriate AWSspecification for the base metal and welding process beingutilized. Meet the requirements of AWS D1.5M/D1.5, Tables, 4.1,


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4.2, or 12.1 for weld metal toughness as applicable. Include the AWS designation of the electrodes to be used in the schedule of welding procedures. Utilize only low hydrogen electrodes for manual shielded metal-arc welding regardless of the thickness of the steel. Utilize a controlled temperature storage oven at the job site as prescribed by AWS D1.5M/D1.5, Clause 12.6 to maintain low moisture of low hydrogen electrodes. Ensure controlled temperature storage ovens are powered at all times. Subject FCAW filler metal to the storage and handling requirements defined in AWS D1.5M/D1.5 Clause 12.6.7.4. The combination of differing filler metals and processes in the same joint or weld is not permitted.

(2) Preheat and Interpass Temperature - Perform preheating as required by the applicable provisions of AWS D1.5M/D1.5 for all welds. Ensure preheat does not produce moisture in the weld joint. Preheat for fracture critical welds is defined in Table 12.3 of AWS D1.5M/D1.5 and should be in accordance with the WPS. Slowly and uniformly heat all welds by approved means to the prescribed temperature, hold at that temperature until the welding is completed and then permit the weld to cool slowly as required and in accordance with the approved WPS in order to prevent cracking or distortion. Preheating by use of oxygen cutting equipment is restricted to the use of "rosebud" heads designed for heating. The use of cutting heads for preheating is not permitted.

d. Workmanship. Conform workmanship for welding in accordance withAWS D1.5M/D1.5, Clause 3 for all welds and other applicable requirements of these specifications

(1) Preparation of Base Metal. Prior to welding, inspect surfaces to be welded to ensure compliance with the applicable sections of AWS D1.5M/D1.5.

(2) Tack and Temporary Welds. Make all tack and temporary welds required for fabrication and erection in accordance with AWS D1.5M/D1.5 under the controlled conditions prescribed herein for permanent work. Tack welds that are to be incorporated into the permanent work are to be subject to the same quality requirements as the permanent welds. Ensure tack welds are be cleaned and fused thoroughly with the permanent welds. Make multiple-pass tack welds with cascaded ends. Remove defective tack welds before permanent welding. Use low-hydrogen electrodes for all welds. Utilize welders qualified for permanent work as specified elsewhere in these specifications for all tack and temporary welds. Preheat permanent tack welds as required by AWS D1.5M/D1.5 . Ensure the method of preheat selected does not produce moisture in the weld joint. Make all tack welds which are incorporated into the final weldment a maximum of 1/8 inch with a minimum length of 1 inch long spaced at a maximum of 6 inch on center. Remove each temporary weld as required by AWS D1.5M/D1.5, Clause 3.3.8. Ground out all arc strikes struck outside the weld zone, and inspect by MT in accordance with AWS D1.5M/D1.5.

(3) Weld Access Holes. Provide weld access holes as shown on the shop drawings. If the oversight of intersecting out-of-plane welds is encountered, notify the Engineer and Contracting Officer for the approval of weld access hole additions in such locations.


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Payment for the addition of weld access holes not shown on plans is the Contractor's responsibility.

(4) Weld Backing Removal. Unless otherwise indicated, remove all steel weld backing material from welded joints prior to testing. Identify all weld backing material that cannot be removed on the shop drawings.

(5) Weld Backing Material. Qualify all weld backing material, other than steel, by testing and include this backing material in all PQR/WPS. Variation from approved weld backing material is not permitted and requires the development and testing of a new weld procedure which addresses the change in backing material. Components of the structure are not to be used as backing for complete joint penetration welds without the permission of the Engineer.

(6) Mock Up Testing. Mock up testing may be required for complex geometries where welding and inspections are difficult due to access restrictions or welding/NDT inspection positions. Testing procedures for connections which do not match typical fabrication practices may require alternate testing procedures to be developed by the fabricator and submitted for approval.

2.1.5 Bolted Connections

Tension all high strength connections to a tension not less than that given below for A325 Bolts. Utilize the turn-of-nut, direct tension indicator, calibrated wrench, or alternative design bolt methods for tensioning all high strength bolts.

5/8 inch 19 kips 3/4 inch 28 kips 7/8 inch 39 kips 1 inch 51 kips 1-1/8 inch 56 kips 1-1/4 inch 71 kips 1-3/8 inch 85 kips 1-1/2 inch 103 kips

Tighten all other connections to the snug-tight condition. The snug tightened condition is the tightness that is attained with a few impacts of an impact wrench or the full effort of an ironworker using an ordinary spud wrench to bring the plies into firm contact. Perform snugging in a systematic manner starting at the most rigid part of the joint and working to the outside of the connection or the free edges. Install all bolts in a connection to a snug tight condition prior to pretensioning. Perform pretensioning in the same order as snug-tightening.

a. Bolts, Nuts, and Washers. Provide bolts, nuts and washers of thetype specified or indicated. Utilize ASTM A563nuts with high strength bolts . Utilize washers with all high strength connections. Utilize ASTM F436 washers with high strength bolts. Where the use of high strength bolts is specified or indicated, conform the materials, workmanship and installation to the applicable provisions of ASTM A325 and RCSC S348. Fabricate all bolts which require the use of alternate high strength bolt materials (ASTM A354 Grade BC or A449 etc.) to match dimensional properties (length, diameter, thread requirements etc) of ASTM A325. Establish job-site tension requirements for all bolt


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assemblies composed of bolts fabricated from alternate bolt specifications (ASTM A354 Grade BC or A449 etc.) as these materials are not addressed in RCSC S348. Seal bolts, nuts, and washers shall be stainless steel.

b. Bolt Holes. Ensure bolt holes are accurately located, smooth,perpendicular to the member and cylindrical in shape.

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

(2) Match-ream or drill all holes for high strength fitted bolts. Remove burrs resulting from reaming. Exclude the threads from the shear plane. The tolerances for fitted bolts and holes are as depicted on contract drawings. .

(3) The provisions of AWS D1.5 Clause 3.7.7 allowing misdrilled holes do not apply. Repair all misdrilled holes as directed by the Engineer. Report all misdrilled or mislocated holes to the Engineer as an NCR along with the proposed repair procedure for approval. Holes that cannot be repaired to the satisfaction of the Engineer requires the replacement of the component.

2.1.6 Miscellaneous Provisions

a. Weldments. Portions of the structure include thick weldments wherelocked in thermal stresses may make final dimensions unstable. The Contractor is required to sequence the work and thermally stress relieve subassemblies of thick weldments such that final machining achieves stable specified dimensions and tolerances.

b. Drain Holes. Locate drain holes as shown on the drawings, unlessotherwise noted. Drill all drain holes and grind square edges to a 1/16 inch radius prior to painting. Flame cutting of holes is not be permitted.

c. Seal Welds. Seal welds are required to maintain water tightness.Show all seal welds on shop drawings. Make all seal welds, fillet weld as indicated on the drawings. In addition, seal welds may require weld wrapping around reentrant corners. Subject all seal welds on fracture critical members to the minimum preheat requirements of AWS D1.5 Table 12.3 as applicable. Subject all seal welds to the same testing requirements required for a fillet weld as required in Section 2.2.4 of this specification.

2.1.7 Shop Assembly

Perform fabrication and assembly in an indoor, climate controlled shop. Ensure all necessary clearances have been provided and that binding does not occur in any moving part. The Engineer or Government representative will witness all shop testing of completed assemblies without cost to the Government. The Contractor shall submit the final weights of each completed, assembled structure.

2.1.7.1 Vertical Lift Gate Section

Gate sections shall be shop fabricated and shall be provided complete with lifting brackets, wheel assemblies, seal assemblies, and other appurtenant


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items as required for installation and proper operation. Determination of Center of Gravity of the design shall be performed prior to fabrication. Notify the Contracting Officer if an unreasonable amount of counter-weighting is required to attain the center of gravity as designed. Surfaces of section framing elements to which skin plates are to be welded shall not vary from a true plane by more than 1/16 inch to provide uniform bearing. The outside surfaces of skin plates welded to framing elements shall not vary from a true plane by more than 1/16 inch. The overall width and height of the fabricated gate leaf shall not vary from the respective dimensions shown by more than 1/16 inch. Gate section shall be stress relieved prior to the attachment of seal assemblies and other appurtenant items.

Shop assembly shall include the attachment of all accessories to the gate section. After being shop assembled, the gate shall be picked up with slings and balanced on a point to verify the center of gravity prior to locating the pick-up point. The location of the center of gravity shall be submitted for approval. The gate shall not be out of plumb by more than 1/4 inch in the total length in the vertical plane in the upstream-downstream direction, or by more than 1/16 inch in the total width in a vertical plane perpendicular to the vertical plane in the upstream-downstream direction. The COR shall be notified when measurements are taken so that he/she or his/her designated representative can be present. The Contractor shall notify the Government 5 business days in advance of when measurements will be taken.

2.1.7.2 Gate Section Wheel Assemblies

Wheels shall be short hub or long hub, rigid type, with a minimum 325 Brinell Hardness Number. Wheel assemblies shall be products of a manufacturer regularly engaged in the manufacture of such products. Each wheel assembly shall be provided complete with wheel, shaft, roller bearing, lock washer, lock nut, bearing cover, seal housing, grease seal, seal retainer, shaft lock plate, lubrication fittings, fasteners, and other accessories as required for complete and proper installation. Wheel diameter and thickness shall not be changed from that shown. Wheels shall be of the size and load capacity shown. Wheel treads shall be machined finished as shown. The dimensions and tolerances of other components may be changed as required for compatibility with the manufacturer's product.

The gate section shall be supported in the horizontal position for adjusting wheel assemblies so that the wheels of the attached wheel assemblies are free to rotate to allow the proper adjustment. Attached wheel assemblies shall be adjusted so that the wheels remain perpendicular to the gate section and the contact surfaces of the wheels on each side of the gate section are in a single plane within 0.005 inch when rotated 360 degrees. The final adjustment of wheel assemblies shall be made after the gate section is assembled with the gate frame and guides in the horizontal position. After aligning gate vertically, jack gate evenly in slot towards the sump side until the double-bulb seal has an initial deflection of 0.1125 inches. Adjust wheels to 0.0625 inch clearance between sump side guide rail. Wheel assemblies shall be lubricated after being locked in position with a lubricant that is suitable for underwater operation, equal to the lubricant recommended by the manufacturer of the wheel rollerbearings, and as approved. Additional lubricant shall be applied at regular intervals until final acceptance of the work.


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2.1.7.3 Seal Assemblies

Seal assemblies shall be attached to the gate leaf during shop assembly and removed for shipment. The rubber seals of the assemblies shall be accurately fitted, drilled to match the seal retainers, match marked, and removed for shipment. Rubber seals shall be continuous over the full length. Splices in seals shall be fully molded, develop a minimum tensile strength of 50 percent of the unspliced seal, and occur only at locations shown. All vulcanizing of splices shall be done in the shop. The vulcanized splices between molded corners and straight lengths shall be located as close to the corners as practicable. Splices shall be on a 45 degree bevel related to the thickness of the seal.

2.1.8 Seals

Provide each vertical lift gate with bulb seals, rubber bearing blocks, and bearing seals as shown on the drawings. Bulb seals, rubber bearing blocks, and bearing seals shall be of the mold type only and compounded of ethylene propylene diene monomer (EPDM) or neoprene (CR). Ensure the surfaces of finished splices are smooth and free of irregularities. Match drill bolt holes in the rubber seals with the seal support and clamping bars, as applicable; to insure proper fit and spacing between holes of the completed seal assembly. Conform seal support and clamping bars to the configurations shown on the drawings. Machine finish all seal support and clamping bars. Install the seals and blocks after painting has been completed.

2.2 Testing and Inspection

2.2.1 General

Have required material tests and analyses performed and certified by an approved laboratory, at the Contractor's expense, to demonstrate that materials are in conformity with the specifications. Conform all tests, inspections, and verifications to the requirements of the particular sections of these specifications for the respective items of work unless otherwise specified or authorized. Furnish specimens and samples for additional independent tests and analyses upon request by the Contracting Officer.

Generate weekly fabrication quality control reports that include records of visual inspection, nondestructive testing progress, weld tracking log, dimensional checks, and a summary of Non-Conformance Reports for the period in question. Submit Nondestructive Testing reports as soon as they are produced. Submit and distribute weekly Fabrication Quality Control Reports as agreed between the fabricator, contractor, Government Quality Assurance Representative and contracting officer.

Submit a complete Fabrication Record for each structure fabricated. Include all inspection records, weld tracking logs, control dimensions, material certifications and other documentation in hard copy bound format and electronic pdf format in the completed fabrication record. The document is a complete record of each individual structure fabricated.

2.2.2 Nondestructive Testing

When doubt exists as to the soundness of any material part, such part may be subjected to any form of nondestructive testing determined by the Contracting Officer. This may include ultrasonic, magnetic particle, dye


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penetrant, radiography or any other test that thoroughly investigates the part in question. The cost of such investigation will be borne by the Government. Any defects will be cause for rejection and rejected parts are to be replaced and retested by the same test method that located the defect at the Contractor's expense.

2.2.3 Inspection of Structural Steel Welding

Maintain an approved inspection system and perform required inspections. Subject all welding to inspection to determine conformance with the requirements of AWS D1.5M/D1.5 and the approved welding procedures and provisions stated in other sections of these specifications. Clean and carefully visually examine all completed welds for insufficient throat or leg sizes, cracks, undercutting, overlap, excessive convexity or reinforcement and other surface defects to ensure compliance with the requirements of AWS D1.5M/D1.5, Clause 6.26 and the additional requirements of Clause 12 for the Fracture Control Plan. In addition, the Government may choose to hire a third party inspector to perform verification of this work. The Government's third party inspection will occur at various times throughout the duration of fabrication. The Contractor is advised that third party inspection may be utilized by the Government which will be coordinated with the GQAR and the Contractor for all verification inspections selected by the Government.

a. Visual Examination. Prior to any welding, a certified weldinspector (CWI) supplied by the Contractor is to visually inspect and document on the weld tracking log the preparation of material for welding at each weld or joint in order to ensure compliance with AWS D1.5M/D1.5 and approved WPS. Ensure the CWI performs visual inspection on all completed welds throughout the welding process to assure compliance with AWS D1.5M/D1.5 and approved WPS. Complete visual inspection in accordance with Clause 6 of AWS D1.5M/D1.5. Clean all completed welds free of oxide, flux, scale, paint spatter, or other foreign matter before inspection. Ensure a CWI meeting the requires of this specification is present during all welding.

b. Nondestructive Examination. The nondestructive examination ofwelds is specified or described on the drawings and is listed in the following paragraphs. Omission of weld testing symbols on contract or shop drawings does not supercede the requirements of these specifications or AWS D1.5M/D1.5.

(1) Testing Agency. The nondestructive examination of welds and the evaluation of examination tests as to the acceptability of the welds is to be performed by a testing agency adequately equipped and competent to perform such services or by the Contractor using suitable equipment and qualified personnel. In either case written approval of the examination procedures is required. Notify the government prior to any testing. The evaluation of examination tests will be subject to the approval of, and all records become the property of, the Government. Certified Weld Inspectors (CWI) are to be qualified and certified in accordance with the provisions of AWS QC1 and are to be familiar with AWS D1.5 fracture critical member inspection as required in AWS D1.5 Clause 12.16. The laboratory and all personnel performing nondestructive testing are to be qualified as specified. Only individuals qualified for NDT Level II or Level III may perform nondestructive testing. The Level III NDT inspector who supervises all NDT is to possess a valid American Society for


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Nondestructive Testing (ASNT) Level III certificate for each of the processes for which they are qualified. Include copies of the certifications, including the ASNT certificate of Level III NDT Technician that certified the Level II Technicians in the submittals.

(2) Examination Procedure and Extent. Comply all nondestructive testing with AWS D1.5M/D1.5, Clause 6 or Clause 12, as applicable. Testing is defined in Section 2.2.4 of these specifications.

(3) Acceptability of Welds. Welds are unacceptable if shown to have defects prohibited by AWS D1.5M/D1.5.

(4) Examination Procedures. Conform examination procedures to the following requirements:

(a) Ultrasonic Testing (UT) - Conform ultrasonic testing of welds to the provisions of AWS D1.5M/D1.5. Scan base metal longitudinally for laminations prior to shear wave examination. Longitudinal examinations conducted by the material producer are not considered acceptable for this testing.Sensitivity reference levels for shear wave examinations are to be established on an IIW type block utilizing the .060 sensitivity hole. Any alternative method requires the approval of the Engineer.Ensure the ultrasonic equipment is capable of making a permanent record of the test indications. Produce a record of each weld tested. Remove all backing bars prior to ultrasonic testing.

(b) Radiographic Testing (RT) - Conform the making, evaluating and reporting of radiographic testing of welds to the applicable requirements of AWS D1.5M/D1.5. Ensure that radiographic film provided is developed with a film density from 2.5 to 3.5. The Government will retain ownership of radiographic film provided by the fabricator. Only ASNT RT Level III's or individuals specifically certified in radiographic film interpretation are allowed to perform the interpretation and acceptance/rejection of radiographs. Submit qualifying documentation for government approval. Only wire IQI's are permitted. IQI's are not permitted to be placed over the weld. Ensure the essential wire of the IQI is visible from end to end without breaks. Film artifacts located in the weld or heat affected zones are cause for rejection of the radiograph.

(c) Magnetic Particle Inspection (MT) - Conform magnetic particle inspection of welds to the provisions of ASTM E709 and AWS D1.5M/D1.5, Clause 6 and Clause 12.16 where applicable. Requirements of AWS D1.5M/D1.5 Clause 6.7.2.3 do not apply to these specifications.. MT by the prod method is prohibited. Permanent magnets are prohibited. Unless specifically approved magnetic particle media suspended in a liquid solution may not be used for field applications. MT particle media must be of a contrasting color to the test material. Use field indicators to verify the correct field strength and direction for all MT.

(d) Dye Penetrant Inspection (PT) - Conform dye penetrant inspection(PT) of welds to the applicable provisions of ASTM E165.


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2.2.4 Welds to be Subject to Nondestructive Examination

a. Structural Steel Non-Fracture Critical Members - Complete JointPenetration Welds. Inspect welds in conformance with AWS D1.5M/D1.5, Clause 6.7. Include a representative sample of welds and weld types from all welders and each of the processes each welder used in all testing. Spread testing throughout the project. Test 100 percent of all Complete Joint Penetration welds on non-fracture critical members to ultrasonic testing or radiographic testing, unless otherwise noted on the drawings.

b. Structural Steel Non-Fracture Critical Member Fillet Welds andPartial Joint Penetration Welds. A minimum of 25 percent of all fillet welds and Partial Joint Penetration welds on non-fracture critical members are to be randomly selected for examination by magnetic particle and or dye penetrant testing procedures described previously. Include a representative sample of welds and weld types from all welders and each of the processes each welder used in the random sampling. The random testing is to be spread throughout the project. Develop and submit a schedule for implementing the random testing prior to fabrication. MT or PT should be concentrated at weld stops, starts, and terminations.Structural Steel Non-Fracture Critical Member Fillet Welds. A minimum of 25 percent of all fillet welds on non-fracture critical members are to be randomly selected for examination by magnetic particle and/or dye penetrant testing procedures described previously. Include a representative sample of welds and weld types from all welders and each of the processes each welder used in the random sampling. The random testing is to be spread throughout the project. Develop and submit a schedule for implementing the random testing prior to fabrication. MT or PT should be concentrated at weld stops, starts, and terminations.

c. Structural Steel Fracture Critical Member Welds. Test all welds onFCM in accordance with AWS D1.5M/D1.5, Clause 12.16. Subject 100 percent of all fracture critical fillet welds and partial joint penetration groove welds to magnetic particle testing. Subject 100 percent of all fracture critical complete joint penetration welds on fracture critical members to both magnetic particle and ultrasonic testing. Test all CJP welds on fracture critical members to the tension criteria of AWS D1.5M/D1.5. Inspect butt joints in tension with both RT and UT. Conduct the testing as early in the project as possible to ensure the quality of the procedure and process. Remove all weld backing from all fracture critical welds prior to all NDT unless the weld backing member is permanent. Include non-rejectable indications with defect severity ratings within 5 db of being rejectable in the UT report. Fully record the indication, rating, size, and location of each weld tested. Record all discontinuities in accordance with AWS D1.5 Clause 12.16.5.3.Structural Steel Fracture Critical Member Welds. Test all welds on FCM in accordance with AWS D1.5M/D1.5, Clause 12.16. Subject 100 percent of all fracture critical fillet welds to magnetic particle testing. Subject 100 percent of all fracture critical complete joint penetration welds on fracture critical members to both magnetic particle and ultrasonic testing. Test all CJP welds on fracture critical members to the tension criteria of AWS D1.5M/D1.5. Inspect butt joints in tension with UT. Conduct the testing as early in the project as possible to ensure the quality of the procedure and process. Remove all weld backing from all fracture critical welds prior to all NDT unless the weld backing member is permanent. Include non-rejectable indications


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with defect severity ratings within 5 db of being rejectable in the UT report. Fully record the indication, rating, size, and location of each weld tested. Record all discontinuities in accordance with AWS D1.5M/D1.5 Clause 12.16.5.3.

d. All CJP groove welds made without steel backing are to bebackgouged to sound weld metal and ground to remove gouging residue (carbon, copper, slag) before welding the second side. Following the grinding operations the backgouge is to be inspected both visually and by Magnetic Particle Testing. Include a permanent record of this MT in the weld tracking log.

2.2.5 Test Coupons

The Government reserves the right to require the Contractor to remove coupons from completed work when doubt as to soundness cannot be resolved by nondestructive examination. Should tests of any two coupons, cut from the work of any welder, show strengths less than that specified for the base metal it will be considered evidence of negligence or incompetence and such welder will be removed from the work. When coupons are removed from any part of a structure, the members cut are to be repaired in an appropriate manner with joints of the proper type to develop the full strength of the members. Repaired joints are to be either be heated or peened as approved or directed to relieve residual stress. The expense for removing and testing coupons, repairing cut members and the nondestructive examination of repairs will be borne by the Government. If the coupons fail testing, repair costs as well as sampling costs, is to be borne by the Contractor.

2.2.6 Supplemental Examination

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

2.2.7 Structural Steel Welding Repairs

Defective welds in the structural steel should be defined as critical repairs or non-critical repairs and are to be repaired in accordance with AWS D1.5M/D1.5, Clause 3.7 for non-FCM and Clause 12 for FCM. Make separate submittals for Welding Repair Plan - Non-Fracture Critical Members and Welding Repair Plan - Fracture Critical Members. All weld repairs to fracture critical members are considered critical welds in accordance with AWS D1.5 Clause 12.17.3 and will be approved by the Engineer of Record. Approval by the Government must be obtained for weld repairs to mill defects in the base metal, repair of cracks, or a revised design to compensate for deficiencies. The Contractor may prepare procedures and specifications for the repair of anticipated routine problems and submit them for approval before fabrication begins. Critical weld repairs require a WPS specific to the weld repair. Submit welding repair plans and procedures prior to any weld repairs. The dispensation of repaired welds is to be documented in the NCR as appropriate. All repair plans must follow the requirements of the FCP. Defective weld metal is to be removed to sound metal by use of air carbon-arc gouging. Oxygen gouging for purposes of weld repair is not be permitted. Clean all surfaces thoroughly before welding. Inadequate removal of welds that damage the


W912EE-17-B-0010

base metal are subject to replacement of the base metal, or compensation for the deficiency in a manner approved by the Engineer. Welds that have been repaired are to be retested by the same methods used in the original inspection. Except for the repair of members cut to remove test coupons and found to have acceptable welds, costs of repairs and retesting are to be borne by the Contractor.

2.2.8 Control Dimensions

Prior to shipping the structures, verify and document all control dimensions as indicated on drawings S-201 and S-501

2.2.9 Verification of Bolted Connections

Ten percent (at least two) of the pretensioned bolts in each connection on the structure are to be selected at random in each connection. The job inspection torque established during pre-installation verification is then applied to each with the inspecting wrench turned in the tightening direction. If this torque turns no bolt head or nut, the bolts in the connection are considered to be properly tensioned. However, if the torque turns one or more bolt heads or nuts, the job inspection torque is to then be applied to all bolts in the connection. Any bolt whose head or nut turns at this stage must be retorqued and reinspected. The Contractor may, however, retension all the bolts in the connection and resubmit it for inspection, so long as bolts are not over tensioned or damaged by this action.

PART 3 EXECUTION

3.1 DELIVERY OF WHEEL GATE SECTIONS

Vertical lift gates shall be delivered in two separate pieces to facilitate installation. Gates are to be delivered with an upper section and a lower section, which are distinguished by the joint.

3.2 REMOVAL OF EXISTING GATES

A Lift Plan shall be submitted by the Contractor for approval by the Government. This should include any details and drawings necessary to demonstrate the methods and equipment required to remove the existing gates and lift the new gates into place for installation. The existing gates shall not be removed until the new gate is delivered to the project site. Prior to installing each new gate, the contractor shall install the 7 emergency stoplogs using the lifting beam provided. The stoplogs and lifting beam shall be transported by the contractor from the Government's compound at 1020 Levee Road, Yazoo City, MS 39194 to the project site. Upon completion of gate installation, the stoplogs and lifting beam shall be returned to storage at the Government's compound. The approximate weight of one stoplog is 8,000 lbs and the approximate weight of the lifting beam is 4,000 lbs. The contractor shall submit a delivery, storage, and handling plan for the stoplogs for Government approval. The Contractor shall provide 48 hours notice of the need to transport stoplogs to or from the project site. Following the installation of the stoplogs, the Contractor shall remove the existing gate. A Gate Removal Plan for removal of the existing gate shall be submitted for approval by the Government. Overhead gate operating hoists and equipment shall not be removed to accommodate removal of existing gates. Upon removal of the existing gate from the structure, it shall be removed from the project site and become the property of the Contractor.


W912EE-17-B-0010

3.3 INSTALLATION

Gate and appurtenant items shall be assembled for installation in strict accordance with the contract drawings, approved installation drawings, and shop match-markings. A Gate Installation Plan for installing the new gate shall be submitted for approval by the Government. Installation of all gates shall occur in the same time frame without demobilizing from the site. Operation of the structure's operating machinery and other equipment shall only be performed by Government personnel or its representatives. Overhead gate operating hoists and equipment shall not be removed to accommodate installation of new gates. The Contractor shall provide 24 hours notice of the need for the Government to operate the structure.

3.3.1 Gate Section

Gate leaf shall be completely assembled, including the attachment of all components and accessories, prior to being placed in the gate frame. All necessary precautions shall be taken to avoid distortion of the gate section and attached components during installation. Rubber seals shall be fastened securely to metal retainers. Before operating the gate, a suitable lubricant shall be applied to the rubber seal rubbing plates to protect the rubber.

3.3.2 Cleaning

Thoroughly clean all parts to be installed prior to installation. Remove all packing compounds, rust, dirt, grit and other foreign matter. Clean all holes and grooves for lubrication. Examine all enclosed chambers or passages to make sure that they are free from damaging materials. Where units or items are shipped as assemblies they will be inspected prior to installation. Disassembly, cleaning and lubrication will not be required except where necessary to place the assembly in a clean and properly lubricated condition. Pipe wrenches, cold chisels or other tools likely to cause damage to the surfaces of rods, nuts or other parts may not be used for assembling and tightening parts. Tighten all non-structural bolts and screws firmly and uniformly. Do not to overstress the threads. When a half nut is used for locking a full nut the half nut is to be placed first and followed by the full nut. Lubricate all threads of all bolts except high strength bolts, nuts and screws with an approved lubricant before assembly. Coat threads of corrosion-resisting steel bolts and nuts with an approved Antigalling Compound. Driving and drifting bolts or keys is not be permitted.

3.3.3 Alignment and Setting

Each machinery component or structural unit attached to structures fabricated according to this specification is to be accurately aligned by the use of steel shims or other approved methods so that no binding in any moving parts or distortion of any member occurs before it is fastened in place. Align all parts within the respective tolerances required. Shims are to remain with the final installation where called for on the drawings. Where parts are press-fit, apply anti seize compound to laying surfaces.


W912EE-17-B-0010

3.4 TEST, INSPECTIONS, AND VERIFICATIONS

3.4.1 Inspection

Shop assembled components shall be inspected for accurate fit and compliance with dimensional tolerances. Sealing, guiding and connecting surfaces shall be inspected to determine if their planes are true, parallel, and in uniform contact with opposing surfaces. With the gate leaf closed and uniformly blocked in the sealing position, gate leaf wheels and rubber seals shall be inspected to determine if they are in continuous contact with track and seal plates. Compression of the rubber seals shall not vary by more than 1/32 inch.

3.4.2 Operation Tests

The operation of the shop-assembled gate assembly shall be tested by opening and closing the gate a minimum of two times by use of the operating machinery. The force used to operate the gate shall be the minimum required to open and close the gate. Adjustments shall be made as required until operations are satisfactory. Under hydrostatic testing, the gate seals shall be sufficiently tight to prevent water leakage.

3.5 PROTECTION OF FINISHED WORK

Clean machined surfaces of foreign matter. Protect all finished surfaces by suitable means to prevent damage. Oil and wrap unassembled pins and bolts with moisture resistant paper or protected by other approved means. Wash finished surfaces of ferrous metals to be in bolted contact with an approved rust inhibitor and coated with an approved rust resisting compound for temporary protection during fabrication, shipping and storage periods. Paint finished surfaces of metals as specified in specification SECTION 09 97 02: PAINTING - HYDRAULIC STRUCTURES.

3.6 PAINTING

Paint all exposed surfaces of the structure as specified in Section 09 97 02: PAINTING - HYDRAULIC STRUCTURES. Grind all edges of plate prior to coating. Grinding plate edges is required before paint preparation in order to remove hardness as a result of flame cutting. Remove all weld spatter. Break all square edges and holes other than bolt holes and grind to a 1/16 inch radius prior to painting.

-- End of Section --


SUBMITTAL FORM,Jan 96 PREVIOUS EDITION IS OBSOLETE PAGE 1 OF 3 PAGES

Steele Bayou Vertical Lift Gates

05 59 13 SD-01 Preconstruction Submittals

1.2.3 G DSQuality Control Plan (QCP)

1.2.3 G DSMaterial Tracking Log Template

1.2.4 G DSWelding Procedure Specifications

(WPS)

2.1.4 G DSWelding Procedure Specifications

(WPS)

1.2.5 G DSFracture Control Plan (FCP)

2.2.7 G DSWelding Repair Plan -

Non-Fracture Critical Members

2.2.7 G DSWelding Repair Plan - Fracture

Critical Members

2.1.1 G DSHeat Straightening Procedure

2.1.1 G DSHeat Straightening Procedure

1.2.1 G DSWeld Tracking Log Template

1.2.3 G DSNon-Conformance Report Form

Template

1.2.6 G DSNDT Written Practice

1.2.6 G DSNDT Equipment Calibration

Records

1.2 G DSWork Plan

1.2 G DSWork Plan

2.1.1 G DSWork Plan

1.4.1 G DSQualification of Welders and

Welding Operators

1.4.2 G DSInspector Qualifications

SUBMITTAL REGISTERCONTRACT NO.

TITLE AND LOCATION CONTRACTOR

CONTRACTOR:SCHEDULE DATES

CONTRACTORACTION

APPROVING AUTHORITY

ACTIVITY NO

TRANSMITTAL NO

SPEC SECT

DESCRIPTION

ITEM SUBMITTED

PARAGRAPH

#

CLASSIFICATION

GOVT OR A/E REVWR SUBMIT

APPROVALNEEDED

BY

MATERIALNEEDED

BY

ACTION CODE

DATEOF

ACTION

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AUTH/

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CONTR

DATE FWDTO OTHERREVIEWER

DATE RCDFROM OTHREVIEWER

ACTION CODE

DATEOF

ACTION

MAILEDTO

CONTR/

DATE RCDFRM APPR

AUTH REMARKS

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

Revised By Amendment 0002



05 59 13 1.4.3 G DSQualification of Structural Steel

Fabricator

2.1.7.1 G DSDetermination of Center of

Gravity

3.2 G DSLift Plan

G DSGate Removal Plan

3.3 G DSGate Installation Plan

1.4.6 FIOField Measurements

SD-02 Shop Drawings

1.4.5 G DSShop Drawings

2.1.2 G DSAssembly and Fabrication

Sequencing Plan

2.2.1 FIOFabrication Quality Control

Reports

1.5 G DSDelivery/Shipping Plan

SD-03 Product Data

2.1.3 FIOMaterials Disposition Record

3.3.2 G DSAntigalling Compound

2.1.7 FIOFinal Weights

SD-06 Test Reports

1.2.3 G DSCertified Test Reports

1.2.2 G DSWeld Tracking Log

1.4 FIOWitness Points

1.2.3 FIONon-Conformance Report

SD-09 Manufacturer’s Field

Reports




CONTRACTORACTION

APPROVING AUTHORITY

ACTIVITY NO

TRANSMITTAL NO

SPEC SECT

DESCRIPTION

ITEM SUBMITTED

PARAGRAPH

#

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BY

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BY

ACTION CODE

DATEOF

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CONTR



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DATEOF

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MAILEDTO

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05 59 13 2.2.8 G DSControl Dimensions

1.2.2 G DSFabrication Record

2.2.1 G DSFabrication Record




CONTRACTORACTION

APPROVING AUTHORITY

ACTIVITY NO

TRANSMITTAL NO

SPEC SECT

DESCRIPTION

ITEM SUBMITTED

PARAGRAPH

#

CLASSIFICATION


APPROVALNEEDED

BY

MATERIALNEEDED

BY

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DATEOF

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Documents

AMENDMENT OF SOLICITATION/MODIFICATION OF CONTRACT Government... · W912EE17B0010 0002 Page 2 of 2 SECTION SF 30 BLOCK 14 CONTINUATION PAGE SUMMARY OF CHANGES . SECTION 00010 - SOLICITATION