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2004 Specifications CSJ 6172-05-001

SPECIAL SPECIFICATION 7349

Marine Structures

1. Description. This Item shall govern for the construction of marine structures, including

transfer span systems.

2. General Requirement. The marine structures work shall be performed in accordance with the details shown on the plans, and in conformity with the requirements of this specification and the following attached specification sections.

3. Attached Sections. Section Description

(1) 09970 Thermal Sprayed Aluminum (TSA) Coatings (2) 09980 Epoxy Coatings (3) 09990 Nonskid Surface Coating (4) 13000 Transfer Span System (5) 13020 Transfer Span Machinery Assemblies (6) 13050 Transfer Span Electrical Controls

4. Measurement. Measurement for “Marine Structures” will be by lump sum.

5. Payment. The work performed and materials furnished in accordance with this Item and measured as provided under “Measurement” will be paid for at the lump sum price bid for “Marine Structures”. This price shall be full compensation for furnishing all materials, labor, tools, equipment, and other incidentals necessary to complete the work.

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SECTION 09970 THERMAL SPRAYED ALUMINUM (TSA) COATINGS

PART 1 GENERAL

1.1 DESCRIPTION

A. This item shall govern for the application of thermal sprayed aluminum (TSA) coatings for steel piling and structural steel associated with wingwalls, inner dolphins, intermediate dolphins, outer dolphins, transfer spans, and the Bolivar north breakwater.

1.2 REFERENCES

A. The following is a list of standards which may be referenced in this section:

1. American Welding Society (AWS): a. C2.18, Guide for the Protection of Steel with Thermal Sprayed

Coatings of Aluminum, Zinc and their Alloys and Composites. b. C2.25, Specification for thermal Spray – Solid and Composite

Wire and Ceramic Rods. 2. ASTM International (ASTM):

a. C633, Standard Test Method for Adhesion or Cohesion Strength of Thermal Spray Coatings.

b. D4417, Field Measurement of Surface Profile of Blast Cleaned Steel.

c. D4541, Standard Test Method for Pull-Off Strength of Coatings Using Portable Adhesion Testers

3. ISO: 209-1, Wrought Aluminum and Aluminum Alloys – Chemical Composition and forms of products – Part 1, Chemical Composition.

4. MIL-W-6712C: Wire, Metallizing. 5. Occupational Safety and Health Act (OSHA). 6. The Society for Protective Coatings (SSPC):

a. SP 1, Solvent Cleaning. b. SP 2, Hand Tool Cleaning. c. SP 3, Power Tool Cleaning. d. SP 5, Joint Surface Preparation Standard White Metal Blast

Cleaning. e. SP 7, Joint Surface Preparation Standard Brush-Off Blast

Cleaning. f. SP 11, Power Tool Cleaning to Bare Metal. g. PA 1, Shop, Field, and Maintenance Painting. h. PA 2, Measurement of Dry Coating Thickness with Magnetic

Gages. i. PA 3, Guide to Safety in Paint Applications.

1.3 DEFINITIONS

A. Terms used in this section:

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1. Coverage: Total minimum dry film thickness in mils or square feet per gallon.

2. MDFT: Minimum Dry Film Thickness, mils. 3. MDFTPC: Minimum Dry Film Thickness Per Coat, mils. 4. Mil: Thousandth of an inch. 5. PSDS: Paint System Data Sheet. 6. SP: Surface Preparation. 7. TSA: Thermal Spray Aluminum.

1.4 SUBMITTALS

A. Shop Drawings:

1. Data Sheets: a. For each component of the TSA coating system, furnish a System

Component Data Sheet (SCDS), Material Safety Data Sheet (MSDS), the manufacturer's technical data sheets, and colors available (where applicable) for each product used in the system. The SCDS form is appended to the end of this section.

b. Technical and performance information that demonstrate compliance with Specification.

c. Certificates of compliance for each batch of thermal spray coating material.

d. Furnish copies of TSA coating system submittals to the coating applicator.

e. Indiscriminate submittal of manufacturer's literature only is not acceptable.

2. Detailed chemical and gradation analysis for each proposed abrasive material.

B. Samples: Provide qualification procedure test coupons and reference panel.

1. Reference Panel: Unless otherwise specified.

C. Quality Control Submittals:

1. Applicator’s quality control procedures and qualification test results. 2. Thermal spray equipment operators qualification. 3. Applicator’s Qualification: List of references substantiating experience. 4. TSA applicator's written instructions and special details for shop and

field application of TSA and sealer to steel substrates. 5. TSA applicator’s written verification that submitted material is suitable

for the intended use.

1.5 QUALITY ASSURANCE

A. Qualifications:

1. TSA Applicator: Minimum 2 years’ experience in application of specified products.

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2. TSA applicators who currently meet the required Quality Assurance requirements include the following companies: a. Sermatech Dynamic

7615 Fairview Houston, TX 77041 (713) 849-9474

b. National Thermospray, Inc. PO Box 1752 Cypress, TX 77410 (281) 373-0609

c. F .W. Gartner PO Box 231305 Houston, TX 77223 (713) 225-0010

B. Regulatory Requirements:

1. Meet federal, state, and local requirements limiting the emission of airborne toxic contaminants and volatile organic compounds.

2. Perform surface preparation, TSA and sealer application in accordance with recommendations of the following: a. Sealer manufacturer's instructions. b. SSPC PA 3, Guide to Safety in Paint Applications. c. Federal, state, and local agencies having jurisdiction.

1.6 INITIAL COATING QUALIFICATION PROCEDURE

A. Quality Control Procedure: Prepare a written quality control procedure for thermal spray aluminum and sealing. The quality control procedure shall include, but not be limited to, the following:

1. Visual inspection and acceptance criteria. 2. Surface profile measurements of abrasive blasted steel. 3. Coating thickness measurements. 4. Adhesion test requirements. 5. Nonconformance processing. 6. Requirements for bend test coupons and production test panels. 7. Coating repair procedures. 8. Reports required.

B. Qualification Procedure Approval: Prior to beginning any work, prepare qualification test coupons in accordance with the quality control plan and as described below.

C. Procedure Qualification:

1. The thermal spray aluminum coating application procedure shall be qualified by coating five carbon or low alloy steel qualification test coupons and three 1-inch diameter test cylinders, using the same materials, techniques, equipment, and methods to be used for thermal

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spray coating in production. Test coupons shall be 2 inches by 6 inches by 0.050 inch thick.

2. Secure test coupons to structural steel component with similar dimensions to that which will be coated in production. The structural component and coupon shall be thermal spray aluminum coated using the same coating parameters in the proposed procedure. The test application may be witnessed and inspected by the Engineer to verify that the thermal spray process will be consistent with production techniques.

3. Cross-Sectional Analysis: One of the coated test coupons shall be made of similar material to the structural components to be coated and shall be sealed with the epoxy sealer as specified herein. After the coupon has been sealed and the sealer has cured, the test coupon shall be sectioned through the thermal spray aluminum coating in at least two locations and examined at a minimum of 50 times magnification to ensure penetration of the sealer coatings into the thermal sprayed aluminum coating. The examined cross section shall have less than or equal to 25 percent porosity and the maximum dimension of any void shall be less than or equal to 50 percent of the thermal spray aluminum thickness.

4. Bend Test: Two of the aluminum coated test coupons shall be bent 180 degrees around a 0.5-inch diameter mandrel. No cracking or only minor cracking shall be observed, as illustrated in Figure C1 or AWS C2.18. Cracking that results in disbonding or delamination, or thermal sprayed aluminum coatings that can be removed with a knife blade, shall be cause for rejection. All discrepancies must be corrected and the bond test repeated, successfully, before the procedure is qualified.

5. Adhesion Test: An adhesion test, consisting of a minimum of three separate pulls, shall be made using the 1-inch diameter test cylinders as used for ASTM C633. The adhesion test cylinders shall be glued to bare blast cleaned cylinders, then removed using a pull-test rig similar to that used for ASTM C633 testing. The adhesion values for each pull shall be 2,000 psi, minimum.

6. If any of the qualification tests do not meet the criteria stated, the process shall be adjusted to correct the defective parameters, and the test sample procedure shall be repeated. No production work shall begin before the application procedure is qualified.

7. The remaining two aluminum coated steel test coupons shall be identified with the applications name and procedure and submitted to the Engineer.

D. Reference Panel:

1. After the application procedure has been qualified, but before thermal spray aluminum production coating work is started, prepare a 2-square-foot sample with the thermal sprayed aluminum and specified sealer on a 3/16-inch thick steel panel as indicated below. a. Abrasive to white metal as specified herein. b. Mask one quarter of the steel plate and apply thermal spray

aluminum coating to three quarters of the sample. Use the

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specified thermal spray aluminum coating material and the actual equipment that will be used on the project. Apply the thermal spray aluminum coating with the techniques that will be used on the project.

c. Apply the specified sealer to two thirds of the thermal sprayed aluminum coated steel sample.

d. Measure and record the sample blast profile and depth, coating and sealer thickness, and adhesion.

2. Preserve and maintain the reference panel in a dry, protected environment to provide a project reference.

E. Thermal Spray Operator Qualification:

1. Manual, Shop or Field Application: To qualify as a thermal spray aluminum application operator, the operator shall set up the manual thermal spray equipment and spray test three test coupons and three test cylinders as described in “Procedure Qualification” as specified herein. These test samples shall be subjected to and pass the tests described in the “Procedure Qualification.” Acceptable criteria shall be the same a those stated for the “Procedure Qualification” tests.

2. Automatic: Each automatic thermal spray operator shall have successfully completed the manual operator qualification specified herein. The operator shall also successfully complete the following: a. Operator shall demonstrate knowledge of the automated spray

system parameters required to apply the thermal spray aluminum coatings in accordance with the requirements specified herein. The operator shall identify machine setup parameters, verify correct adjustment of the parameters, demonstrate operation of the machine, and correct execution of documentation.

b. The operator shall be requalified if the operator has not thermal sprayed aluminum to the approved procedure for a period of 6 months.

1.7 DELIVERY, STORAGE, AND HANDLING

A. Shipping:

1. Where precoated items are to be shipped to the site, protect TSA coating from damage. Batten coated items to prevent abrasion.

2. Shop coated surfaces shall be protected during shipment and handling by suitable provisions including padding, blocking, and use of canvas or nylon slings.

B. Storage:

1. Protect metallizing wire spools from corrosion and environmental deterioration.

2. Store sealer products in a protected area that is heated or cooled to maintain temperatures within the range recommended by the sealer manufacturer.

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PART 2 MATERIALS

2.1 MANUFACTURERS

A. Nationally recognized manufacturers who are regularly engaged in the production of such materials for essentially identical service conditions.

B. Minimum of 3 years’ verifiable experience in manufacture of specified product.

2.2 ABRASIVE MATERIALS

A. Select abrasive type and size to produce surface profile specified herein.

B. Blasting abrasives shall be clean, dry, sharp, and angular and shall be free of clay, slat, oil, and other foreign matter.

2.3 THERMAL SPRAY COATING MATERIAL

A. Conforming to the requirements of MIL-W-6712 or ISO 209-1, Type A1 99.5. Provide certificates of compliance for each batch of material supplied.

B. Individual wire spools shall be clearly and permanently labeled to indicate manufacturer’s name, material type, lot number, net weight, wire diameter, and date of manufacturer.

C. TSA applicator shall sample, store, and retain a sample of wire from each batch for a period of 12 months following substantial completion of the project.

2.4 SEALER MATERIALS

A. Two component, converted epoxy, Carboline 893 or approved equal.

B. Thinners, Cleaners, Driers, and Other Additives: As recommended by the sealer manufacturer.

C. Mixing:

1. Prepare using each component as packaged by sealer manufacturer. 2. No partial batches will be permitted. 3. Do not use multiple-component sealers that have been mixed beyond

their pot life. 4. Mix only components specified and furnished by sealer manufacturer. 5. Do not intermix additional components for reasons of color or

otherwise, even within the same generic type of sealer.

D. Color:

1. Gray. 2. Formulate sealer with colorants free of lead or lead compounds.

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2.5 THERMAL SPRAY EQUIPMENT

A. Each type and model of thermal spray equipment shall be qualified in accordance with this section. The equipment shall be capable of maintaining current and voltage output, wire feed rates, atomized air pressure, and flow volumes at set values without deviating by 5 percent during a 15-minute period. The wire feed mechanism shall be designed for automatic alignment. The equipment shall be capable of continuous start and stop operation for a minimum of 15 cycles of 10 seconds on and 5 seconds off, without fusing, sputtering, or deposition of nodules. The equipment shall be capable of uniform spray application when operating continuously for a 20-minute period without sputter, pop, or stopping.

PART 3 EXECUTION

3.1 GENERAL

A. Provide Engineer minimum 7 days' advance notice to start of field surface preparation work and coating application work.

B. Perform the Work only in presence of Engineer, unless Engineer grants prior approval to perform the Work in Engineer’s absence.

C. Schedule inspection with Engineer in advance for cleaned surfaces and all coats prior to succeeding coat.

3.2 PROTECTION OF ITEMS NOT TO BE PAINTED

A. Remove, mask, or otherwise protect hardware, machined surfaces, couplings, shafts, bearings, nameplates on machinery, and other surfaces not specified elsewhere to be coated.

B. Protect working parts of mechanical and electrical equipment from damage during surface preparation and painting process.

3.3 ENVIRONMENTAL CONTROLS

A. General:

1. Contractor shall provide heating, cooling, or dehumidification equipment as required to meet the surface preparation and coating application environmental requirements as specified.

2. Products shall comply with federal, state, and local requirements limiting the emission of volatile organic compounds and worker exposure.

3. Comply with applicable federal, state, and local, air pollution and environmental control regulations for surface preparation, blast cleaning, disposition of spent aggregate and debris, and application of metal and solvent-based coatings.

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4. Do not perform abrasive blast cleaning whenever the relative humidity exceeds 85 percent, whenever surface temperature is less than 5 degrees F above the dew point of the ambient air.

5. Do not apply coating when: a. In dust or smoke-laden atmosphere, blowing dust or debris, damp

or humid weather, or under conditions that could cause icing on the metal surface.

b. When it expected that surface temperatures would drop below 5 degrees above dew point within 4 hours after application of coating.

6. Where weather conditions or project requirements dictate, TSA applicator shall provide and operate heaters and/or dehumidification equipment to allow surfaces be abrasive blasted and coated as specified and in accordance with the manufacturers coating application recommendations.

7. Work activities can be restricted by the Engineer until adequate temperature and humidity controls are in place and functioning within the environmental limits specified.

3.4 SURFACE PREPARATION

A. Metal Surface Preparation:

1. General: Compressed air for cleaning and blasting operations shall be clean and dry.

2. Where indicated, meet requirements of SSPC Specifications summarized below: a. SP1, Solvent Cleaning: Removal of all visible oil, grease, soil,

drawing and cutting compounds, and other soluble contaminants by cleaning with solvent.

b. SP5, White Metal Blast Cleaning: Removal of all visible oil, grease, dust, dirt, mill scale, rust, coatings, oxides, corrosion products, and other foreign matter by blast cleaning.

3. The words “solvent cleaning,” “hand tool cleaning,” “wire brushing,” and “blast cleaning,” or similar words of equal intent in these Specifications or in paint manufacturer's specification refer to the applicable SSPC Specification.

4. Round or chamfer sharp edges and grind smooth burrs, jagged edges, and surface defects.

5. Welds and Adjacent Areas: a. Prepare such that there is:

1) No undercutting or reverse ridges on weld bead. 2) No weld spatter on or adjacent to weld or any area to be

painted. 3) No sharp peaks or ridges along weld bead.

b. Grind embedded pieces of electrode or wire flush with adjacent surface of weld bead.

6. Preblast Cleaning Requirements: a. Remove oil, grease, welding fluxes, and other surface

contaminants prior to blast cleaning.

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b. Cleaning Methods: Steam, open flame, hot water, or cold water with appropriate detergent additives followed with clean water rinsing.

c. Clean small isolated areas as above or solvent clean with suitable solvent and clean cloth.

7. Blast Cleaning Requirements: a. Type of Equipment and Speed of Travel: Design to obtain

specified degree of cleanliness and anchor profile. Minimum surface preparation is as specified herein and takes precedence over coating manufacturer's recommendations.

b. Use only dry blast cleaning methods. c. Do not reuse abrasive, except for designed recyclable systems. If

recycled abrasives are used in conjunction with a recyclable abrasive blast system, maintain abrasive particle size distribution such that a consistent blast profile is obtained.

d. Meet applicable federal, state, and local air pollution and environmental control regulations for blast cleaning, confined space entry (if required), and disposition of spent aggregate and debris.

8. Post-Blast Cleaning and Other Cleaning Requirements: a. Clean surfaces of dust and residual particles from cleaning

operations by dry (no oil or water vapor) air blast cleaning or other method prior to painting. Vacuum clean enclosed areas and other areas where dust settling is a problem and wipe with a tack cloth.

b. Coat and seal surfaces the same day they are blasted. Reblast surfaces that have started to rust before they are painted.

3.5 SURFACE CLEANING

A. Solvent Cleaning:

1. Consists of removal of foreign matter such as oil, grease, soil, drawing and cutting compounds, and any other surface contaminants by using solvents, emulsions, cleaning compounds, steam cleaning, or similar materials and methods which involve a solvent or cleaning action.

2. Meets requirements of SSPC SP 1.

3.6 APPLICATION

A. General:

1. For coatings subject to immersion, obtain full cure for completed system. Consult coatings manufacturer's written instructions for these requirements. Do not immerse coating until completion of curing cycle.

2. Apply coating and sealer in accordance with these Specifications, the applicator’s approved procedures, and special details.

3. Coat units or surfaces to be bolted together or joined closely to structures or to one another prior to assembly or installation.

4. Keep TSA sealer materials sealed when not in use.

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B. Metallizing Application:

1. Shop and field apply thermal spray aluminum coatings as specified herein and as shown on the Drawings.

2. Metallizing methods which employ metal wire feed stock with oxygen-fuel gas flame spray or electric-arc spray that produce coatings in conformance with requirements of this specification are acceptable.

3. Set up and operate metallizing equipment in accordance with the equipment manufacturer’s directions and in the same manner used to prepare the sample.

4. Preheat surfaces to be coated, as required. Arc spray application does not require preheating of the substrate.

5. Metallizing equipment shall be operated by qualified applicators in accordance with these specifications and the equipment manufacturer’s recommendations.

6. Mask or otherwise protect surfaces that are not intended to be coated. 7. Spray guns used to apply thermal sprayed aluminum coatings shall be

held approximately perpendicular to the surface to be coated and at a distance required to deposit an even, continuous film of uniform thickness. Gun distance from the work-piece shall not exceed 8 inches.

8. Coating passes shall overlap a minimum of 40 percent. 9. Thermal spray coatings shall not be applied closer than 1 inch to any

surface that will be welded after the coating is applied. 10. Give particular attention to edges, angles, flanges, and other similar

areas, where insufficient film thicknesses are likely to be present, and ensure proper millage in these areas.

C. Coating System Check:

1. Manual or Field Application: a. For each structure or component to be coated, a production test

panel shall be blast-cleaned and thermal spray aluminum coated at the same time and in an identical manner to the structure or component being coated. The test panel shall be carbon steel, at least 36 inches square, and the same nominal thickness as the structure or component being coated.

b. Production test panels shall be labeled in such a way as to permanently identify the test sample and the companion structure or component.

c. Provide one production test panel per 10 components and per operator.

d. Perform three adhesion tests on each production panel in accordance with ASTM D4541. Adhesion shall be 1,000 psi, minimum.

e. If any adhesion values are less than 1,000 psi, three tests shall be made at random on the structure or component. If the production panel represents multiple structures or components, three tests shall be made on each component coated by that operator since that operators last successful production test panel or component. All three adhesion test values shall be 1,000 psi, minimum. If the

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adhesion value does not meet the specified value, the structure or component shall be completely blast cleaned and recoated as specified herein. 1) Dollies for adhesion testing shall be glued to the coating

surface and permitted to cure a minimum of 12 hours. 2) Repair coating damaged by the adhesion tests in accordance

with the coating applicator’s standard, written instructions. f. Production test panels shall be retained for a period of 1 year after

delivery of the structure or component and shall be available for inspection by the Engineer.

2. Automated Application: a. Perform a system check at the start of each production run. The

system check shall be performed before thermal spray application to components and after any change to the machine setup parameters. The system check shall consist of thermal spray aluminum application one carbon steel test coupon, 2 inches by 6 inches by 0.050 inch thick, and one 1-inch diameter test cylinder. The coupon and test cylinder shall be fixed to the length of production component so that they are approximately the same distance from the guns as the production component. The test coupons shall then be coated using the same methods and parameters as the production component.

b. The coupon and cylinder shall be removed from the production component and tested. The coupon shall be bent to 180 degrees around a 0.5-inch mandrel in two places. After bending, the coupon shall be free of significant cracking that exposes the steel substrate, and shall conform to the requirements of bend test coupons described in ANSI/AWS C2.18. Small hairline cracks or “alligatoring” of the coating in the vicinity of the bend are permissible.

c. An adhesion test shall be made on the 1-inch diameter test cylinder as used for ASTM C633. The adhesion test cylinder shall be glued to another test cylinder of bare substrate that has been abraded by blasting. The test cylinder will then be removed using a pull-test rig similar to that used for ASTM C633. The adhesion value shall be 2,000 psi, minimum.

d. If the coupon or cylinder does not meet the specified criteria, the process shall be corrected and testing repeated until the operator can demonstrate that the thermal spray coating can be applied to meet the test requirements.

e. If the coupon and cylinder tests indicate that the process does not meet the specified requirements, any component that had been coated after the coupon and cylinders were prepared shall be tested. Three adhesion tests shall be made at random on each structure or component that was coated subsequent to application of coating to and testing of the test coupon or cylinder. Adhesion tests shall be made in accordance with ASTM D4251, and all three adhesion values shall be 1,000 psi, minimum. If the adhesion value does not meet the specified value, the structure or

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component shall be completely blast cleaned and recoated as specified herein 1) Dollies for adhesion testing shall be glued to the coating

surface and permitted to cure a minimum of 12 hours. 2) Repair coating damaged by the adhesion tests in accordance

with the coating applicator’s standard, written instructions.

D. Sealer Application:

1. Apply sealer within 24 hours of the thermal spray aluminum coating is application. Sealer coat shall not be applied to any surfaces with any visible signs of rust or thermal spray aluminum coating degradation.

2. Apply sealer in strict accordance with the manufacturer’s written directions.

3. Do not use sealer materials that have exceeded the manufacturer’s expiration date, as marked on the container.

4. Sealer materials may be thinned in accordance with the manufacturer’s written instructions. Provide a letter from the coating manufacturer indicating that additional thinning is acceptable for thermal spray aluminum sealing purposes.

5. Apply a stripe coat of sealer to edges, corners, welds, brackets, and other irregular surfaces prior to application of a full sealer coat. Stripe coating shall consist of one coat of sealer, brush applied, to the thickness specified.

6. Brush out runs and sags.

3.7 INSPECTION AND TESTING

A. General: Applicator shall conduct quality control inspection and testing of the coating system in accordance with these specifications and the applicator’s approved quality procedure qualifications. The frequency of testing and inspections shall be determined by the applicator.

B. Abrasive Blast Cleaned Surfaces:

1. Abrasive Blast Air Cleanliness: At the beginning of each work shift, check compressed air cleanliness in accordance with ASTM D4285. The compressed air source shall not be used if there is any oil or water contamination present.

2. Abrasive Cleanliness: At the beginning of each work shift and at four hour intervals, the cleanliness of the abrasive shall be checked as described below. a. Fill a small, clean, clear glass bottle half full of abrasive mix. b. Fill the remainder of the bottle with distilled or deionized water. c. Stir the contents; cap and shake the bottle. d. Examine the water for the presence of an oil sheen. If any oil

sheen is present, discontinue use of the media and equipment until the source of the contamination is identified and corrected.

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e. Examine the water for the presence of dust particles. If excessive fine particles are present, recycling screens shall be adjusted and the abrasive recycled prior to continued use.

3. Anchor Profile Measurements: a. Measure the anchor profile on representative samples of the

component using replica tape. One anchor profile measurements shall be made for each 500 square feet of surface area. Perform a minimum of one anchor profile measurement on each component.

b. Anchor profile measurements shall be randomly spaced. c. Spot measure anchor profile at weldments and flame-cut edges. d. Areas not meeting the specified anchor profile shall be re-blasted.

4. Cleanliness of Prepared Surfaces: a. Visually inspect cleaned, prepared surfaces to verify that no oil,

grease, dust, moisture, or other contaminants are on the surface prior to application of the thermal spray aluminum coating.

b. Use clear adhesive tape to determine the presence of dust. Place a piece of clear tape on the surface and inspect the removed tape for the presence of adherent particles. Perform one tape test for each 500 square feet of prepared and cleaned surface.

c. Reclean surfaces that are found to be contaminated.

C. Thermal Spray Aluminum Coated Surfaces:

1. Visual Inspection: Thermal spray aluminum coated surfaces shall be free from lumps, coarse areas, loosely adherent particles, blisters, cracks, chips, or pits. The coating shall have a uniform appearance with no discoloration.

2. Adhesion Testing: Perform adhesion tests as specified in Coating System Check, this section.

3. Film Thickness Measurements: a. Perform with properly calibrated instruments. b. Perform film thickness measurements in accordance with SSPC

PA-2, with the exception that the absolute minimum film thickness shall be 7 mils.

c. Mark areas of deficient coating thickness. Areas of deficient coating thickness shall be repaired prior to application of the sealer.

D. Sealed Surfaces:

1. The sealed coating shall be free from blisters, cracks, holidays, sags, excessive runs, drips, or sags, and other visual defects. Each coat shall have a uniform appearance.

2. Inspect sealed areas at with a 30 power magnifier to verify that there are no voids or missed areas in coverage. Check each component at a minimum of three random locations.

3. Prepare surfaces and reseal areas that have evidence of improper application or insufficient coverage.

3.8 COATING REPAIRS

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A. Defective work shall be identified. No subsequent coating shall be performed until the cause of the defective work is identified and rectified.

B. For areas with damaged sealer, clean to remove contamination and prepare surfaces as recommended by the applicator. Feather edges of adjacent sealer, as required.

C. For areas where the thermal spray aluminum coating is damaged to the substrate, the coating shall be completed removed in the damaged area by abrasive blast cleaning and the full coating system replaced in that area and overlap intact coating as recommended in the applicator’s quality control procedures. Feather edges of adjacent, intact coating. Overlap sealer onto existing coatings around the repaired area.

D. Retest all coating repairs to verify that the repairs meet the requirements of this specification.

3.9 PROTECTIVE COATING SYSTEM

A. System No. TSA. Use this coating system for steel piling and structural steel associated with the following structures and as indicated on the plans:

1. Wingwalls. 2. Inner and Intermediate Dolphins. 3. Outer Dolphins. 4. Bolivar North Breakwater. 5. Transfer Spans.

Surface Prep. Material Thickness

Thermal Spray Aluminum

1 coat, 7 mils minimum, 14 mils maximum

SP1, Solvent Cleaning

SP5, White Blast Cleaning

Anchor Profile: 3 mils minimum, 5 mils maximum

Epoxy Sealer 1 coat, 1.5 MDFT

3.10 MANUFACTURER'S SERVICES

A. The coating manufacturer's representative shall be present at site as follows:

1. On first day of application of any coating system. 2. A minimum of two additional site inspection visits, each for a minimum

of 4 hours, in order to provide Manufacturer's Certificate of Proper Installation.

3. As required to resolve field problems attributable to or associated with manufacturer’s product.

4. To verify full cure of coating prior to coated surfaces being placed into immersion service.

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3.11 SUPPLEMENTS

A. The supplement listed below, following “END OF SECTION,” are a part of this Specification:

1. Data Sheet: Example Coating System Data Sheet (CSDS).

PART 4 MEASUREMENT AND PAYMENT

4.1 MEASUREMENT AND PAYMENT

A. The work performed, materials furnished and all labor, tools, equipment and incidentals necessary to complete the work under this Item will not be measured or paid for directly, but will be considered subsidiary to the various bid items of the contract.

END OF SECTION

176866A.SEA

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COATING SYSTEM DATA SHEET

Complete and attach manufacturer's Technical Data Sheet to this CSDS for each coating system.

Paint System Number (from Spec.):

Paint System Title (from Spec.):

Coating Supplier:

Representative:

Surface Preparation:

Coating Material (Generic)

Product Name/Number (Proprietary)

Min. Coats, Coverage

Provide sealer’s manufacturer’s recommendations for the following parameters at temperature (F)/ relative humidity:

Temperature/RH 50/50 70/30 90/25

Induction Time

Pot Life

Shelf Life

Drying Time

Curing Time

Min. Recoat Time

Max. Recoat Time

Provide manufacturer’s recommendations for the following:

Mixing Ratio:

Maximum Permissible Thinning:

Ambient Temperature Limitations: min.: max.: Surface Temperature Limitations: min.: max.: Surface Profile Requirements: min.: max.:

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Attach additional sheets detailing manufacturer’s recommended storage requirements and holiday testing procedures.

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SECTION 09980 EPOXY COATINGS

PART 1 GENERAL

1.1 DESCRIPTION

A. This work consists of all labor, materials, equipment, and supervision necessary to provide coatings as specified herein, complete.

B. This work includes, but is not limited to, cleaning and epoxy coating portions of exposed structural steel, concrete encased steel, and specific surfaces of steel pipe piling and sheet piling, as indicated on the plans.

1.2 REFERENCES

A. The following is a list of standards which may be referenced in this section:

1. International Organization for Standardization: 8502-6, extraction of soluble contaminants for Analysis - the Bresle Method.

2. National Association of Corrosion Engineers (NACE): Manual for Painter Safety.

3. Occupational Safety and Health Act (OSHA). 4. The Society for Protective Coatings (SSPC):

a. PA 1, Shop, Field, and Maintenance Painting b. PA 2, Measurement of Dry Coating Thickness with Magnetic

Gauges. c. PA Guide 3, A Guide to Safety in Paint Application. d. SP1, Solvent Cleaning. e. SP 2, Hand Tool Cleaning. f. SP 3, Power Tool Cleaning. g. SP 5, Joint Surface Preparation Standard, White Metal Blast

Cleaning. h. SP 7, Joint Surface Preparation Standard, Brush-Off Blast

Cleaning. i. SP 10, Joint Surface Preparation Standard, Near-White Blast

Cleaning.

1.3 DEFINITIONS

A. Terms used in this section:

1. Coverage: Total minimum dry film thickness in mils, or square feet per gallon.

2. MDFT: Minimum Dry Film Thickness. 3. MDFTPC: Minimum Dry Film Thickness Per Coat. 4. Mil: Thousandth of an inch. 5. PSDS: Paint System Data Sheet. 6. SP: Surface Preparation. 7. VOC: Volatile Organic Compounds

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1.4 SUBMITTALS

A. Shop Drawings:

1. Data Sheets: a. For each paint and/or protective coating system, furnish a Paint

System Data Sheet (PSDS), the manufacturer's Technical Data Sheets, and paint colors available (where applicable) for each product used in the paint system. The PSDS form is appended to the end of this section.

b. Submit required information on a system-by-system basis. c. Furnish copies of paint system submittals to the coating

applicator. d. Indiscriminate submittal of manufacturer's literature only is not

acceptable. 2. Detailed chemical and gradation analysis for each proposed abrasive

material.

B. Quality Control Submittals:

1. Applicator’s Experience: List of references substantiating experience. 2. If the field applied coatings differ from the epoxy sealer applied to

thermal spray aluminum coatings, provide both coating manufacturers’ written confirmation that the materials are compatible.

3. Manufacturer's written instructions and special details for applying each type of paint.

4. Submit procedures for field repair of damaged coating and field application of coatings.

5. Coating Applicator’s Quality Control Plan for bulkhead wall system coatings with letter of approval from the coating manufacturer.

6. Submit Coating Application Quality Control Test Data if requested by the Engineer.

7. Manufacturers' Certificate of Proper Installation.

1.5 QUALITY ASSURANCE

A. Qualifications:

1. Applicator: Minimum 5 years’ experience in application of specified products.

B. Regulatory Requirements:

1. Meet federal, state, and local requirements limiting the emission of volatile organic compounds.

2. Perform surface preparation and painting in accordance with recommendations of the following: a. Paint manufacturer's instructions. b. SSPC-PA Guide No. 3, Guide to Safety in Paint Applications. c. Federal, state, and local agencies having jurisdiction.

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C. Applicator’s Quality Control Program:

1. Quality control tests shall be conducted in accordance with the test equipment manufacturer’s recommended procedures with accurately calibrated test equipment.

2. Quality control test frequency shall be in accordance with the coating manufacturer’s recommended quality control program parameters and these specifications.

3. The minimum testing parameters shall include: a. Environmental conditions, including, but not limited to, date and

time, weather conditions, precipitation, ambient temperature, relative humidity, and dew point.

b. Steel temperature at time of surface preparation. c. Surface chloride tests. d. Visual observations of prepared surface. e. Anchor pattern of prepared steel using Surface Profile Comparator

Reference Disks and 10 power magnifier, Testex Press-O-Film, or approved equal.

f. Wet film coating thickness. g. Dry film coating thickness. h. Results of final coating inspection. i. Record and number of coating repairs.

4. Quality control test data shall be recorded on forms approved by the Engineer and be readily accessible to either the coating manufacturer or Engineer, if requested.

1.6 DELIVERY, STORAGE, AND HANDLING

A. Store products in a protected area that is heated or cooled to maintain temperatures within the range recommended by paint manufacturer.

B. Shipping:

1. Where precoated items are to be shipped to the site, protect coating from damage. Batten coated items to prevent abrasion.

2. Use nonmetallic or padded slings and straps in handling. 3. Items with excessive coating damage as determined by the Engineer

will be rejected.

1.7 ENVIRONMENTAL REQUIREMENTS

A. Do not apply paint in temperatures outside of manufacturer's recommended maximum or minimum allowable, or in dust, smoke-laden atmosphere, damp or humid weather.

B. Do not perform abrasive blast cleaning whenever relative humidity exceeds 85 percent, or whenever surface temperature is less than 5 degrees F above dew point of ambient air.

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PART 2 PRODUCTS

2.1 MANUFACTURERS

A. Coatings Manufacturers:

1. Ameron Protective Coatings, Brea, CA. 2. Carboline Coatings Co., St. Louis, MO. 3. ICI Devoe, Louisville, KY. 4. International Coatings, Houston, TX.

2.2 MATERIALS

A. General:

1. Product Verification: Provide letter from coating manufacturer stating that the proposed materials are compatible and suitable for the intended exposure.

2. Material Quality: Manufacturer's highest quality products and suitable for intended service.

3. Materials Including Primer and Finish Coats: Produced by same manufacturer.

4. Thinners, Cleaners, Driers, and Other Additives: As recommended by manufacturer of the particular coating.

B. Products are listed below according to their approximate order of appearance in the systems:

1. High Solids Epoxy Coating: Two-component, high-solids, low VOC, epoxy coating that will continue to cure when immersed in water; capable of 14 to 20 mils dry film thickness in one coat application; suitable for application to marine structural steel components that will be exposed to atmosphere, tidal zone, immersion and mud; International Coatings Interzone 954, or approved equal.

2.3 MIXING

A. Multiple Component Coatings:

1. Prepare using the contents of the container for each component as packaged by paint manufacturer.

2. No partial batches will be permitted. 3. Do not use multiple component coatings that have been mixed beyond

their pot life. 4. Furnish small quantity kits for touchup painting and for painting other

small areas. 5. Mix only components specified and furnished by paint manufacturer. 6. Do not intermix additional components for reasons of color or

otherwise, even within the same generic type of coating.

B. Colors: Formulate paints with colorants free of lead and lead compounds.

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PART 3 EXECUTION

3.1 GENERAL

A. All coatings on the breakwater sheet piles shall be shop applied. No field coating of the sheet piling, with the exception of coating repairs, shall be allowed.

3.2 EXAMINATION

A. Surface Preparation Verifications:

1. Inspect and provide substrate surfaces prepared in accordance with these Specifications and the printed directions and recommendations of paint manufacturer whose product is to be applied. The more stringent requirements shall apply.

2. Provide Engineer minimum 7 days' advance notice to start of shop or field surface preparation work and coating application work.

3. Perform such work only in presence of Engineer, unless Engineer grants prior approval to perform such work in Engineer’s absence.

B. Schedule inspection with Engineer in advance for cleaned surfaces and all coats prior to succeeding coat.

3.3 PREPARATION

A. Shop Blast Cleaning: Notify Engineer at least 7 days prior to start of shop blast cleaning to allow for inspection of the work during surface preparation and shop application of paints.

B. Field Abrasive Blasting: Perform blasting for items and equipment where specified and as required to restore damaged surfaces previously shop or field blasted and primed.

C. Protection of Items not to be Painted:

1. Protect all surfaces adjacent to, or downwind of Work area from overspray. Contractor shall be responsible for any damages resulting from overspray.

2. Take all necessary precautions to prevent any materials from entering the water.

3. Remove, mask, or otherwise protect hardware and other surfaces not intended to be painted.

4. Provide drop cloths to prevent paint materials from falling on or marring adjacent surfaces.

5. Protect working parts of mechanical and electrical equipment from damage during surface preparation and painting process.

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3.4 PREPARATION OF SURFACES

A. Metal Surfaces:

1. Where indicated, meet requirements of the following SSPC Specifications: a. Solvent Cleaning: SP 1. b. Hand Tool Cleaning: SP 2. c. Power Tool Cleaning: SP 3. d. White Metal Blast Cleaning: SP 5. e. Brush-Off Blast Cleaning: SP 7. f. Near-White Blast Cleaning: SP 10.

2. The words “solvent cleaning,” “hand tool cleaning,” “wire brushing,” and “blast cleaning,” or similar words of equal intent in these Specifications or in paint manufacturer's specifications refer to the applicable SSPC Specifications.

3. Where OSHA or EPA regulations preclude standard abrasive blast cleaning, wet or vacu-blast methods may be required. Coating manufacturers' recommendations for wet blast additives and first coat application shall apply.

4. Hand tool clean areas that cannot be cleaned by power tool cleaning. 5. Round or chamfer sharp edges and grind smooth burrs, jagged edges,

and surface defects. 6. Welds and Adjacent Areas:

a. Prepare such that there is: 1) No undercutting or reverse ridges on weld bead. 2) No weld spatter on or adjacent to weld or any other area to

be painted. 3) No sharp peaks or ridges along weld bead.

b. Grind embedded pieces of electrode or wire flush with adjacent surface of weld bead.

7. Preblast Cleaning Requirements: a. Remove oil, grease, welding fluxes, salts, and other surface

contaminants prior to blast cleaning. b. Test steel surfaces for chloride contamination as described in IOS

8502-6. Perform a minimum of one test per each five pilings. Surface chlorides must be below the coating manufacturer’s recommendations. Clean surfaces in accordance with the coating manufacturer’s recommendations for those surfaces that exceed the surface contamination levels specified by the coating manufacturer.

c. Cleaning Methods: Steam, open flame, hot water, or cold water with appropriate detergent additives followed with clean water rinsing.

d. Clean small isolated areas as above or solvent clean with suitable solvents and clean cloths.

8. Blast Cleaning Requirements: a. Type of Equipment and Speed of Travel: Design to obtain

specified degree of cleanliness. Minimum surface preparation is as

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specified herein and takes precedence over coating manufacturer's recommendations.

b. Select type and size of abrasive to produce a surface profile that meets coating manufacturer's recommendations for particular coating to be used.

c. Use only dry blast cleaning methods. d. Do not reuse abrasive, except for designed recyclable systems. e. Meet applicable federal, state, and local air pollution and

environmental control regulations for blast cleaning, confined space entry (if required), and disposition of spent aggregate and debris.

9. Post-Blast Cleaning and Other Cleaning Requirements: a. Clean surfaces of dust and residual particles from cleaning

operations by dry (no oil or water vapor) air blast cleaning or other method prior to painting. Vacuum clean enclosed areas and other areas where dust settling is a problem and wipe with a tack cloth.

b. Paint surfaces the same day they are blasted. Reblast surfaces that have started to rust before they are painted.

3.5 SURFACE CLEANING METHODS

A. Brushoff Blast Cleaning:

1. Equipment, procedure, and degree of cleaning shall meet requirements of SSPC-SP 7, Brushoff Blast Cleaning.

2. Abrasive: Either wet or dry blasting sand, grit, or nut shell. 3. Select various surface preparation parameters such as size and hardness

of abrasive, nozzle size, air pressure, and nozzle distance from surface such that surface is cleaned without pitting, chipping, or other damage.

4. Verify parameter selection by blast cleaning a trial area that will not be exposed to view.

5. Engineer will approve acceptable trial blast cleaned area and will use area as a representative sample of surface preparation.

6. Repair or replace surfaces damaged by blast cleaning.

B. Solvent Cleaning:

1. Consists of removal of foreign matter such as oil, grease, soil, drawing and cutting compounds, and any other surface contaminants by using solvents, emulsions, cleaning compounds, steam cleaning, or similar materials and methods which involve a solvent or cleaning action.

2. Meets requirements of SSPC-SP 1.

3.6 APPLICATION

A. General:

1. The intention of these Specifications is for new, exterior, exposed and submerged metal surfaces to be painted, as indicated on the plans.

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2. For coatings subject to immersion, obtain full cure for completed system. Consult coatings manufacturer's written instructions for these requirements. Do not immerse coating for any purpose until completion of curing cycle.

3. Apply coatings in accordance with these Specifications and the paint manufacturers' printed recommendations and special details. The more stringent requirements shall apply.

4. For Multiple Coat Systems: a. Allow sufficient time between coats to assure thorough drying of

previously applied paint. b. Alternate color to provide a visual reference that the required

number of coats have been applied. c. Vacuum clean surfaces free of loose particles. Use tack cloth just

prior to applying next coat. 5. Coat units or surfaces to be bolted together or joined closely to

structures or to one another prior to assembly or installation. 6. Keep paint materials sealed when not in use. 7. Field painting shall be by brush, roller, or spray.

B. Shop Finished Surfaces: Schedule inspection with Engineer before shop coated items delivered to site.

C. Film Thickness:

1. Number of Coats: Minimum required without regard to coating thickness. Additional coats may be required to obtain minimum required paint thickness, depending on method of application, differences in manufacturers' products, and atmospheric conditions.

2. Maximum film build per coat shall not exceed coating manufacturer's recommendations.

3. Film Thickness Measurements: a. Perform with properly calibrated instruments. b. Recoat and repair as necessary for compliance with the

Specifications. c. All coats are subject to inspection by Engineer and coating

manufacturer's representative. 4. Give particular attention to edges, angles, flanges, and other similar

areas, where insufficient film thicknesses are likely to be present, and ensure proper millage in these areas.

5. Thickness Testing: a. After repaired and recoated areas have dried sufficiently, final

tests will be conducted by the Engineer. b. Measure coating thickness specified in mils with a magnetic type

dry film thickness gauge. c. Check each coat for correct millage. Do not make measurement

before a minimum of 8 hours after application of coating.

D. Unsatisfactory Application:

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1. If item has an improper finish color, or insufficient film thickness, clean surface and topcoat with specified paint material to obtain specified color and coverage. Obtain specific surface preparation information from coating manufacturer.

2. Hand or power sand visible areas of chipped, peeled, or abraded paint, and feather the edges. Follow with repair coat.

3. Evidence of runs, bridges, shiners, laps, or other imperfections is cause for rejection.

4. Repair defects in accordance with written recommendations of coating manufacturer and these specifications.

5. Leave staging up until Engineer has inspected surface or coating. Replace staging removed prior to approval by Engineer.

3.7 FIELD QUALITY CONTROL

A. Testing Gauges: Provide a magnetic type dry film thickness gauge to test coating thickness specified in mils, as manufactured by Nordson Corp., Anaheim, CA, Mikrotest.

3.8 MANUFACTURERS’ SERVICES

A. Provide manufacturer's representative at site in accordance with Section 01640, MANUFACTURERS' SERVICES, for installation assistance, inspection, and certification of installation.

B. The paint manufacturer shall provide a technical representative to make a minimum of four person-day visits; one to observe surface preparation and application of the shop coating, one to observe surface preparation and application of the field coating, and two to verify that field repairs are made in accordance with the manufacturer’s directions and these specifications. Additional site visits may be required at other intervals during surface preparation and coating application for product application quality assurance and resolution of field problems attributed to, or associated with, manufacturer’s products furnished under this project.

3.9 CLEANUP

A. Place cloths and waste that might constitute a fire hazard in closed metal containers or destroy at the end of each day.

B. Upon completion of the Work, remove staging, scaffolding, and containers from the site or destroy in a legal manner.

C. Completely remove paint spots, oil, or stains upon adjacent surfaces and floors and leave entire job clean.

3.10 PROTECTIVE COATINGS SYSTEMS

A. Sheet and Pipe Pile Surfaces Exposed to Mud: Where indicated on plans, this system shall be used on steel sheet and pipe piling that is exposed to mud. See

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plans for vertical limits of epoxy coating. Coat both sides of sheet piling, and extend epoxy coating 1/2 to 1 inch into pile interlocks.

Surface Prep. Paint Material Min. Coats, Cover

Abrasive Blast, or Centrifugal Wheel Blast (SP-10)

High Solids Epoxy Coating

1 coat, 16 MDFT

B. Coating System Repair, Epoxy Coated Surfaces of Sheet and Pipe Piles Exposed to Mud: Use this system to repair minor epoxy coating damage (scrapes, abrasions, scratches) during shipment and handling.

Surface Prep. Paint Material Min. Coats, Cover

Manufacturer’s Recommended Primer Power Tool Clean (SP-3), Feathering Edges, and in Accordance with the Manufacturer’s Directions

High Solids Epoxy 1 coat, 16 MDFT

C. Exposed and Concrete Encased Metals with Thermal Spray Aluminum Coating: Use this system on the following surfaces:

1. Exposed metal surfaces of thermal spray aluminum coated surfaces, as indicated on the plans.

2. Thermal spray aluminum coated surfaces that are in contact with or embedded in concrete.

Surface Prep. Paint Material Min. Coats, Cover

Solvent Clean (SP-1) followed by Epoxy Manufacturer’s Recommendations

High Solids Epoxy Coating

1 coat, 16 MDFT

PART 4 MEASUREMENT AND PAYMENT

4.1 MEASUREMENT AND PAYMENT

A. The work performed, materials furnished and all labor, tools, equipment and incidentals necessary to complete the work under this Item will not be measured or paid for directly, but will be considered subsidiary to the various bid items of the contract.

(See PSDS form attached)

END OF SECTION

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PAINT SYSTEM DATA SHEET

Complete and attach manufacturer’s Technical Data Sheet to this PSDS for each coating system.

Paint System Number (from Spec.):

Paint System Title (from Spec.):

Coating Supplier:

Representative:

Surface Preparation:

Paint Material (Generic) Product Name/Number

(Proprietary) Min. Coats, Coverage

Provide manufacturer’s recommendations for the following parameters at temperature (F)/relative humidity:

Temperature/RH 50/50 70/30 90/25

Induction Time

Pot Life

Shelf Life

Drying Time

Curing Time

Min. Recoat Time

Max. Recoat Time

Provide manufacturer’s recommendations for the following:

Mixing Ratio:

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Maximum Permissible Thinning:

Ambient Temperature Limitations: min.: max.: Surface Temperature Limitations: min.: max.: Surface Profile Requirements: min.: max.:

Attach additional sheets detailing manufacturer’s recommended storage requirements and holiday testing procedures.

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SECTION 09990 NONSKID SURFACE COATING

PART 1 GENERAL

1.1 DESCRIPTION

A. This work shall consist of applying a nonskid surface treatment, and shall be used on the following:

1. The top surface of the transfer span checkered plate decking, including decking for wing assemblies.

1.2 DEFINITIONS

A. MMA: Methyl methacrylate.

1.3 SUBMITTALS

A. The Contractor shall prepare and submit the design mix for methyl methacrylate concrete, including samples of all components for each lot, and deliver to the Engineer. The Contractor shall obtain approval prior to ordering any materials for application of methyl methacrylate concrete.

B. The Contractor shall submit each of the following to the Engineer for approval:

1. The Request for Approval of Aggregate Material Source. 2. The design mix report for Methyl Methacrylate Overlay. 3. A table showing the expected cure time in minutes at the corresponding

temperatures between 40 degrees F and 90 degrees F in 10-degree increments of the concrete overlay.

4. Certification that key personnel to be used in the application of the overlay material have experience in the application of this type of material.

C. Samples of the mixed resin prior to placement excluding any aggregate shall be taken at the initial application of the overlay, and again at the midpoint and end of each application. These samples shall be placed in straight-sided plastic 8-ounce (minimum) sealed containers. The containers shall be labeled with the date, time, and location where taken.

D. The samples shall be retained and submitted for analysis. These samples shall be used to verify the final mix ratio of the MMA placed on the surface. If a laboratory analysis determines these samples vary from the approved mix ratio, then these overlay sections shall be subject to rejection.

E. The Contractor shall allow 3 weeks for approval after submitting these samples.

1.4 DELIVERY, STORAGE AND HANDLING OF MATERIALS

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A. All materials shall be delivered unopened in their original containers bearing the manufacturer’s label. This label shall specify date of manufacture, batch number, trade name brand, quantity and mixing ratio.

B. Sufficient material to perform the entire methyl methacrylate concrete overlay application shall be in storage at the site prior to field preparation.

C. The material shall be stored to prevent damage by the elements and to ensure the preservation of their quality and fitness for the work. The storage space shall be kept clean and dry and shall contain a high-low thermometer. The temperatures of the storage space shall not fall below nor rise above that recommended by the manufacturer. Every precaution shall be taken to avoid contact with the flame. The containers shall be stored in a manner that will not allow leakage or spillage from one material to contact other containers.

D. Stored materials shall be inspected prior to use, and shall meet the requirements of these Specifications at the time of use.

E. Any material that is rejected because of failure to meet the required tests or that has been damaged so as to cause rejection shall be immediately replaced by the Contractor at no additional cost to the State.

F. Each shipment of methyl methacrylate concrete resin shall be accompanied by Material Safety Data Sheets (MSDS) and a Certificate of Compliance certifying that the materials conform to the requirements of these Special Provisions.

G. Appropriate impermeable protective garments shall be used by all workers who may contact the resins to prevent skin contact. If skin contact occurs the resins shall be immediately washed off. Clothing that becomes saturated with resins shall be removed immediately.

PART 2 PRODUCTS

2.1 MATERIALS

A. Overlay material shall be methyl methacrylate (MMA) concrete resurfacing material.

B. Methyl Methacrylate (MMA) Concrete Overlay:

1. Methyl methacrylate overlay shall be composed of the following three components: a. Flexible methyl methacrylate. b. Methyl methacrylate base hardener. c. Aggregate.

2. The methyl methacrylate shall be one of the following: a. DEGADUR, manufactured by Degussa Corp. , 2 Turner Place ,

Piscataway, New Jersey 08855 , Phone; (800) 477-4545

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b. R66, manufactured by Silikal , 173 Interstate Lane , Waterbury, Connecticut 06705 , Phone: (203) 754-8373

c. Cryl-A-Flex system, manufactured by Duraflex , 95 Goodwin

Street , East Hartford, Connecticut 06108 , Phone: (800) 253-3539

C. Aggregate: Aggregate shall be from an approved pit site. The aggregate shall be 100 percent fractured, thoroughly washed, and kiln dried. The fracture requirements shall be at least one mechanically fractured face and will apply to material retained on US Sieve No. 10.

Aggregate Grading/US Sieve # % Retained

6 0 - 30

10 65 - 90

20 10 - 30

20 minus 0 - 3

PART 3 EXECUTION

3.1 CONSTRUCTION REQUIREMENTS

A. The Contractor shall arrange to have the material supplier furnish technical service relating to application of material and health and safety training for personnel who are to handle the methyl methacrylate concrete. This shall include a technical service representative on site for the first applications.

3.2 EQUIPMENT FOR SURFACE PREPARATION

A. All equipment for preparing and cleaning the surfaces and mixing and applying the overlay shall be in strict accordance with manufacturer requirements and approved by the Engineer prior to commencement of work.

B. Prior to placing the methyl methacrylate overlay, the surface shall be cleaned to remove contaminants. Surfaces shall be clean, free of dust, and dry for proper bonding of the methyl methacrylate concrete. Automatic shot blast cleaning shall be used for this purpose. The unit shall be equipped with its own dust collector and shall recycle the abrasives.

C. The unit shall be composed of a blasting unit and vacuum unit, both self-propelled. All contaminants shall be picked up and stored in the vacuum.

3.3 SURFACE PREPARATION

A. Surfaces shall be prepared by removing all material that may act as a bond breaker between the surface and the overlay. Provide a suitable grit/shot abrasive mixture that provides the manufacturer’s recommended anchor profile.

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B. Those surfaces that are not accessible for cleaning by the shot blasting unit shall be blast cleaned using conventional methods, subject to prior approval of the Engineer.

C. The Contractor shall take all necessary precautions to ensure that no dust or debris leaves the work area and that all passengers and crew are protected from rebound and dust during the blast cleaning process. All necessary precautions shall be taken to prevent any materials from entering the water.

3.4 MIXING COMPONENTS

A. The base and hardener shall be combined according to the manufacturer’s written instructions in an approved mixer, with blades that wipe the inside of the mixer clean. These components shall be mixed thoroughly and applied immediately. A slow motion mixing device shall be used to prevent air entrapment in the mix.

B. The MMA overlay shall not be proportioned by a continuous volume machine.

C. The methyl methacrylate concrete shall use the aggregate described under “Aggregate Grading No. 10” for filler adjustment as recommended by the manufacturer.

3.5 PRE-OVERLAY PREPARATION

A. The MMA overlay placement shall not begin if rain is expected within 24 hours. If the surface is wet it shall be allowed to dry for 24 hours prior to the overlay applications. The overlay shall not be placed when temperature of the surface is less than 45 degrees F or greater than 90 degrees F.

B. If in the opinion of the Engineer the surface has become soiled or contaminated prior to the application of the concrete overlay, the surface shall be cleaned again to the satisfaction of the Engineer, at no additional cost to the State.

3.6 PLACEMENT OF METHYL METHACRYLATE (MMA)

A. Immediately prior to applying the prime coat, the surface shall be swept clean by compressed air to remove accumulated dust and any other loose material. Following the cleaning operation MMA primer shall be applied to the surface. The MMA primer shall be applied using paint rollers or brooms at an application rate of 60 square feet per gallon and a sufficient rate to achieve a uniform layer of primer without puddles or dried areas. The MMA primer cure time shall be as specified by the manufacturer.

B. Apply primer the same day that the surfaces are shot blasted. The area to receive the prime coat shall be surface dry prior to applying the prime coat.

C. The prime resin shall be applied in a manner to ensure complete coverage of the areas.

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D. If the prime surface becomes contaminated, the contaminated areas shall be cleaned by abrasive blasting in accordance with the manufacturer’s directions and re-primed.

E. Apply the primer to one 12-inch by 12-inch random test area to verify that the primer dries properly before application to the full surface. If the primer does not dry properly within 30 minutes, obtain specific instructions from the MMA manufacturer and reapply a test patch to verify that corrective actions provide a cured primer.

F. After the MMA primer has cured, the MMA shall be applied using squeegees or trowels at the application rate specified by the manufacturer to obtain a 1/8-inch thickness above the metal surface.

G. Aggregate shall be broadcast on the freshly placed MMA system so that the entire surface is covered to excess and in the manner that will not create waves (wrinkles) or an uneven overlay surface. The aggregate shall be embedded by a roller or other approved method prior.

H. Prior to completion, a low viscosity sealer tie coat comprised of the same polymer that was used in the overlay shall be spray applied to the exposed aggregate. The sealer tie coat shall be applied at an application rate specified by the manufacturer.

I. The Contractor shall provide adequate dams to contain the overlay material.

J. Trowel the MMA to feather the edges of the material along the sides of the decking plate.

3.7 FINISHED OVERLAY SURFACE

A. The finished overlay surface thickness shall be 1/8-inch minimum.

3.8 REPAIR OF SURFACE DEFECTS

A. The repair method for surface defects of the overlay shall be identical to the original application of the overlay, and shall be in accordance with the MMA manufacturer’s written instructions.

3.9 CURING

A. The methyl methacrylate overlay including sealer tie coat shall be allowed to cure sufficiently before subjecting it to loads of any nature that may damage the overlay. The Contractor shall inform the Engineer of the expected cure time based upon the ambient and surface temperatures at the time of the application.

B. Actual degrees of cure and stability for loads on the actual methyl methacrylate overlay shall be determined by the manufacturer and be approved by the Engineer. The manufacturer shall determine, prior to bid, that

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its system will cure in sufficient time to satisfy the requirements for operations.

3.10 CHECKING FOR BOND

A. After the requirements for curing have been met, the entire overlaid surface shall be sounded by the Contractor, in a manner approved by and in the presence of the Engineer to ensure total bond of the methyl methacrylate concrete to the structural surfaces. Methyl methacrylate concrete in unbonded areas shall be removed and replaced with methyl methacrylate concrete by the Contractor, at no expense to the State.

PART 4 MEASUREMENT AND PAYMENT

4.1 MEASUREMENT AND PAYMENT

A. The work performed, materials furnished and all labor, tools, equipment and incidentals necessary to complete the work under this Item will not be measured or paid for directly, but will be considered subsidiary to the various bid items of the contract.

END OF SECTION

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SECTION 13000 TRANSFER SPAN SYSTEM

PART 1 GENERAL

1.1 SCOPE OF WORK

A. This work consists of removing, installing, testing and commissioning the Transfer Span Machinery Assembly and all of its associated subsystems at Galveston Slip 2 and 3 and Bolivar Slip 3. Specific tasks associated with this work include but are not limited to:

1. Transporting the completed and shop tested Transfer Span Machinery Assembly from the shop test location to the site.

2. Placing, leveling and aligning the Transfer Span Machinery Assembly onto the prepared pile cap and then securing the Assembly in place with anchor bolts and nonshrink grout.

3. Installing and testing all hydraulic and electrical interconnections that tie the Transfer Span Hydraulic Control Unit to the Transfer Span Machinery Assembly.

4. Performing and documenting the final span balance for each system. 5. Testing and commissioning the complete Transfer Span System.

1.2 SYSTEM DESCRIPTION

A. Each Transfer Span System consists of a Transfer Span Machinery Assembly and all necessary interconnecting hydraulic piping and control wiring.

B. One complete Transfer Span System is to be installed at each of the new slips (Galveston Slip 2 and 3 and Bolivar Slip 3).

1.3 SEQUENCE OF OPERATION

A. Purpose:

1. This section is provided as reference material only and is intended to aid in the understanding of the operation of the overall system. This section is for reference only and in the event that information contained herein is in conflict with the plans or other special specifications, those documents shall govern. The sequence of operation for the traffic control gate and fuel boom are also discussed in this section in order to provide a complete and consistent description of the overall systems operation. The purchase and installation of these systems are not included as a part of this Work.

B. Initial Power Up:

1. To power up the control system, the operator will proceed to the Main Operator Control Station located on the Slip Control Cabinet in the maintenance area of the transfer span. The Slip Control Cabinet houses

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the all the controls for the loading ramp, including the Main Disconnect Switch, the Programmable Logic Controller (PLC), and the HPU Main Pump Drive Motor Controller. A separate lockable enclosure, the Main Operator Control Station, is located on the door of the cabinet and contains a Message Display to aid in troubleshooting the system, buttons for raising and lowering the ramp and traffic barrier gate, and selector switches for the Main Pump, Traffic Gates and Cylinder Selection. The Main Operator Control Station is primarily a maintenance control station. The majority of operations will be conducted using the remote infrared control pendants mounted on board the ferries. On occasion it may be necessary to use the Main Operator Control Station in lieu of the remote pendant to operate the Transfer Span.

2. In order to activate (start the system), the operator turns the power On to the system by closing the Main Disconnect Switch (handle in Up position) on the Slip Control Cabinet. This disconnect is located in a lockable enclosure and is capable of being locked in the Off position with a padlock if necessary for security purposes. The Power Available light located in the Main Operator Control Station should now be On. Unlock the door to the Main Operator Control Station and set the selector switches as needed.

C. Lowering the Ramp From the Remote Pendant:

1. Assuming the ramp is in the “Park” position and the boat is properly placed in the slip and the Operator has selected the PENDANT position of the SYSTEM CONTROL selector switch. a. The Operator points the Infrared Transmitter (Remote Pendant) at

the Infrared Sensor (IR Sensor) located on the right hand (looking on shore) connecting link between the counterbalance Beam and the Loading Ramp and depresses the green ENABLE button.

b. When the transmitter to sensor infrared communication link is established a green light immediately above the sensor, known as the IR SYSTEM READY indicator, will illuminate indicating the link is secure. The operator must keep the pendant pointed at the sensor until the link is active. If the communication link is lost, it will be necessary to re-establish it prior to moving the ramp. If there are no commands issued from the pendant for one (1) minute, the IR System will be automatically disabled and the IR SYSTEM READY light will turn Off. The Operator can release the ENABLE button once the IR SYSTEM READY light is On.

c. When the Infrared Communication System (IR System) is ready, the Hydraulic Power Unit (HPU) is ready to begin lowering the ramp.

d. With the HPU ready, the operator begins the ramp motion by pressing the LOWER RAMP button on the Pendant. This will cause an audible and visual alert to turn On to warn others of the impending ramp motion and will begin lowering the ramp after a short delay. This is a two speed function when the ramp is above the FAST/SLOW LIMIT set point. (See “Fast/Slow Limit” Sensor

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and “High Speed Safety Limit” switch). The pendant must be pointed at the IR Sensor while motion commands are being issued. Losing the pendant-to-IR-Sensor communication link while actuating a pendant button will stop the motion.

e. The buttons on the pendant have two (2) positions. As they are pressed, the upper position is slow speed. When the button is pressed past the detent, the control changes to high speed. All the motion control buttons on the pendant are detented two speed, but only the RAISE RAMP and LOWER RAMP buttons are used as two speed. The others operate only as single speed.

f. Pressing the LOWER RAMP button on the pendant will cause the ramp to accelerate to the selected speed in the downward direction. Releasing the button will cause the ramp to stop as will pressing the STOP button. Note that pressing the STOP button will also disable the IR System and the IR SYSTEM READY light will turn Off.

g. A blue light located immediately above the IR SYSTEM READY light, known as the HPU/RAMP MODE indicator, will signal when the HPU is running by being on steady. This is a multi-mode signal light with the other modes described later in the text.

h. A white light, known as the COMMAND light, located immediately above the HPU/Ramp Mode Indicator, will illuminate when any of the six (6) motion buttons or the ENABLE button on the pendant are activated to give the operator some visual feedback of the control. Losing the pendant-to-IR-Sensor communication link while actuating a pendant button will stop the motion (the IR SYSTEM READY light will remain On, indicating the pendant control system is still active, but the COMMAND light will turn Off, since a command is not being received). 1) Please Note: The ramp will only lower slowly below the

HIGH SPEED SAFETY LIMIT switch set point if the boat deck is not detected by the FAST/SLOW LIMIT (long range) sensor when the ramp reached the HIGH SPEED SAFETY LIMIT set point. The boat must be in the proper position to allow fast speed lowering. Also, if the sensor has determined the boat is in the proper position, then loses contact with it when the ramp is below the HIGH SPEED SAFETY LIMIT set point, the ramp motion will stop.

i. When the ramp has lowered to the FAST/SLOW LIMIT set point, the ramp speed will be reduced to slow. All ramp movement below the fast/slow set point will be at slow speed. The Operator may stop and/or reverse motion at any time. While the ramp is above the FAST/SLOW LIMIT set point, the pendant buttons control the ramp speed, below the set point, the speed will be slow.

j. When the ramp is lowered to the deck of the boat, the FLOAT GAP sensor will detect a movement of the trunnion ball and the FAST/SLOW LIMIT (short range) sensor will verify that the ramp is resting on the deck. This will initiate the Float Mode. The operator can release the LOWER RAMP button once the

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Float Mode is established. The HPU/RAMP MODE indicator will blink slowly (2 seconds On, 2 seconds Off) while the ramp is floating. The audible and visual ramp motion warning devices will turn Off when the ramp is floating.

k. When the Float Mode is initiated, the PLC will cause the cylinders to continue to extend another 2 inches or so as controlled by the Float Gap sensor. At this point, the HPU will shut off. If the boat load and/or the up/down motion of the boat (and therefore the ramp) is severe enough, and the FLOAT GAP sensor determines the gap is not adequate to prevent the cylinder rod cap from hitting the ramp trunnion ball, it will signal the PLC. The PLC will start the HPU and extend the cylinder to the prescribed gap. If a problem is detected while the ramp is floating, the HPU/RAMP MODE indicator will blink rapidly (1 second On, ½ second Off) and the ramp may be taken out of Float by the system. If this occurs, the amber RAMP MOTION rotating beacons and the red SYSTEM ALARM rotating beacon will turn On.

D. Raising the Ramp Using the Remote Pendant:

1. Assuming the ramp is in the Float Mode and the boat is properly positioned in the slip and the Operator has selected the PENDANT position of the SYSTEM CONTROL selector switch. a. The Operator points the Infrared Transmitter (Remote Pendant) at

the Infrared Sensor (IR Sensor) located on the connecting link between the counterbalance Beam and the Loading Ramp and depresses the green ENABLE button.

b. When the transmitter-to-sensor infrared communication link is established, the IR SYSTEM READY indicator will illuminate indicating the link is secure. The operator must keep the pendant pointed at the sensor until the link is active. If the communication link is lost, it will be necessary to re-establish it prior to moving the ramp. If there are no commands issued from the pendant for one (1) minute, the IR System will be automatically disabled and the IR SYSTEM READY light will turn Off. The Operator can release the ENABLE button once the IR SYSTEM READY light is On.

c. The buttons on the pendant have two (2) positions. As they are pressed, the upper position is slow speed. When the button is pressed past the detent, the control changes to high speed. All the motion control buttons on the pendant are detented two speed, but only the RAISE RAMP and LOWER RAMP buttons are used as two speed. The others operate only as single speed.

d. Pressing the RAISE RAMP button on the pendant will cause the ramp to accelerate to the selected speed in the upward direction. Releasing the button will cause the ramp to stop as will pressing the STOP button. Note that pressing the STOP button will also disable the IR System and the IR SYSTEM READY light will turn Off.

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e. When the Infrared Communication System (IR System) is ready, the Hydraulic Power Unit (HPU) is ready to begin raising the ramp.

f. With the HPU ready, the operator can raise the Ramp by pressing the RAISE RAMP button on the Pendant. This is a single speed function when the ramp is below the FAST/SLOW LIMIT set point and a two speed function when the ramp is above the FAST/SLOW LIMIT set point. (See Fast/Slow Limit sensor). The pendant must be pointed at the IR Sensor while motion commands are being issued. Losing the pendant-to-IR-Sensor communication link while actuating a pendant button will stop the motion (the IR SYSTEM READY light will remain On, indicating the pendant control system is still active, but the COMMAND light will turn Off, since a command is not being received.

g. When the ramp has risen to the FAST/SLOW LIMIT set point or the HIGH SPEED SAFETY LIMIT, the ramp speed will increase to high speed automatically and continue to the Park position. The Operator may release the RAISE RAMP button and the ramp will continue upward. Actuating the LOWER button once, or the STOP button (assuming the pendant is pointed at the IR Sensor), will stop the ramp motion. If the ramp motion is stopped during its automatic upward travel from the Float Mode, the Operator will have to manually control the ramp motion with the pendant until the ramp is either parked or floating. When the ramp is no longer in the Float Mode, the HPU/RAMP MODE indicator will turn to steady On, indicating the ramp is not floating.

h. When the ramp reaches the Park position, the HPU will automatically shut off, causing the ramp to stop, and the HPU/RAMP MODE light to turn Off. The audible and visual ramp motion warning devices will turn Off, and the pendant-to-sensor communication link will be disconnected after one minute of non-use and the IR SYSTEM READY indicator will turn Off.

E. Operating the Traffic Gates From the Remote Pendant:

1. The following description assumes that the Operator has selected the PENDANT position of the SYSTEM CONTROL selector switch, and that he/she has established the IR System communication link. a. To OPEN (raise) the traffic gate, the Operator points the Infrared

Transmitter (Remote Pendant) at the Infrared Sensor (IR Sensor) and actuates the OPEN GATE button which will signal the PLC to turn on the gate motion warning audible and visual alerts, and after ten (10) seconds start raising the traffic gate arm, thereby opening the lane to vehicle traffic. This is an automatic function - releasing the button or moving the transmitter so that it points away from the IR Sensor will not stop the motion. To stop the motion, press the CLOSE GATE button once, or the STOP button.

b. To CLOSE (lower) the traffic gates, the Operator points the Infrared Transmitter (Remote Pendant) at the Infrared Sensor (IR Sensor) and actuates the CLOSE GATE button which will signal

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the PLC to turn On the gate motion warning audible and visual alerts, and after ten (10) seconds start lowering the traffic gate arm, thereby closing the lane to vehicle traffic. This is an automatic function - releasing the button or moving the transmitter so that it points away from the IR Sensor will not stop the motion. To stop the motion, press the OPEN GATE button once, or the STOP button.

F. Operating the Utility Hose Boom Using the Remote Pendant:

1. The following description assumes that the Operator has selected the PENDANT position of the SYSTEM CONTROL selector switch, and that he/she has established the IR System communication link. a. To Raise the Utility Hose Boom, the Operator points the Infrared

Transmitter (Remote Pendant) at the Infrared Sensor (IR Sensor) and actuates the RAISE BOOM button while simultaneously pressing the ENABLE button which will signal the PLC to raise the Utility Hose Boom. Releasing either button or moving the transmitter so that it points away from the IR Sensor will stop the motion.

b. To Lower the Utility Hose Boom, the Operator points the Infrared Transmitter (Remote Pendant) at the Infrared Sensor (IR Sensor) and actuates the LOWER BOOM button while simultaneously pressing the ENABLE button which will signal the PLC to lower the Utility Hose Boom. Releasing either button or moving the transmitter so that it points away from the IR Sensor will stop the motion.

G. Lowering the Ramp From the Main Operator Control Station:

1. Assuming the ramp is in the Park position and the boat is properly placed in the slip and the Operator has selected the LOCAL position of the SYSTEM CONTROL selector switch. a. The FLOAT/PARK MODE light will be On indicating that the

Ramp is in the Park position. The Operator first actuates the LOWER RAMP push button which will signal the PLC to start the HPU. The HPU will start and continue to run until the ramp has engaged Float Mode, has reached the end of travel or has been manually stopped by the operator. When the HPU starts an audible and visual alert will turn On to warn others of the impending ramp motion.

b. The operator can lower the Ramp by pressing the LOWER RAMP button. Pressing the LOWER RAMP button will cause the ramp to accelerate to a pre-selected speed in the downward direction. Releasing the button will cause the ramp to stop. 1) Please Note: The ramp will lower at high speed until the

HIGH SPEED SAFETY LIMIT set point is reached, and then continue lowering at slow speed if the boat deck is not detected by the FAST/SLOW LIMIT (long range) sensor. The boat must be in the proper position for the ramp to

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lower at the high rate of speed. Also if the sensor loses contact with the boat while the ramp is below the HIGH SPEED SAFETY LIMIT set point, the ramp motion will return to slow speed.

c. When the ramp has lowered to the FAST/SLOW LIMIT set point, the ramp speed will be reduced to slow. All ramp movement below the FAST/SLOW LIMIT set point will be at slow speed. The Operator may stop and/or reverse motion at any time. While the ramp is above the FAST/SLOW LIMIT set point (and the sensor has detected the boat deck), the ramp speed will be high, below the set point, the speed will be slow.

d. When the ramp is lowered to the deck of the boat, the FLOAT GAP sensor will detect a motion of the trunnion ball, and the FAST/SLOW LIMIT (short range) sensor will verify that the ramp is resting on the deck. This will initiate the Float Mode. The FLOAT/PARK MODE light will blink slowly (2 seconds On, 2 seconds Off). The operator can release the LOWER RAMP button” once the Float Mode is established. The HPU/RAMP MODE indicator will blink slowly (2 seconds On, 2 seconds Off) while the ramp is floating. The audible and visual ramp motion warning devices will turn Off when the ramp is floating

e. When the Float Mode is initiated the PLC will cause the cylinders to continue to extend roughly another 2 inches as controlled by the FLOAT GAP sensor. If the boat load and/or the up/down motion of the boat (and therefore the ramp) is severe enough, and the FLOAT GAP sensor determines the gap is not adequate to prevent the cylinder rod cap from hitting the trunnion ball, it will signal the PLC. The PLC will start the HPU and extend the cylinder to the prescribed gap.

H. Raising the Ramp From the Main Operator Control Station:

1. Assuming the ramp is in the “Float Mode” and the boat is properly positioned in the slip and the Operator has selected the LOCAL position of the SYSTEM CONTROL selector switch. a. The FLOAT/PARK MODE light will be On blinking slowly,

indicating that the Ramp is in the Float Mode. The Operator first actuates the RAISE RAMP push button which will signal the PLC to start the HPU. Before the HPU starts an audible and visual alert will turn On to warn others of the impending ramp motion.

b. The operator can raise the Ramp by pressing the RAISE RAMP button. The ramp will initially rise at a slow speed.

c. When the ramp has risen to the FAST/SLOW LIMIT set point, the ramp speed will increase to high speed automatically and continue to the Park position. The Operator may release the RAISE RAMP button and the ramp will continue upward. Actuating the Lower button once will stop the upward motion. If the ramp motion is stopped during its automatic upward travel from the Float Mode, the Operator will have to manually control the ramp motion with the RAISE and LOWER buttons until the ramp is either parked or

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floating. When the ramp is no longer in the Float Mode, the HPU/RAMP MODE indicator will turn to steady On, indicating the HPU is running and the ramp is not floating. The FLOAT/PARK MODE light will turn Off.

d. When the ramp reaches the Park position, it will automatically stop, the audible and visual ramp motion warning devices will turn Off, and the HPU/RAMP MODE indicator will turn Off indicating the ramp is in the Park position. The FLOAT/PARK MODE light will turn steady On indicating the ramp is in the Park position..

I. Operating the Traffic Gates From the Main Operator Control Station:

1. Assuming the Operator has selected the LOCAL position of the SYSTEM CONTROL selector switch. a. To Open (raise) the traffic gate, the Operator actuates the OPEN

GATE button which will signal the PLC to turn the gate motion warning audible and visual alerts On, and after ten (10) seconds start raising the traffic gate arm, thereby opening the lane to vehicle traffic. This is an automatic function - releasing the button will not stop the motion. To stop the motion, press the CLOSE GATE button once.

b. To Close (lower) the traffic gates, the Operator actuates the CLOSE GATE button which will signal the PLC to turn the gate motion warning audible and visual alerts On, and after ten (10) seconds start lowering the traffic gate arm, thereby closing the lane to vehicle traffic. This is an automatic function - releasing the button will not stop the motion. To stop the motion, press the OPEN GATE button once.

J. Operating the Utility Hose Boom From the Utility Boom Controller:

1. Assuming the Operator has selected the LOCAL position of the HOSE BOOM selector switch at the Hose Boom Controller. a. To raise the Utility Hose Boom, the Operator actuates the RAISE

BOOM button on the Utility Hose Boom Controller which will signal to raise the Utility Hose Boom. Releasing the button will stop the motion.

b. To lower the Utility Hose Boom, the Operator actuates the LOWER BOOM button on the Utility Hose Boom Controller which will signal to lower the Utility Hose Boom. Releasing the button will stop the motion.

K. Operating the Traffic Gates From the Traffic Gate Controller:

1. The Operator must first open the Traffic Gate Controller door, which is an integral part of the traffic gate pedestal. The internal selector switch has three (3) positions: a. AUTO: This is the normal position for this switch. The AUTO

position allows control of the gates from remote locations.

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b. CLOSE: Placing and holding the switch in the CLOSE position will cause the traffic gate arm to lower, thereby closing the lane to traffic. Turning the switch to AUTO will stop the motion.

c. OPEN: Placing and holding the switch in the OPEN position will cause the traffic gate arm to rise, thereby opening the lane to traffic. Turning the switch to AUTO will stop the motion.

L. System Operating Modes:

1. Local Mode: The Local Mode allows control of the ramp from the Main Operator Control Station. The control system is in the Local Mode when the SYSTEM CONTROL LOCAL-OFF-PENDANT selector switch is in the LOCAL position.

2. Remote Pendant Mode: The Remote Pendant Mode allows control of the ramp from the Infrared Transmitter (Remote Pendant). The control system is in the Remote Pendant Mode when the SYSTEM CONTROL LOCAL-OFF-PENDANT selector switch is in the PENDANT position.

3. Float Mode: The Float Mode is enabled when the two (2) FAST/SLOW LIMIT Sensors recognize the boat deck is within a specific distance from the ramp and the hydraulic system simultaneously sees an increase in the FLOAT GAP sensor and the operator is actively lowering the ramp. When the ramp has made deck contact, the cylinders will continue to extend the prescribed distance as determined by the FLOAT GAP sensor. a. The Float Mode is disabled when the operator raises the ramp OR

the short range FAST/SLOW LIMIT Sensor loses contact with the boat deck (indicating the boat has moved out from the docking position). If this latter scenario occurs, the HPU will raise the ramp, causing the cylinder to retract to zero (0) clearance with the cylinder trunnion ball and stop, thereby holding the ramp in position. If the ramp is moved upward by the action of the boat, the cylinder will retract accordingly, holding the ramp in its last position. This will continue until the Operator again resumes control of the ramp.

4. Automatic Park Mode: The Auto Park Mode is achieved when the operator raises the ramp from the boat deck, disabling the Float Mode. When the ramp crosses the FAST/SLOW LIMIT set point going up, the PLC will cause the ramp to go to fast speed, continue to the Park position, and stop automatically. When the ramp reaches the Park position, the HPU will automatically shut down. The Operator may stop or reverse the ramp direction at any time.

5. Park Position: The Park Position is a location in the ramp’s travel close to the physical upper travel limit. When the PARK LIMIT switch is actuated, its signal will cause the PLC to stop ramp motion and shutoff the ramp motion warning devices. This is the normal position of the ramp while the boat is not in the slip or when restricting access to the boat.

6. Bypass Mode: The Bypass Mode is utilized by the operator actuating the BYPASS button and the RAISE RAMP or LOWER RAMP button simultaneously on the Main Operator Control Station when the ramp

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has actuated either the PARK LIMIT switch or the LOWER LIMIT switch. This will cause the ramp to raise or lower past the limit switch at a very slow speed until the physical end of travel is reached. When the ramp is positioned above the PARK LIMIT switch or below the LOWER LIMIT switch, the BYPASS button must be used to move the ramp into the normal operating range.

7. Single Cylinder Mode: The Single Cylinder Mode is to be utilized when it is necessary to move the ramp and one of the two hydraulic actuating cylinders is out of service or disabled. It allows operation of the ramp using one hydraulic cylinder. This mode is enabled by selection the SINGLE position of the RAMP CYLINDER SINGLE-NORMAL selector switch in the Main Operator Control Station when the SYSTEM CONTROL selector switch is in the LOCAL position and the HPU is not running. It is necessary to make some mechanical adjustments if this situation arises. This switch should remain in the NORMAL position during everyday operating conditions.

M. Operator Control Devices in the Main Operator Control Station:

1. The following is a brief description of the functions of the various operator control devices, limit switches, and sensors. There are 11 devices for controlling the Loading System functions in the Main Operator Control Station. They are: a. POWER ON: This indicator light is illuminated when the Control

System power is available. b. SYSTEM CONTROL, LOCAL-OFF-PENDANT: This selector

switch allows the Operator to choose the active control station for ramp and gate operation or prevent its operation. In the LOCAL position, the devices in the Main Operator Control Station are active, the pendant devices are not. In the PENDANT position, only the remote pendants on the boats and this selector switch in the Main Operator Control Station are active. All the Loading Ramp and Traffic Gate controls in the Main Operator Control Station will be disabled. In the OFF position, all system controls except this selector switch and the MAIN PUMP selector switches are non-functioning.

c. RAISE RAMP: Actuating this push-button causes the ramp to raise when the SYSTEM CONTROL is in the LOCAL position. The ramp will move upward in the Slow Speed mode if the ramp is below the FAST/SLOW LIMIT set point and in the High Speed mode if the ramp is above the FAST/SLOW LIMIT set point and has just left the Float Mode, otherwise the ramp will move upward at slow speed.

d. LOWER RAMP: Actuating this push-button causes the Ramp to lower when the SYSTEM CONTROL is in the LOCAL position. The ramp will move downward at high speed until it reaches the HIGH SPEED SAFETY LIMIT set point, and then will continue lowering at high speed if the FAST/SLOW LIMIT sensor detects the boat deck. The ramp will lower at slow speed if the boat deck

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is not detected by the FAST/SLOW LIMIT sensor or when it is below the FAST/SLOW LIMIT set point.

e. RAMP CYLINDER, SINGLE-NORMAL: This selector switch allows operation on one hydraulic cylinder in the event of a cylinder failure. It is active only in the LOCAL position. It is necessary to make some mechanical adjustments if this situation arises. This switch should remain in the NORMAL position during everyday operating conditions. The mode will not change if the switch is operated while the HPU is running. The mode change becomes effective when the HPU is restarted after being turned Off.

f. MAIN PUMP, RUN-OFF-AUTO: This selector switch allows the Operator to start and run the main hydraulic pump on a continuous basis for maintenance purposes when in the RUN position. The OFF position prevents the main pump from starting or running. The normal position for this switch is in AUTO, which allows the PLC to control the pump, monitor safety circuits, and respond to system requirements automatically. Selecting the RUN position causes the main pump to run continuously and also disables the remote pendant, making only the local controls active.

g. SYSTEM CONTROL BYPASS: This push-button can only be utilized when the SYSTEM CONTROL selector switch is in the LOCAL position. Its purpose is to allow the Operator to bypass the ramp upper travel limit (PARK LIMIT switch) for maintenance or storm protection purposes, and to bypass the ramp down travel limit (LOWER LIMIT switch) for maintenance purposes. The ramp must be actuating the applicable limit switch, and then the Operator must actuate the RAISE RAMP or LOWER RAMP while concurrently depressing the BYPASS button in order for the ramp to travel beyond the limits. Ramp movement between the limit switches and the physical end of travel will be at a very slow speed. If the ramp is set on the boat deck and the LOWER RAMP and BYPASS buttons are actuated concurrently the hydraulic cylinders will continue to extend to their physical end of travel.

h. FLOAT/PARK MODE: This indicator is On steadily when the ramp is in the Park position, and blinking slowly (2 seconds On, 2 seconds Off) when the Ramp is in the Float Mode. It will blink rapidly (1 second On, ½ second Off) if the ramp is taken out of float due to the Fast/Slow Limit sensor losing contact with the boat deck.

i. OPEN TRAFFIC GATE: Actuating this push-button when the SYSTEM CONTROL is in the LOCAL position causes the traffic gate arm to raise, thereby opening the lane to vehicle traffic. The Operator may release the button after the gate motion audible and visual warnings turn On. Once the command is given, the motion warning will run for (10) seconds, then the gate will open. The motion warning will continue until the gate stops in the Open position. To stop the gate or cancel the command, the Operator will have to actuate the Close Traffic Gate button once. If the

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automatic gate operation is interrupted, the Operator will have to manually Open or Close the gate using the Open Traffic Gate or Close Traffic Gate buttons in the Main Operator Control Station.

j. CLOSE TRAFFIC GATE: Actuating this push-button when the SYSTEM CONTROL is in the LOCAL position causes the traffic gate arm to lower, thereby closing the lane to vehicle traffic. The Operator may release the button after the gate motion audible and visual warnings turn On. Once the command is given, the motion warning will run for (10) seconds, then the gate will close. The motion warning will continue until the gate stops in the Closed position. To stop the gate or cancel the command, the Operator will have to actuate the Open Traffic Gate button once. If the automatic gate operation is interrupted, the Operator will have to manually Open or Close the gate using the Open Traffic Gate or Close Traffic Gate buttons in the Main Operator Control Station.

N. Operator Control Devices – Remote Pendant:

1. The following is a brief description of the functions of the various operator control devices, limit switches, and sensors. There are (8) devices for controlling the Loading Ramp, Traffic Gates, and Utility Hose Boom in the Remote Pendant. They are: a. ENABLE: When the Infrared Transmitter (Remote Pendant) is

within range (less than 60’) and pointed at the IR Sensor, and the ENABLE button is actuated, the IR transmitter-receiver system is enabled and is ready to receive other commands from the transmitter. The system will remain enabled for one (1) minute after the last command is sent from the transmitter or until the STOP button is actuated, whichever occurs first. 1) The ENABLE is also used as a safety interlock for the

Utility Hose Boom functions. When the IR transmitter-receiver system is already enabled, pointing the transmitter at the IR Sensor and actuating the ENABLE button will allow the receiver to accept simultaneous commands regarding the Utility Hose Boom.

b. STOP: When the IR transmitter-receiver system is enabled, pointing the transmitter at the IR Sensor and actuating the STOP button will shut off the enable circuit and all devices in motion will stop. This button functions similarly to an “Emergency Stop” button except the transmitter must be pointed at the IR Receiver for it to operate.

c. RAISE RAMP: When the IR transmitter-receiver system is enabled, pointing the transmitter at the IR Sensor and actuating the RAISE RAMP button will signal the PLC to raise the ramp. Releasing the button or moving the transmitter so that it points away from the IR Sensor will stop the motion unless the ramp is in the Automatic Park Mode.

d. LOWER RAMP: When the IR transmitter-receiver system is enabled, pointing the transmitter at the IR Sensor and actuating the LOWER RAMP button will signal the PLC to lower the ramp.

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Releasing the button or moving the transmitter so that it points away from the IR Sensor will stop the motion. If the ramp is in the Automatic Park Mode, actuating the Lower button once will stop the upward motion of the ramp.

e. OPEN GATE: When the IR transmitter-receiver system is enabled, pointing the transmitter at the IR Sensor and actuating the OPEN GATE button will signal the PLC to turn On the gate motion warning audible and visual alerts, and after ten (10) seconds, start raising the traffic gate arm, thereby opening the lane to vehicle traffic. This is an automatic function - releasing the button or moving the transmitter so that it points away from the IR Sensor will not stop the motion. To stop the motion, press the CLOSE GATE button once.

f. CLOSE GATE: When the IR transmitter-receiver system is enabled, pointing the transmitter at the IR Sensor and actuating the CLOSE GATE button will signal the PLC to turn On the gate motion warning audible and visual alerts, and after ten (10) seconds, start lowering the traffic gate arm, thereby closing the lane to vehicle traffic. This is an automatic function - releasing the button or moving the transmitter so that it points away from the IR Sensor will not stop the motion. To stop the motion, press the OPEN GATE button once.

g. RAISE BOOM: When the IR transmitter-receiver system is enabled, pointing the transmitter at the IR Sensor and actuating the RAISE BOOM button while simultaneously pressing the ENABLE button will signal the PLC to raise the Utility Hose Boom. Releasing either button or moving the transmitter so that it points away from the IR Sensor will stop the motion.

h. LOWER BOOM: When the IR transmitter-receiver system is enabled, pointing the transmitter at the IR Sensor and actuating the LOWER BOOM button while simultaneously pressing the ENABLE button will signal the PLC to lower the Utility Hose Boom Releasing either button or moving the transmitter so that it points away from the IR Sensor will stop the motion.

O. Limit Switches/Sensor:

1. The following is a brief description of the functions of the various limit switches and sensors used to monitor and control the system. a. Park Limit: The Park Limit (proximity) switch set point is the

normal stopping point for the loading ramp while going upward. It is possible to proceed past (above) this point by using manual override (BYPASS button) while in the Local Mode. Ramp travel beyond this set point is done at a very slow speed. There is no limit switch at the Full Up position.

b. Lower Limit: The Lower Limit (proximity) switch set point is the lowest operable position allowed for the ramp (not the cylinder which may extend further when the Float mode is active). It is possible to proceed past (below) this point by using manual override (BYPASS button) while in the Local Mode. Ramp travel

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beyond this set point is done at a very slow speed. There is no limit switch at the Full Down position.

c. Float Gap Sensor: The Float Gap (ultrasonic) Sensor maintains a specific gap between the end of the cylinder rod cap and the trunnion ball. The gap is reduced when the ramp is operating at the LOWER LIMIT position. If the ramp is in the Float Mode and the short range FAST/SLOW LIMIT sensor loses contact with the boat deck, the measured gap will close to zero (0) and remain there. If the ramp moves upward when forced by the action of the boat, the FLOAT GAP sensor signals the PLC that the gap has increased, and the PLC causes the HPU to retract the cylinders, closing the gap to zero (0).

d. High Speed Safety Limit Switch: The High Speed Safety Limit switch set point is the lowest point that the ramp may lower at high speed if the deck of the boat is not detected by the FAST/SLOW LIMIT sensor. Its purpose is to prevent the ramp from colliding with the boat deck at high speed and to prevent the ramp from being lowered via the remote pendant when the boat deck is not detected by the FAST/SLOW LIMIT sensor.

e. Fast/Slow Limit Sensor (Long Range): The long range Fast/Slow Limit (ultrasonic) sensor is located under the tip of the ramp. Its purpose is to detect the boat deck when it is in position for the ramp to be lowered to a specific height above the deck. It has a range of about 8 meters. If this sensor does not detect the boat deck, it will signal the PLC to allow only slow speed lowering. This device is active only below the HIGH SPEED SAFETY LIMIT switch set point and also acts as a redundant safety for the short range FAST/SLOW LIMIT sensor.

f. Fast/Slow Limit Sensor (Short Range): The short range Fast/Slow Limit (ultrasonic) sensor is located under the tip of the ramp. Its purpose is to detect the boat deck when it is close to and below the FAST/SLOW LIMIT set point and has a range of about 1 meter. When the sensor determines the boat deck is at the Fast/Slow Limit set point, it signals the PLC to reduce the ramp speed to slow. This sensor also confirms deck contact when indicated by the Float Gap Sensor showing motion at the trunnion ball. This device also acts as a redundant safety for the long range FAST/SLOW LIMIT sensor.

g. System Pressure Sensor: The System Pressure (transducer) sensor allows the PLC to monitor the hydraulic pressure generated by the Main Hydraulic Pump for use in controlling the actions of the loading ramp. It is located on the HPU. The PLC uses the signals produced by this device to determine, among other things, the allowable operating pressures during the Normal and Single Cylinder operation.

h. Reservoir Level Sensor: The Reservoir Level (ultrasonic) sensor allows the PLC to monitor the hydraulic oil level in the oil reservoir and to use this data to determine if there is adequate oil in the tank to continue operation.

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P. Alert/Warning Signals:

1. Ramp Motion Audible and Visual Warning: There are two (2) rotating beacons located on the underside of the counterweight beams, one on each beam. These lights are arranged to prevent being directly viewed by anyone in the boat pilot house, but are exposed (or have their light reflected) to the boat deck. There is also an audible warning device located on the “A” frame across from the System Control Cabinet. These warning devices turn On when the HPU starts in its automatic mode and the ramp is in the Park position and continue to operate until the ramp is either in the Float Mode or the HPU has shut off, whichever occurs first. They also turn on when the HPU starts in its automatic mode and the ramp is in the Float Mode and continue to operate until the ramp is in the Park position. This device has a multi-tone horn and a different audible signal will sound if the ramp is taken out of the float mode by the control system.

2. Traffic Gate Motion Audible and Visual Warning: There are a series of red lights placed on top of the traffic gate arm and an audible warning device located on the traffic gate pedestal. These warning devices turn on ten (10) seconds before the traffic gate starts to move and turn off when the gate motion has stopped.

3. IR SYSTEM READY Indicator: This green signal light is located adjacent to the IR Sensor on the left hand (looking offshore) connecting link between the counterbalance beam and the ramp. Its purpose is to signal the Operator on the boat that the Infrared Transmitter (Remote Pendant) to Infrared Receiver communication link is enabled and the system is ready to receive commands from the pendant.

4. HPU/RAMP MODE Indicator: This blue signal light is located adjacent to the IR Sensor on the left hand (looking offshore) connecting link between the counterbalance beam and the ramp. Its purpose is to signal the Operator on the boat of three (3) operational conditions by varying signals. They are: a. On Steady: Indicates that the HPU is running and the ramp is out

of the Float Mode. b. Slow Blink (2 seconds On, 1 second Off): Indicates the Ramp is

in the Float Mode. c. Normal Blink (1 second On, 1 second Off): Indicates that the

ramp is in the Float Mode and the HPU is not running. d. Rapid Blink (1 second On, ½ second Off): Indicates that Ramp

was in the Float Mode and has been taken out by the control system. This signal will remain On until the Operator intervenes and is accompanied by an audible warning.

5. COMMAND Indicator: This white signal light is located adjacent to the IR Sensor on the left hand (looking offshore) connecting link between the counterbalance beam and the ramp. Its purpose is to signal the Operator on the boat deck that a pendant command signal has been received. Its purpose is to provide system feedback to the Operator of the remote pendant.

6. Alarm Indicator: This light is a red rotating beacon located on the Hydraulic power unit cabinet adjacent to the System Control Cabinet.

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Its purpose is to alert the Operator and/or maintenance personnel that the self checking logic in the PLC has detected a fault condition somewhere in the System Controls. Pressing the “F1” key on the Message Display will acknowledge the most recent alarm and turn the light Off. If there are multiple alarms, the Operator must scroll through them using the “Prev” and “Next” buttons on the Message Display, acknowledging each individual alarm with the “F1” key until the light turns Off.

7. Message Display: An interactive device that displays alert and alarm messages and that can be used to display operating system settings and parameters. The message display is located on the front cover of the System Control Cabinet in the lockable Main Operator Control Station.

1.4 SUBMITTALS

A. Before delivering materials, setting equipment or performing any testing/commissioning of the system, the Contractor shall submit to the Engineer six (6) copies of the following for review and approval:

1. Mill Certifications and test reports for all raw materials. 2. Transfer Span Installation, Alignment and Fit Check Plan as required by

this specification. 3. Final Span Balancing Plan as required by this specification. 4. Field Installed Hydraulic Piping Cleaning and Flushing Plan as required

by these specifications and the plans. 5. System functional testing plan as required by this specification. 6. Commissioning Plan as required by these specifications. 7. Shop drawings of the field installed high pressure hydraulic piping,

including location of all valves, flanges, pipe supports, and pipe lengths. 8. Welding submittals for field installed hydraulic piping, which shall

include: a. All weld processes, including pre-qualified and Contractor-

proposed welding procedure specifications (including weld rod data).

b. Detailed welding drawings including proposed inspection plans and repair procedures.

c. Welder qualifications and certifications. d. Qualifications and certification of the AWS Certified Welding

Inspector who shall witness all welding of the Diesel Fuel line. e. Welding inspection/testing results to the Engineer for approval.

9. Shop drawings of the field installed interconnecting wiring and conduits, including the location and size off all junction boxes, conduits, conduit supports and conduit lengths.

B. Prior to inspection and acceptance as described below, the Contractor shall submit to the Engineer four (4) complete copies of the following documents for review and approval:

1. As-built drawings. 2. Operation and Maintenance Manuals.

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C. The drawings and submittals shall be submitted on suitable size sheets that are completely clear and legible.

D. The Contractor shall be responsible for the completeness of the drawings and other information. The Contractor shall clearly indicate any deviations from the plans on the submittals.

E. The review and approval of drawings and other information shall conform with the design concept and shall be understood to be an acceptance of the character and sufficiency of the details and not a check of detailed dimensions or other key data.

1.5 QUALITY ASSURANCE

A. The Contractor shall provide a manufacturer’s certificate of quality that the actual valves, supports, flanges and pipe material etc supplied conforms to the test reports, supplemental test documentation and certifications that were submitted.

B. The Owner Certified Welding Inspector shall perform Quality Assurance inspections of the Contractor’s welding.

1.6 COORDINATION

A. The Contractor shall coordinate the submittal of drawings and other information in a timely manner to allow sufficient time for review and approval by the Engineer (21 calendar days) and time for fabrication and delivery of the material so as to not delay completion of the construction within the established schedule for completion of the project.

B. The Engineer shall have ten (10) working days to review and comment on all submittals.

PART 2 PRODUCTS

2.1 GENERAL

A. All materials shall generally be provided as specified on the plans.

B. Wherever a material, article, device product or fixture is identified by a manufacturers name, or by a manufacturers name and either partial or complete catalog part number, such specification shall be deemed to be used for the purposes of facilitating a description of the material or process desired, establishing a standard of quality, and stating a preference for a specific manufacturer. This procedure is not to be construed as eliminating from competition other products of equal or better quality by the same or other manufacturers where such products are fully suitable in the design, functionality and physical interchangeability, and shall be followed by the words “or approved equal”. The decision as to equality shall be made solely by the Engineer.

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C. Wherever a material, article, device product or fixture is identified by a generic term or trade name, such specification shall be deemed to be used for the purposes of describing the device or process desired, not establishing a standard of quality or stating a preference for a specific manufacturer, and shall be understood to be followed by the words “or equal”.

2.2 FIELD INSTALLED HYDRAULIC PIPE AND HOSES

A. Field installed, high pressure hydraulic piping and tubing shall generally be fabricated, installed and supported per the plans.

B. All raw materials, valves, tube and pipe supports and other components shall be supplied as described in the plans.

C. Unless otherwise noted, the Contractor may propose the use of equivalent materials or components in place of those indicated on the plans per Article 2.1 above.

D. If alternate materials or components are proposed, the Contractor shall take full responsibility for coordination of any revisions required to any other portion of the transfer span system or its subcomponents required to accommodate the proposed substitutions. Any required design revisions shall be identified and a design solution shall be identified in writing and shall be submitted along with the shop drawings for the proposed substitution.

2.3 FIELD INSTALLED ELECTRICAL WIRING, CONDUIT AND JUNCTION BOXES

A. Field installed, interconnecting wiring and conduits shall generally be fabricated, installed and supported per the plans.

B. All raw materials, wires, cables conduit, junction boxes and other components shall be supplied as described in the plans.

C. Unless otherwise noted, the Contractor may propose the use of equivalent materials or components in place of those indicated on the plans per Article 2.1 above.

D. If alternate materials or components are proposed, the Contractor shall take full responsibility for coordination of any revisions required to any other portion of the transfer span system or its subcomponents required to accommodate the proposed substitutions. Any required design revisions shall be identified and a design solution shall be identified in writing and shall be submitted along with the shop drawings for the proposed substitution.

PART 3 EXECUTION

3.1 GENERAL

A. All equipment, interconnecting high pressure hydraulic piping/tubing, and wiring shall be installed and connected per the plans.

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B. The location of major equipment such as the Transfer Span Machinery Assembly and the Hydraulic Control Unit is critical and should not be modified with out the express authorization of the Engineer.

C. The location of flanged connections on the high pressure hydraulic pipe/tubing and the location of junction boxes for the interconnecting electrical wiring are critical both for construction of the system and for future maintenance of the facility. The Contractor shall not significantly modify the location of these items.

D. The routing and support of high pressure hydraulic piping/tubing and electrical conduits is provided to illustrate the quality and workmanship that is required by the Engineer. The Contractor’s installation may deviate from the “as designed” routing and support configurations shown on the plans as long as the proposed installation is of comparable quality and workmanship and provides equivalent or better accessibility for ongoing maintenance and repairs.

3.2 INSTALLATION, ALIGNMENT AND FIT CHECK OF THE TRANSFER SPAN MACHINERY ASSEMBLY

A. Correct installation and alignment of the Transfer Span Machinery Assembly is absolutely critical to the operation of this system.

B. The Transfer Span Machinery Assembly shall be installed, aligned and fit checked against the ferries in accordance with the plans.

C. The Contractor shall prepare a detailed Transfer Span Installation, Alignment and Fit Check Plan as required by this specification.

D. This plan shall as a minimum identify:

1. The procedure for transporting the Transfer Span Machinery Assembly to the site for installation.

2. The equipment and methods that will be used to set the Assembly onto the prepared pile cap and to adjust the alignment of this system to fit the installed wing walls and fixed trestle.

3. The methodology and equipment that will be used to measure the span alignment relative to the Wing Walls.

4. The methodology and equipment that will be employed to complete a fit-check of the installed and aligned Transfer Span Machinery Assembly as described in the documents.

5. The acceptance criteria for the alignment and fit check as described in the plans along with a box for recording the actual field data observed.

6. Signature boxes beside each acceptance criteria to accept the initials of the individual supervising the installation/check and the installation/check witness.

E. The Engineer shall witness the installation, alignment and fit check of the Transfer Span Machinery Assembly.

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3.3 INTERCONNECTING HYDRAULIC PIPING AND HOSES

A. Interconnecting High Pressure Piping/Tubing shall generally be installed per the Plans.

B. The Contractor may deviate from the indicated routing and support details as long as he/she can demonstrate that his/her plan are equivalent in quality, workmanship and accessibility for future maintenance. These changes shall be thoroughly documented in the shop drawings and must be explicitly approved by the Engineer.

C. The Contractor shall provide detailed shop drawings showing the routing of each hydraulic pipe/tube and hoses, all support locations, the type of support hardware employed, the location and type of welds, pipe/tube and hose materials used and the end termination fitting type for each pipe/tube or hose.

D. The Contractor shall provide a detailed Field Installed Hydraulic Piping Cleaning and Flushing Plan describing the equipment and methodologies that will be used to clean and flush the field piping/tubing as required by the plans.

3.4 INTERCONNECTING ELECTRICAL WIRING, CONDUIT AND JUNCTION BOXES

A. Interconnecting wiring and conduit system shall generally be installed per the plans.

B. The Contractor may deviate from the indicated routing and support details as long as he/she can demonstrate that his/her plan are equivalent in quality, workmanship and accessibility for future maintenance. These changes shall be thoroughly documented in the shop drawings and must be explicitly approved by the Engineer.

C. The Contractor shall provide detailed shop drawings showing the routing of each conduit; all support locations, the type of support hardware employed, conduit and junction boxes utilized and other relevant data.

3.5 FINAL SPAN BALANCING

A. The span balance of the Transfer Span Machinery shall be checked and adjusted if required in accordance with the plans.

B. The purpose of this testing is to insure that the span balance of the Transfer Span Machinery Assembly has not been disturbed during transport, installation and alignment. Initial span balancing shall be accomplished during the off-site commissioning and testing of the Transfer Span Machinery Assembly prior to delivery of the system to the site.

C. The Contractor shall perform a final check of the span balance per the requirements of the plans.

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D. The Contractor shall prepare and submit a Final Span Balancing Plan that details the equipment and methodology that will be employed to complete the final span balancing.

E. The Engineer shall witness the final span balancing of the Transfer Span Machinery Assembly.

3.6 FIELD FUNCTIONAL TESTING

A. The performance and functionality of the Transfer Span System shall be checked and adjusted as necessary in accordance with the plans.

B. The purpose of this testing is to insure that alignment of the Transfer Span Machinery Assembly has not been disturbed during transport; that that all of the set points for the limit switches and other control devices have not been inadvertently altered and that all operator control devices are providing the functionality as designed. The test shall demonstrate the full range of motion of the Transfer Span System and shall record the time required to traverse from one extreme ramp limit to the opposite extreme. All control devices shall be set and the alignment of the machinery adjusted during off-site Functional testing prior to delivery of the system to the site.

C. The Contractor shall perform Field Functional Test of the system per the requirements of the plans.

D. The Contractor shall prepare and submit a Field Functional Test Plan that details the equipment and methodology that will be employed to complete this testing.

E. The Engineer shall witness the field functional test of the Transfer Span Machinery Assembly.

3.7 COMMISSIONING

A. The completed Transfer Span System shall be commissioned in accordance with the requirements of the plans.

B. The purpose of commissioning is to operate and observe the system over a longer period of time in order to identify any operational issues with the equipment that are not evident during the functional testing.

C. The Contractor shall prepare and submit a Commissioning Plan that details the equipment and methodology that will be employed to commission the completed system.

3.8 AS-BUILT DOCUMENTATION

A. The Contractor shall provide the Owner four (4) full sets of as-built drawings for the Transfer Span System and all of it’s sub-components as required by the plans.

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B. As a minimum, each as-built drawing set shall consist of a clean copy of the contract documents with all changes clearly and neatly marked with permanent red ink.

C. Each sheet shall also be clearly labeled “as-built” using permanent red ink.

D. These as-built drawings shall be submitted to the Engineer for review.

3.9 OPERATION AND MAINTENANCE MANUALS

A. The Contractor shall prepare and submit four (4) complete Operations and Maintenance Manuals for the Owners records.

B. As a minimum these manuals shall:

1. Identify the manufacturer and part or model number of all purchased components or materials used by the Contractor in this work.

2. Identify all components that require maintenance and provide a recommended maintenance interval for these components.

3. Provide a check list summarizing the required maintenance and recommended maintenance intervals.

3.10 CLEANING

A. Prior to final inspection, the Contractor shall thoroughly clean and inspect all work that they have installed.

B. Any damage to protective coatings or decorative surfaces shall be repaired or touched up.

3.11 INSPECTION

A. After the Contractor has completed cleaning the installed equipment per the above section, the Contractor shall make a final inspection of the installation to insure all work meets the requirements established in the plans.

B. Once the Contractor believes the system is complete and that it fully meets the requirements established by the plans, they shall notify the Engineer and schedule a Final Inspection.

C. During the Final Inspection, the Contractor shall prepare and maintain a formal punch list identifying any discrepancies that are identified by the Inspection and shall submit copies of this punch list to the Engineer.

3.12 ACCEPTANCE

A. Final acceptance of the Work shall be contingent on the Contractor demonstrating the following:

1. Final Inspection has been completed and the punch list generated has been fully addressed.

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2. Field functional testing is complete and has been certified by the Engineer.

3. Commissioning is complete and has been certified by the Engineer 4. As-built Documentation and Operation and Maintenance Manuals have

been submitted and certified by the Engineer.

PART 4 MEASUREMENT AND PAYMENT

4.1 MEASUREMENT AND PAYMENT

A. The work performed, materials furnished and all labor, tools, equipment and incidentals necessary to complete the work under this Item will not be measured or paid for directly, but will be considered subsidiary to the various bid items of the contract.

END OF SECTION

176866A.SEA

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SECTION 13020 TRANSFER SPAN MACHINERY ASSEMBLIES

PART 1 GENERAL

1.1 SCOPE OF WORK

A. This work consists of fabricating, assembling and shop testing three (3) new transfer span systems that will be installed in Slips 2 and 3 at the Galveston Terminal and in Slip 3 at the Bolivar Terminal. Specific tasks associated with this work include but are not limited to:

1. Fabricating, machining and coating the transfer span structure assembly for each system.

2. Fabricating, machining and coating the transfer span finger assemblies, drag link assemblies, guard rail and other miscellaneous structural brackets for each system.

3. Procure the transfer span pintle bearings, sliding pintle bearings and other self lubricating bearings along with the required pins and retaining hardware required for each system.

4. Assembling all components into a complete transfer span machinery assembly including the installation of the transfer span main bridge actuators (cylinder).

5. Provide access to the assembled transfer span machinery and support personnel to assist in the installation of all shop installed interconnecting hydraulic piping and control system wiring and conduit.

6. Provide the facilities, electric power and support personnel required to temporarily connect the transfer span hydraulic control unit to the transfer span machinery assembly. Perform all shop testing of the completed assembly.

7. Disconnect the hydraulic control unit from the transfer span machinery assembly and prepare both units for transport to the site for installation.

1.2 SYSTEM DESCRIPTION

A. Each transfer span machinery assembly consists of a transfer span assembly and other assorted sub assemblies.

B. One complete transfer span machinery assembly is to be installed at each of the new slips (Galveston Slips 2 and 3 and Bolivar Slip 3).

1.3 SUBMITTALS

A. Before delivering materials, fabricating components or performing any shop testing/commissioning of the system, the Contractor shall submit to the Engineer six (6) copies of the following for review and approval:

1. Mill certifications and test reports for all raw materials. 2. Transfer span machinery assembly alignment and fit check plan as

required by this specification.

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3. Shop Span Balancing Plan as required by this specification. 4. Shop-Installed Hydraulic Piping Cleaning and Flushing Plan as required

by these specifications and the plans. 5. Shop Functional Testing Plan as required by this specification. 6. Commissioning Plan as required by these specifications. 7. Shop drawings of the field installed high pressure hydraulic piping,

including location of all valves, flanges, pipe supports, and pipe lengths. 8. Shop Drawings of all primary structures including the Transfer Span. 9. Welding submittals which shall include:

a. All weld processes, including pre-qualified and Contractor-proposed welding procedure specifications (including weld rod data).

b. Detailed welding drawings including proposed inspection plans and repair procedures.

c. Welder qualifications and certifications. d. Qualifications and certification of the AWS certified welding

inspector who shall witness all welding of the diesel fuel line. e. Welding inspection/testing results to the Engineer for approval.

10. Shop drawings of the shop installed interconnecting wiring and conduits, including the location and size off all junction boxes, conduits, conduit supports and conduit lengths.

B. Prior to inspection and acceptance as described below, the Contractor shall submit to the Engineer four (4) complete copies of the following documents for review and approval:

1. As-built plans. 2. Operation and Maintenance Manuals.

C. The drawings and submittals shall be submitted on suitable size sheets that are completely clear and legible.

D. The Contractor shall be responsible for the completeness of the drawings and other information. The Contractor shall clearly indicate any deviations from the plans on the submittals.

E. The review and approval of drawings and other information shall conform with the design concept and shall be understood to be an acceptance of the character and sufficiency of the details and not a check of detailed dimensions or other key data.

1.4 QUALITY ASSURANCE

A. The Contractor shall provide a manufacturer’s certificate of quality that the actual bearings, raw materials and other purchased components supplied conforms to the test reports, supplemental test documentation and certifications that were submitted.

B. The certified welding inspector shall perform quality assurance inspections of the Contractor’s welding.

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1.5 COORDINATION

A. The Contractor shall coordinate the submittal of drawings and other information in a timely manner to allow sufficient time for review and approval by the Engineer (21 calendar days) and time for fabrication and delivery of the material so as to not delay completion of the construction within the established schedule for completion of the project.

B. The Engineer shall have ten (10) working days to review and comment on all submittals.

PART 2 PRODUCTS

2.1 GENERAL

A. All materials shall be new and shall generally be provided as specified on the plans.

B. Wherever a material, article, device product or fixture is identified by a manufacturers name, or by a manufacturers name and either partial or complete catalog part number, such specification shall be deemed to be used for the purposes of facilitating a description of the material or process desired, establishing a standard of quality, and stating a preference for a specific manufacturer. This procedure is not to be construed as eliminating from competition other products of equal or better quality by the same or other manufacturers where such products are fully suitable in the design, functionality and physical interchangeability, and shall be followed by the words “or approved equal.” The decision as to equality shall be made solely by the Engineer.

C. Wherever a material, article, device product or fixture is identified by a generic term or trade name, such specification shall be deemed to be used for the purposes of describing the device or process desired, not establishing a standard of quality or stating a preference for a specific manufacturer, and shall be understood to be followed by the words “or equal.”

2.2 BEARING SYSTEMS

A. Both custom fabricated and standard self lubricated marine bearings are used extensively in this design. The plans specify the use of Karon V self lubricated liners from Kamatics Corporation for these bearings.

B. The Contractor may propose an alternate bearing systems if those systems can demonstrate equivalent performance and application history. Any substitutions on the bearing systems must be explicitly approved by the Engineer in writing.

C. If alternate materials or components are proposed, the Contractor shall take full responsibility for coordination of any revisions required to any other portion of the transfer span system or its subcomponents required to accommodate the proposed substitutions. Any required design revisions shall

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be identified and a design solution shall be identified in writing and shall be submitted along with the shop drawings for the proposed substitution.

2.3 SHOP INSTALLED HYDRAULIC PIPE AND HOSES

A. Shop installed, high pressure hydraulic piping and tubing shall generally be fabricated, installed and supported per the plans.

B. All raw materials, valves, tube and pipe supports and other components shall be supplied as described in the plans.

C. Unless otherwise noted, the Contractor may propose the use of equivalent materials or components in place of those indicated on the plans per Article 2.1 above.

D. If alternate materials or components are proposed, the Contractor shall take full responsibility for coordination of any revisions required to any other portion of the transfer span system or its subcomponents required to accommodate the proposed substitutions. Any required design revisions shall be identified and a design solution shall be identified in writing and shall be submitted along with the shop drawings for the proposed substitution.

2.4 SHOP-INSTALLED ELECTRICAL WIRING, CONDUIT, AND JUNCTION BOXES

A. Shop-installed, interconnecting wiring, and conduits shall generally be fabricated, installed, and supported per the plans.

B. All raw materials, wires, cables conduit, junction boxes and other components shall be supplied as described in the plans.

C. Unless otherwise noted, the Contractor may propose the use of equivalent materials or components in place of those indicated on the plans per Article 2.1 above.

D. If alternate materials or components are proposed, the Contractor shall take full responsibility for coordination of any revisions required to any other portion of the transfer span system or its subcomponents required to accommodate the proposed substitutions. Any required design revisions shall be identified and a design solution shall be identified in writing and shall be submitted along with the shop drawings for the proposed substitution.

PART 3 EXECUTION

3.1 GENERAL

A. All structures, bearings, pins, shop-installed interconnecting high-pressure hydraulic piping/tubing, and shop-installed wiring shall be installed and connected per the plans.

B. The shape, size and configuration all structures, bearings, pins and other components shown by the plans are critical to the performance of the overall

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system. The Contractor shall not significantly alter any parts of this system without the explicit approval of the Engineer.

3.2 SHOP ASSEMBLY, ALIGNMENT AND FIT CHECK OF TRANSFER SPAN MACHINERY ASSEMBLY.

A. The transfer span machinery assembly shall be completely assembled, fit checked and tested off site at a site chosen by the Contractor.

B. The Contractor shall prepare a detailed Transfer Span Machinery Assembly Alignment and Fit Check Plan. The purpose of this plan is to establish a methodology for checking that all moving components are moving freely and not binding, and to verify the overall range of motion of each component.

C. This plan shall as a minimum identify:

1. Which components are to be fit-checked. 2. The range of motion to be verified for each component as defined by the

plans. 3. The equipment and methods that will be used to carry out the fit-check

and measure the range of motion of each component 4. The acceptance criteria for the fit-check and range of motion as

described in the plans along with a box for recording the actual field data observed

5. Signature boxes beside each acceptance criteria to accept the initials of the individual supervising the fit-check and the fit-check witness

D. The Engineer shall witness all fit-checks and range of motion tests of the transfer span machinery assembly.

3.3 SHOP INSTALLED INTERCONNECTING HYDRAULIC PIPING AND HOSES

A. Interconnecting high-pressure piping/tubing shall generally be installed per the plans.

B. The Contractor may deviate from the indicated routing and support details as long as he/she can demonstrate that his/her plan are equivalent in quality, workmanship and accessibility for future maintenance. These changes shall be thoroughly documented in the shop drawings and must be explicitly approved by the Engineer.

C. The Contractor shall provide detailed shop drawings showing the routing of each hydraulic pipe/tube and hoses, all support locations, the type of support hardware employed, the location and type of welds, pipe/tube and hose materials used and the end termination fitting type for each pipe/tube or hose.

D. The Contractor shall provide a detailed Shop Installed Hydraulic Piping Cleaning and Flushing Plan describing the equipment and methodologies that will be used to clean and flush the field piping/tubing as required by the plans.

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3.4 INTERCONNECTING ELECTRICAL WIRING, CONDUIT AND JUNCTION BOXES

A. Interconnecting wiring and conduit system shall generally be installed per the plans.

B. The Contractor may deviate from the indicated routing and support details as long as he/she can demonstrate that his/her plan are equivalent in quality, workmanship and accessibility for future maintenance. These changes shall be thoroughly documented in the shop drawings and must be explicitly approved by the Engineer.

C. The Contractor shall provide detailed shop drawings showing the routing of each conduit; all support locations, the type of support hardware employed, conduit and junction boxes utilized and other relevant data.

3.5 SHOP SPAN BALANCING

A. After the components that make up the transfer span machinery assembly have been assembled, the Contractor shall set the span balance per the instructions in the plans.

B. The Contractor shall prepare and submit a Shop Span Balancing Plan that details the equipment and methodology that will be employed to complete the shop span balancing.

C. The Engineer shall witness the shop span balancing of the transfer span machinery assembly.

3.6 SHOP FUNCTIONAL TESTING

A. The purpose of the shop functional testing is to allow the Contractor to set all of the control devices which control the ramp range of motion and to verify the general performance of the overall system.

B. Shop functional testing shall be done with a standard hydraulic control unit (HCU) supplied by TxDot. The Contractor shall provide space to conduct the functional testing, and any temporary piping/tubing , hoses wiring and other items required to conduct the tests.

C. The performance and functionality of the transfer span system shall be checked and adjusted as necessary in accordance with the plans.

D. The Contractor will be responsible for adjusting sensor external to the HCU. The Engineer shall be responsible for any adjustments to the HCU.

E. The Contractor shall perform shop functional test of the system per the requirements of the plans.

F. The Contractor shall prepare and submit a Shop Functional Test Plan that details the equipment and methodology that will be employed to complete this testing.

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G. The Engineer shall witness all shop functional test of the transfer span machinery assembly.

3.7 AS-BUILT DOCUMENTATION

A. The Contractor shall provide the Owner four (4) full sets of as-built plans for the transfer span system and all of its subcomponents as required by the plans.

B. As a minimum, each as-built drawing set shall consist of a clean copy of the contract documents with all changes clearly and neatly marked with permanent red ink.

C. Each sheet shall also be clearly labeled “as-built” using permanent red ink.

D. These as-built drawings shall be submitted to the Engineer for review.

3.8 OPERATION AND MAINTENANCE MANUALS

A. The Contractor shall prepare and submit four (4) complete Operation and Maintenance Manuals for the Owner’s records.

B. As a minimum these manuals shall:

1. Identify the manufacturer and part or model number of all purchased components or materials used by the Contractor in this work.

2. Identify all components that require maintenance and provide a recommended maintenance interval for these components.

3. Provide a check list summarizing the required maintenance and recommended maintenance intervals.

3.9 CLEANING

A. Prior to final inspection, the Contractor shall thoroughly clean and inspect all work that they have installed.

B. Any damage to protective coatings or decorative surfaces shall be repaired or touched up.

3.10 INSPECTION

A. After the Contractor has completed Cleaning the installed equipment per the above section, the Contractor shall make a final inspection of the installation to insure all work meets the requirements established on the plans.

B. Once the Contractor believes the system is complete and that it fully meets the requirements established by the plans, he/she shall notify the Engineer and schedule a final inspection.

C. During the final inspection, the Contractor shall prepare and maintain a formal punch list identifying any discrepancies that are identified by the Inspection and shall submit copies of this punch list to the Engineer.

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3.11 ACCEPTANCE

A. Final Acceptance of the work shall be contingent on the Contractor demonstrating the following:

1. Final inspection has been completed and the punch list generated has been fully addressed.

2. Field functional testing is complete and has been certified by the Engineer.

3. Commissioning is complete and has been certified by the Engineer 4. As-built documentation and Operation and Maintenance Manuals have

been submitted and certified by the Engineer.

PART 4 MEASUREMENT AND PAYMENT

4.1 MEASUREMENT AND PAYMENT

A. The work performed, materials furnished and all labor, tools, equipment and incidentals necessary to complete the work under this Item will not be measured or paid for directly, but will be considered subsidiary to the various bid items of the contract.

END OF SECTION

176866A.SEA

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SECTION 13050 TRANSFER SPAN ELECTRICAL CONTROLS

PART 1 GENERAL

1.1 SCOPE OF WORK

A. This work consists of all electrical control cabinets required for this project including six (6) Transfer Span Slip Control Cabinets (including Programmable Logic Controllers).

1.2 SUBMITTALS

A. Before fabricating and assembling equipment or performing any testing electrical control cabinets, the Contractor shall submit to the Engineer six (6) copies of the following for review and approval:

1. Mill Certifications and test reports for all raw materials. 2. Manufacturer’s certificates for all purchased components. 3. Vendor Cut Sheets for any component if required per Article 2.1. 4. Shop drawings of any component or assembly if required per Article 2.1

below.

B. Prior to inspection and acceptance as described below, the Contractor shall submit to the Engineer four (4) complete copies of the following documents for review and approval:

1. As-built drawings. 2. Operation and Maintenance Manuals.

C. The drawings and submittals shall be submitted on suitable size sheets that are completely clear and legible.

D. The Contractor shall be responsible for the completeness of the drawings and other information. The Contractor shall clearly indicate any deviations from the plans on the submittals.

E. The review and approval of drawings and other information shall conform with the design concept and shall be understood to be an acceptance of the character and sufficiency of the details and not a check of detailed dimensions or other key data.

1.3 QUALITY ASSURANCE

A. The Contractor shall develop a Quality Assurance Plan covering the fabrication and testing of the electrical control cabinets. This plan shall identify how the Contractor will insure that each control cabinet will be fully functional and will meet the performance requirements identified in the engineering drawings and these special specifications.

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1.4 COORDINATION

A. The Contractor shall coordinate the submittal of drawings and other information in a timely manner to allow sufficient time for review and approval by the Engineer (21 calendar days) and time for fabrication and delivery of the material so as to not delay completion of the construction within the established schedule for completion of the project.

B. The Engineer shall have ten (10) working days to review and comment on all submittals.

PART 2 PRODUCTS

2.1 GENERAL

A. All materials shall generally be provided as specified on the plans.

B. Wherever a material, article, device product or fixture is identified by a manufacturers name, or by a manufacturers name and either partial or complete catalog part number, such specification shall be deemed to be used for the purposes of facilitating a description of the material or process desired, establishing a standard of quality, and stating a preference for a specific manufacturer. This procedure is not to be construed as eliminating from competition other products of equal or better quality by the same or other manufacturers where such products are fully suitable in the design, functionality and physical interchangeability, and shall be followed by the words “or approved equal.” The decision as to equality shall be made solely by the Engineer.

C. Wherever a material, article, device product or fixture is identified by a generic term or trade name, such specification shall be deemed to be used for the purposes of describing the device or process desired, not establishing a standard of quality or stating a preference for a specific manufacturer, and shall be understood to be followed by the words “or equal.”

D. No vendor cut sheet submittals are required if the Contractor decides to provide the components identified on the engineering drawings.

E. The Contractor shall submit vendor cut sheets for any component that is proposed as a substitution for one shown on the engineering drawings.

F. If the Contractor chooses to make a substitution for a component, they are solely responsible for identifying and coordinating all design revisions required to insure that the new component works correctly in the overall system.

PART 3 EXECUTION

3.1 GENERAL

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A. If the Contractor chooses to propose design changes, they are solely responsible for identifying and coordinating the overall system to accept the design.

3.2 AS-BUILT DOCUMENTATION

A. As a minimum, each as-built drawing set shall consist of a clean copy of the Contract Documents with all changes clearly and neatly marked with permanent red ink.

B. Each sheet shall also be clearly labeled “as-built” using permanent red ink.

C. These as-built drawings shall be submitted to the Engineer for review.

3.3 OPERATION AND MAINTENANCE MANUALS

A. The Contractor shall prepare and submit four (4) complete Operations and Maintenance Manuals for the Owner’s records.

B. As a minimum, these manuals shall:

1. Identify the manufacturer and part or model number of all purchased components or materials used by the Contractor in this work.

2. Identify all components that require maintenance and provide a recommended maintenance interval for these components.

3. Provide a check list summarizing the required maintenance and recommended maintenance intervals.

3.4 CLEANING

A. Prior to final inspection, the Contractor shall thoroughly clean and inspect all work that they have installed.

B. Any damage to protective coatings or decorative surfaces shall be repaired or touched up.

3.5 INSPECTION

A. After the Contractor has completed cleaning the control cabinets per the above section,

B. The Contractor shall make a final inspection of the installation to insure all work meets the requirements established in the plans.

C. Once the Contractor believes the cabinets are complete and that they fully meet the requirements established by the plans, they shall notify the Engineer and schedule a Final Inspection.

D. During the Final Inspection, the Contractor shall prepare and maintain a formal punch list identifying any discrepancies that are identified by the Inspection and shall submit copies of this punch list to the Engineer.

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3.6 ACCEPTANCE

A. Final acceptance of the Work shall be contingent on the Contractor demonstrating the following:

1. Final Inspection has been completed and the punch list generated has been fully addressed.

2. Component testing is complete and has been certified by the Engineer. 3. Functional testing is complete and has been certified by the Engineer. 4. As-built Documentation and Operation and Maintenance Manuals have

been submitted and certified by the Engineer.

PART 4 MEASUREMENT AND PAYMENT

4.1 MEASUREMENT AND PAYMENT

A. The work performed, materials furnished and all labor, tools, equipment and incidentals necessary to complete the work under this Item will not be measured or paid for directly, but will be considered subsidiary to the various bid items of the contract.

END OF SECTION

176866A.SEA