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USACE / NAVFAC / AFCESA / NASA UFGS-35 20 16.39 (April 2006)
-----------------------------
Preparing Activity:
USACE (CW) Replacing without change
UFGS-11286A (August 2004)
UNIFIED FACILITIES GUIDE SPECIFICATIONSReferences are in agreement with UMRL dated 1 April 2006
Section Table of Contents
SECTION 35 20 16.39
SECTOR GATES
04/06
PART 1 GENERAL
1.1 REFERENCES
1.2 UNIT PRICES
1.2.1 Furnishing and Installing Sector Gates and Appurtenant Items
1.2.1.1 Payment
1.2.1.2 Unit of Measure
1.2.2 Furnishing Sector Gates and Appurtenant Items
1.2.2.1 Payment
1.2.2.2 Unit of Measure
1.2.3 Installing Sector Gates and Appurtenant Items
1.2.3.1 Payment
1.2.3.2 Unit of Measure
1.3 SUBMITTALS
1.4 QUALIFICATION OF WELDERS AND WELDING OPERATORS
1.5 DELIVERY, STORAGE, AND HANDLING
1.5.1 Materials and Fabricated Items
1.5.2 Rubber Seals
PART 2 PRODUCTS
2.1 MATERIALS
2.1.1 Metals
2.1.1.1 Structural Steel Shapes
2.1.1.2 Structural Steel Plates
2.1.1.3 Steel Pipe
2.1.1.4 Steel Castings
2.1.1.5 Steel Forgings
2.1.1.6 High-Strength Steel Bar
2.1.1.7 Stainless Steel Bars and Shapes
2.1.1.8 Stainless Steel Plate, Sheet, and Strip
2.1.1.9 Bronze Castings
2.1.1.10 Aluminum-Bronze Castings
2.1.2 Rubber Seals
2.1.2.1 Physical Characteristics
2.1.2.2 [Fabrication
2.1.3 Bumpers and Fenders
2.1.4 Asphalt Mastic
2.2 MANUFACTURED UNITS
2.2.1 Bolts, Nuts and Washers
2.2.2 Screws
2.3 FABRICATION
2.3.1 Detail Drawings
2.3.1.1 Fabrication Drawings
2.3.1.2 Shop Assembly Drawings
2.3.1.3 Delivery Drawings
2.3.1.4 Field Installation Drawings
2.3.2 Structural Fabrication
2.3.3 Welding
2.3.4 Bolted Connections
2.3.5 Machine Work
2.3.6 Miscellaneous Provisions
2.3.7 Fabrications
2.3.7.1 Gate Leaf
2.3.7.2 Hinge Assembly
2.3.7.3 Pintle Assembly
2.3.7.4 Seal Assemblies
2.3.7.5 Appurtenant Items
2.3.8 Shop Assembly
2.4 TESTS, INSPECTIONS, AND VERIFICATIONS
2.4.1 [Testing of Rubber Seals
PART 3 EXECUTION
3.1 INSTALLATION
3.1.1 Embedded Metals
3.1.2 Hinge Assembly Embedded Anchorages
3.1.3 Pintle Base Anchor Frame and Pintle Base
3.1.4 Pintle
3.1.5 Gate Leaf
3.1.6 Hinge Bracket and Hinge Pin
3.1.7 Painting
3.1.8 Seal Assemblies
3.2 CATHODIC PROTECTION SYSTEM
3.3 OPERATING MACHINERY
3.4 FIELD TESTS AND INSPECTIONS
3.4.1 [Skinplate Watertightness Test
3.4.2 Acceptance Trial Operation
3.5 PROTECTION OF FINISHED WORK
SECTION 35 20 16.39
SECTOR GATES
NOTE: This guide specification covers the requirements for the fabrication,
assembly, delivery, and installation of sector gates and appurtenant items as
specified and shown on the drawings.
Comments and suggestions on this guide specification are welcome and should
be directed to the technical proponent of the specification. A listing of
technical
proponents, including their organization designation and telephone number, is
on the Internet.
Recommended changes to a UFGS should be submitted as a
Criteria Change Request
(CCR).
Use of electronic communication is encouraged.
Brackets are used in the text to indicate designer choices or locations where
text must be supplied by the designer.
PART 1 GENERAL
1.1 REFERENCES
NOTE: This paragraph is used to list the publications cited in the text of
the guide specification. The publications are referred to in the text by basic
designation only and listed in this paragraph by organization, designation,
date, and title.
Use the Reference Wizard's Check Reference feature when you add a RID outside
of the Section's Reference Article to automatically place the reference in the
Reference Article. Also use the Reference Wizard's Check Reference feature
to update the issue dates.
References not used in the text will automatically be deleted from this section
of the project specification when you choose to reconcile references in the
publish print process.
The publications listed below form a part of this specification to the extent referenced. The publications are
referred to within the text by the basic designation only.
| AMERICAN WELDING SOCIETY (AWS) |
| |
| AWS D1.1/D1.1M | | (2006) Structural Welding Code - Steel |
| |
| AWS D1.2 | | (2003) Structural Welding Code - Aluminum |
| AMERICAN WOOD-PRESERVERS' ASSOCIATION (AWPA) |
| |
| AWPA C2 | | (2003) Lumber, Timber, Bridge Ties and Mine
Ties - Preservative Treatment by Pressure Processes |
| |
| AWPA P3 | | (2001) Standard for Creosote - Petroleum Oil
Solution |
| ASTM INTERNATIONAL (ASTM) |
| |
| ASTM A 148/A 148M | | (2003) Steel Castings, High Strength, for Structural
Purposes |
| |
| ASTM A 167 | | (2004) Stainless and Heat-Resisting Chromium-Nickel
Steel Plate, Sheet, and Strip |
| |
| ASTM A 176 | | (2004) Stainless and Heat-Resisting Chromium
Steel Plate, Sheet, and Strip |
| |
| ASTM A 240/A 240M | | (2004ae1) Chromium and Chromium-Nickel Stainless
Steel Plate, Sheet, and Strip for Pressure Vessels
for General Applications |
| |
| ASTM A 27/A 27M | | (2005) Steel Castings, Carbon, for General Application |
| |
| ASTM A 276 | | (2005) Stainless Steel Bars and Shapes |
| |
| ASTM A 307 | | (2004) Carbon Steel Bolts and Studs, 60 000
PSI Tensile Strength |
| |
| ASTM A 320/A 320M | | (2004)Alloy/Steel Bolting Materials for Low-Temperature
Service |
| |
| ASTM A 325 | | (2004b) Structural Bolts, Steel, Heat Treated,
120/105 ksi Minimum Tensile Strength |
| |
| ASTM A 325M | | (2004b) Structural Bolts, Steel, Heat Treated,
830 Mpa Minimum Tensile Strength (Metric) |
| |
| ASTM A 36/A 36M | | (2005) Carbon Structural Steel |
| |
| ASTM A 490 | | (2004a) Structural Bolts, Alloy Steel, Heat
Treated, 150 ksi Minimum Tensile Strength |
| |
| ASTM A 490M | | (2004a) High-Strength Steel Bolts, Classes 10.9
and 10.9.3, for Structural Steel Joints (Metric) |
| |
| ASTM A 501 | | (2001) Hot-Formed Welded and Seamless Carbon
Steel Structural Tubing |
| |
| ASTM A 53/A 53M | | (2004a) Pipe, Steel, Black and Hot-Dipped, Zinc-Coated,
Welded and Seamless |
| |
| ASTM A 564/A 564M | | (2004) Hot-Rolled and Cold-Finished Age-Hardening
Stainless Steel Bars and Shapes |
| |
| ASTM A 572/A 572M | | (2004) High-Strength Low-Alloy Columbium-Vanadium
Structural Steel |
| |
| ASTM A 588/A 588M | | (2005) High-Strength Low-Alloy Structural Steel
with 50 ksi (345 MPa) Minimum Yield Point to
4 in. (100 mm) Thick |
| |
| ASTM A 668/A 668M | | (2004) Steel Forgings, Carbon and Alloy, for
General Industrial Use |
| |
| ASTM A 722/A 722M | | (1998; R 2003) Uncoated High-Strength Steel
Bar for Prestressing Concrete |
| |
| ASTM B 148 | | (1997; R 2003e1) Aluminum-Bronze Sand Castings |
| |
| ASTM B 22 | | (2002) Bronze Castings for Bridges and Turntables |
| |
| ASTM D 2240 | | (2005) Rubber Property - Durometer Hardness |
| |
| ASTM D 395 | | (2003) Rubber Property - Compression Set |
| |
| ASTM D 412 | | (1998a; R 2002e1) Vulcanized Rubber and Thermoplastic
Elastomers - Tension |
| |
| ASTM D 413 | | (1998; R 2002e1) Rubber Property - Adhesion
to Flexible Substrate |
| |
| ASTM D 471 | | (1998e1) Rubber Property - Effect of Liquids |
| |
| ASTM D 572 | | (2004) Rubber Deterioration by Heat and Oxygen |
| THE SOCIETY FOR PROTECTIVE COATINGS (SSPC) |
| |
| SSPC Paint 12 | | (1982; R 2000) Cold-Applied Asphalt Mastic (Extra
Thick Film) |
1.2 UNIT PRICES
NOTE: If Section 01 22 00.00 10 MEASUREMENT AND PAYMENT is included in the
project specifications, this paragraph title (UNIT PRICES) should be deleted
from this section and the remaining appropriately edited subparagraphs below
should be inserted into Section 01 22 00.00 10.
Select Alternate 1 (one pay item) or Alternate 2 (two pay items). Delete all
paragraphs of Alternate not selected.
1.2.1 Furnishing and Installing Sector Gates and Appurtenant Items
1.2.1.1 Payment
Payment will be made for costs associated with furnishing and installing sector gates and appurtenant items,
which includes full compensation for the materials, fabrication, delivery, installation, and testing of sector
gates and appurtenant items including gate leaves, pintle assemblies, hinge assemblies, seal assemblies, [walkways,]
[bridgeways,] bumpers, fenders, and other items necessary for complete installation.
1.2.1.2 Unit of Measure
Unit of measure: lump sum.
1.2.2 Furnishing Sector Gates and Appurtenant Items
1.2.2.1 Payment
Payment will be made for all costs associated with furnishing sector gates and appurtenant items, which includes
full compensation for the materials, fabrication, and delivery of sector gates and appurtenant items including
gate leaves, pintle assemblies, hinge assemblies, seal assemblies, [walkways,] [bridgeways,] bumpers, fenders,
and other items necessary for complete installation.
1.2.2.2 Unit of Measure
Unit of Measure: lump sum.
1.2.3 Installing Sector Gates and Appurtenant Items
1.2.3.1 Payment
Payment will be made for costs associated with the installation of sector gates and appurtenant items, which
includes full compensation for the complete installation and testing of sector gates and appurtenant items.
1.2.3.2 Unit of Measure
Unit of measure: lump sum.
1.3 SUBMITTALS
NOTE: Review submittal description (SD) definitions in Section 01 33 00 SUBMITTAL
PROCEDURES and edit the following list to reflect only the submittals required
for the project. Submittals should be kept to the minimum required for adequate
quality control.
A “G” following a submittal item indicates that the submittal requires Government
approval. Some submittals are already marked with a “G”. Only delete an existing
“G” if the submittal item is not complex and can be reviewed through the Contractor’s
Quality Control system. Only add a “G” if the submittal is sufficiently important
or complex in context of the project.
For submittals requiring Government approval on Army projects, a code of up
to three characters within the submittal tags may be used following the "G"
designation to indicate the approving authority. Codes for Army projects using
the Resident Management System (RMS) are: "AE" for Architect-Engineer; "DO"
for District Office (Engineering Division or other organization in the District
Office); "AO" for Area Office; "RO" for Resident Office; and "PO" for Project
Office. Codes following the "G" typically are not used for Navy, Air Force,
and NASA projects.
Choose the first bracketed item for Navy, Air Force and NASA projects, or choose
the second bracketed item for Army projects.
Government approval is required for submittals with a "G" designation; submittals not having a "G" designation
are for [Contractor Quality Control approval.][information only. When used, a designation following the "G"
designation identifies the office that will review the submittal for the Government.] The following shall be
submitted in accordance with Section
01 33 00
01 33 00
01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Detail Drawings[; G][; G, [_____]]
SD-03 Product Data
Materials
System of identification which shows the disposition of specific lots of approved materials
and fabricated items in the work shall be submitted before completion of the contract.
Materials orders, materials lists and materials shipping bills shall be submitted as specified
in Section
05 50 03.00 10
05 50 03.00 10
05 50 03.00 10 METALWORK FABRICATION, MACHINE WORK, MISCELLANEOUS PROVISIONS.
[Pintle Base Anchor Frame
Pintle Base
Record of the prestressing of the pintle base anchors shall be submitted immediately after
the prestressing operations are completed.]
Hinge Assembly Embedded Anchorages
Record of the prestressing of hinge bracket anchors shall be submitted immediately after completion
of the prestressing operations.
Welding[; G][; G, [_____]]
SD-04 Samples
Materials[; G][; G, [_____]]
Manufactured Units[; G][; G, [_____]]
Fabrications[; G][; G, [_____]]
Samples shall be submitted and approved prior to use of the represented materials or items
in the work. Samples of standard and shop fabricated items shall be full size and complete
as required for installation in the work. Approved samples may be installed in the work provided
each sample is clearly identified and its location recorded.
SD-06 Test Reports
Tests, Inspections, and Verifications
Certified test reports for material tests shall be submitted with all materials delivered
to the site.
1.4 QUALIFICATION OF WELDERS AND WELDING OPERATORS
1.5 DELIVERY, STORAGE, AND HANDLING
Delivery, handling, and storage of materials and fabricated items shall be as described below.
1.5.1 Materials and Fabricated Items
Delivery, handling, and storage of materials and fabricated items shall conform to the requirements specified
[and] in Section
05 50 03.00 10
05 50 03.00 10
05 50 03.00 10 METALWORK FABRICATION, MACHINE WORK, MISCELLANEOUS PROVISIONS. [Materials and
equipment delivered to the site by the Contracting Officer shall be unloaded by the Contractor. The Contractor
shall verify the condition and quantity of the items delivered by the Contracting Officer and acknowledge receipt
and condition thereof in writing to the Contracting Officer. If delivered items are damaged or a shortage is
determined, the Contractor shall notify the Contracting Officer of such in writing within 24 hours after delivery.]
1.5.2 Rubber Seals
Rubber seals shall be stored in a place which permits free circulation of air, maintains a temperature of 20
degrees C 70 degrees F or less, and prevents the rubber from being exposed to the direct rays of the sun. Rubber
seals shall be kept free of oils, grease, and other materials which would deteriorate the rubber. Rubber seals
shall not be distorted during handling.
PART 2 PRODUCTS
2.1 MATERIALS
Materials orders, materials lists, and materials shipping bills shall conform with the requirements of Section
05 50 03.00 10
05 50 03.00 10
05 50 03.00 10 METALWORK FABRICATION, MACHINE WORK, MISCELLANEOUS PROVISIONS.
2.1.1 Metals
Structural steel, steel forgings, steel castings, stainless steel, bronze, aluminum-bronze, and other metal materials
used for fabrication shall conform to the requirements shown and specified herein and in Section
05 50 04
05 50 04
05 50 04 METALS:
MISCELLANEOUS, STANDARD ARTICLES, SHOP FABRICATED ITEMS FOR CIVIL WORKS STRUCTURES.
2.1.1.1 Structural Steel Shapes
ASTM A 36/A 36M.
2.1.1.2 Structural Steel Plates
[ASTM A 36/A 36M,] [ASTM A 572/A 572M, Grade 50,] [or] [ASTM A 588/A 588M, Grade 50].
2.1.1.3 Steel Pipe
[ASTM A 53/A 53M, Type S, Grade B, seamless, black, normal size and weight class or outside diameter and nominal
wall thickness as shown, [plain] [threaded] [threaded and coupled] ends.] [ASTM A 501, seamless, outside diameter
and nominal wall thickness as shown.]
2.1.1.4 Steel Castings
ASTM A 27/A 27M, Grade [_____], Class [_____]; or ASTM A 148/A 148M, Grade [_____].
2.1.1.5 Steel Forgings
ASTM A 668/A 668M, Class [_____], carbon content not exceeding 0.35 percent, and chemical composition which results
in satisfactory weldability.
2.1.1.6 High-Strength Steel Bar
ASTM A 722/A 722M, Type [_____], and complying with all supplementary requirements.
2.1.1.7 Stainless Steel Bars and Shapes
ASTM A 276, UNS [S 20910,] [S 30400,] [S 40500,] Condition A, hot-finished or cold-finished, Class C; or ASTM A 564/A 564M
, UNS [S 17400,] [S 45000,] Condition A, age-hardened heat treatment, hot-finished or cold-finished, Class C.
2.1.1.8 Stainless Steel Plate, Sheet, and Strip
ASTM A 167, UNS S 30400; ASTM A 176, UNS S 40500 or UNS S 41008; and ASTM A 240/A 240M, UNS [S 20910,] [S 30400,]
[S 40500,]. Plate finish shall be hot-rolled, annealed or heat-treated, and blast-cleaned or pickled. Sheet
and strip finish shall be No. 1.
2.1.1.9 Bronze Castings
ASTM B 22, Copper Alloy UNS No. C91300.
2.1.1.10 Aluminum-Bronze Castings
ASTM A 148/A 148M, Copper Alloy UNS No. [_____].
2.1.2 Rubber Seals
NOTE: If fluorocarbon (Teflon) clad seals are not used, delete paragraph FABRICATION.
Rubber seals shall be [fluorocarbon (Teflon) clad rubber seals of the mold type only, shall be] compounded of
natural rubber, synthetic polyisoprene, or a blend of both, and shall contain reinforcing carbon black, zinc
oxide, accelerators, antioxidants, vulcanizing agents, and plasticizers.
2.1.2.1 Physical Characteristics
Physical characteristics of the seals shall meet the following requirements:
TEST METHOD
PHYSICAL TEST TEST VALUE SPECIFICATION
Tensile Strength 17.2 MPa (min.) ASTM D 412
Elongation at Break 450 percent (min.) ASTM D 412
300 percent Modulus 6.2 MPa (min.) ASTM D 412
Durometer Hardness 60 to 70 ASTM D 2240
(Shore Type A)
*Water Absorption 5% by weight (max.) ASTM D 471
Compression Set 30% (max.) ASTM D 395
Tensile Strength 80% tensile ASTM D 572
(after aging 48 hrs) strength (min.)
TEST METHOD
PHYSICAL TEST TEST VALUE SPECIFICATION
Tensile Strength 2500 psi (min.) ASTM D 412
Elongation at Break 450 percent (min.) ASTM D 412
300 percent Modulus 900 psi (min.) ASTM D 412
Durometer Hardness 60 to 70 ASTM D 2240
(Shore Type A)
*Water Absorption 5% by weight (max.) ASTM D 471
Compression Set 30% (max.) ASTM D 395
Tensile Strength 80% tensile ASTM D 572
(after aging 48 hrs) strength (min.)
* The "Water Absorption" test shall be performed with distilled water. The washed specimen shall be blotted
dry with filter paper or other absorbent material and suspended by means of small glass rods in the oven at a
temperature of 70 degrees C plus or minus 2 degrees for 22 plus or minus 1/4 hour. The specimen shall be removed,
allowed to cool to room temperature in air, and weighed. The weight shall be recorded to the nearest 1 mg as
M subscript 1 (M subscript 1 is defined in ASTM D 471). The immersion temperature shall be 70 degrees C plus
or minus one (1) degree and the duration of immersion shall be 166 hours.
2.1.2.2 [Fabrication
Rubber seals shall have a fluorocarbon film vulcanized and bonded to the sealing surface of the bulb. The film
shall be [0.762] [1.524] mm[0.030] [0.060] inch thick Huntington Abrasion Resistant Fluorocarbon Film No. 4508,
or equal, and shall have the following physical properties:
Tensile strength ............... 13.8 MPa (min.)
Elongation...................... 250 percent (min.)
Tensile strength ............... 2,000 psi (min.)
Elongation...................... 250 percent (min.)
The outside surface of the bonded film shall be flush with the surface of the rubber seal and shall be free of
adhering or bonded rubber. Strips and corner seals shall be molded in lengths suitable for obtaining the finish
lengths shown and with sufficient excess length to provide test specimens for testing the adequacy of the adhesion
bond between the film and bulb of the seal. At one end of each strip or corner seal to be tested, the fluorocarbon
film shall be masked during bonding to prevent a bond for a length sufficient to hold the film securely during
testing.]
2.1.3 Bumpers and Fenders
[Bumpers and fenders shall be "Rubbumper," a product of Missouri Dry Dock & Repair Co., or an approved equal.]
[Timber bumpers and fenders shall conform to [west coast fir] [or] [southern yellow pine], structural grade,
dressed surfacing, pressure treated with creosote conforming to [AWPA P3] in accordance with AWPA C2. Bumpers
and fenders shall be cut, beveled, or bored as required before being pressure treated.]
2.1.4 Asphalt Mastic
SSPC Paint 12.
2.2 MANUFACTURED UNITS
Bolts, nuts, washers, screws and other manufactured units shall conform with the requirements shown and specified
and in Section
05 50 04
05 50 04
05 50 04 METALS: MISCELLANEOUS, STANDARD ARTICLES, SHOP FABRICATED ITEMS FOR CIVIL WORKS STRUCTURES.
2.2.1 Bolts, Nuts and Washers
High-strength bolts, nuts, and washers shall conform toASTM A 325MASTM A 325, Type [_____], [hot-dip galvanized]
or ASTM A 490MASTM A 490, Type [_____]. Bolts, nuts, studs, stud bolts and bolting materials other than high-strength
shall conform to ASTM A 307, Grade A, [hot-dip galvanized] or ASTM A 320/A 320M, [Ferritic Steel, Grade [_____]]
[Austenitic Steel, Grade [_____], Class [_____]]. Bolts M16 1/2 inch and larger shall have hexagon heads. The
finished shank of bolts shall be long enough to provide full bearing. Washers for use with bolts shall conform
to the requirements specified in the applicable specification for bolts.
2.2.2 Screws
Screws shall be of the type indicated on the drawings.
2.3 FABRICATION
2.3.1 Detail Drawings
Detail drawings, including fabrication drawings, shop assembly drawings, delivery drawings, and field installation
drawings, shall conform to the requirements specified and in Section
05 50 03.00 10
05 50 03.00 10
05 50 03.00 10 METALWORK FABRICATION, MACHINE
WORK, MISCELLANEOUS PROVISIONS.
2.3.1.1 Fabrication Drawings
Fabrication drawings shall show complete details of materials, tolerances, connections, and proposed welding
sequences which clearly differentiate shop welds and field welds.
2.3.1.2 Shop Assembly Drawings
Shop assembly drawings shall provide details for connecting the adjoining fabricated components in the shop to
assure satisfactory field installation.
2.3.1.3 Delivery Drawings
Delivery drawings shall provide descriptions of methods of delivering components to the site, including details
for supporting fabricated components during shipping to prevent distortion or other damages.
2.3.1.4 Field Installation Drawings
Field installation drawings shall provide a detailed description of the field installation procedures. The description
shall include the location and method of support of installation and handling equipment; provisions to be taken
to protect concrete and other work during installation; method of maintaining components in correct alignment;
plan for prestressing hinge bracket anchors, which shall include descriptions of connections, riggings, anchorages,
and measuring equipment; methods for installing pintle and hinge assemblies, including checking and maintaining
alignments during concreting; and methods for installing other appurtenant items.
2.3.2 Structural Fabrication
Structural fabrication shall conform with the requirements shown and specified herein and in Section
05 50 03.00 10
05 50 03.00 10
05 50 03.00 10 METALWORK FABRICATION, MACHINE WORK, MISCELLANEOUS PROVISIONS. Components shall be shop-fabricated
of the materials specified and shown. Dimensional tolerances shall be as specified and shown. Splices shall
occur only where shown or approved. Pin holes shall be bored in components after welding, straightening, stress-relieving,
and threading operations are completed. Brackets, eye bar sections, and other components requiring straightening
shall be straightened by methods which will not damage the material. Bronze bushings shall be press-fitted with
supporting components. Bolt connections, lugs, clips, or other pick-up assembly devices shall be provided for
components as shown and required for proper assembly and installation. Provisions shall be made for the installation
of appurtenances as required.
2.3.3 Welding
NOTE: List applicable welds requiring radiographic examination.
Welding shall conform with [
AWS D1.1/D1.1M,
AWS D1.2,] the requirements specified, and in Section
05 50 03.00 10
05 50 03.00 10
05 50 03.00 10 METALWORK FABRICATION, MACHINE WORK, MISCELLANEOUS PROVISIONS. Welds shall be of the type shown
on the contract drawings and approved detail drawings. Radiographic examination is required on the major shop
and field welds of the type and location indicated on the drawings and as follows: [_____]. Welds which have
been designated to receive radiographic examination and are found to be inaccessible to a radiation source or
film, or are otherwise so situated that radiographic examination is not feasible may be examined, with written
approval of the Contracting Officer, by dye penetrant, magnetic particle tests, or ultrasonic tests. [Components
shall be stress-relief heat treated after welding where shown. Stress-relieving of components shall be performed
prior to the attachment of miscellaneous appurtenances.]
2.3.4 Bolted Connections
2.3.5 Machine Work
2.3.6 Miscellaneous Provisions
2.3.7 Fabrications
Fabrications shall conform to the following requirements.
2.3.7.1 Gate Leaf
Gate leaf shall be of welded fabrication except for bolted appurtenances. Gate leaf shall consist of a pintle
socket, pipe column, and hinge pin housing integrally framed with horizontal and vertical trusses supporting
vertical ribs faced with a continuous skin plate. Pintle socket shall be of cast steel conforming to ASTM A 27/A 27M
. Pintle socket shall be press-fitted with bronze bushing conforming ASTM B 22. Bearing surfaces of the bronze
bushing shall have a truly hemispherical 0.4 micrometer 16 microinch finish. Pipe column shall conform to [ASTM A 53/A 53M
] [ASTM A 501]. Hinge pin housing shall be of [cast steel conforming to ASTM A 27/A 27M] [structural steel conforming
to ASTM A 36/A 36M]. Trusses and vertical ribs shall be of structural steel conforming to ASTM A 36/A 36M.
Skin plate shall conform to [ASTM A 36/A 36M] [ASTM A 572/A 572M, Grade 50,] [ASTM A 588/A 588M, Grade 50].
Gate leaf shall be shop-fabricated. Contractor proposed shop-fabrication of gate leaf in separate segments to
facilitate handling and shipping must be approved and shall be as shown on approved detail drawings. Such segments
shall permit easy field-assembly and shall be as few as practicable to minimize the number of joints to be field-welded.
The overall height of the gate leaf shall not vary from the nominal dimension or differ from the mating gate
leaf by more than 6 mm 1/4 inch. The surfaces of the vertical ribs to which skin plates are to be welded shall
not vary from a true plane by more than 5 mm 3/16 inch. The outside surfaces of skin plates welded to the vertical
ribs shall not vary from a true plane by more than 5 mm 3/16 inch. Splices in skin plates shall be located only
where shown or approved. [In addition to welds specifically indicated on the drawings for nondestructive testing,
[_____] percent of the welds in the [hinge pin housing] [joints between trusses and pintle socket] [joints between
trusses and hinge pin housing] [joints between vertical webs and skin plate] [and] skin plate shall receive nondestructive
testing. The location of these additional welds for testing shall be as directed by the Contracting Officer.]
Gate leaf shall be provided complete with pintle assembly, hinge assembly, seal assembly, and other appurtenant
components as required for complete installation as specified and shown.
2.3.7.2 Hinge Assembly
Hinge assembly shall consist of hinge bracket support anchor frame, hinge bracket support, hinge bracket, and
hinge pin. Hinge bracket support anchor frame shall be a welded structural steel frame with high strength anchor
bolts conforming to ASTM A 722/A 722M for prestressed anchorage of the hinge bracket support. Hinge bracket
support and hinge bracket shall be of [cast steel conforming to ASTM A 27/A 27M] [structural steel conforming
to ASTM A 36/A 36M]. The hinge pin barrel section of the hinge bracket shall be fitted with [a stainless steel
collar conforming to ASTM A 564/A 564M and] [a bronze bushing conforming with ASTM B 22] [an aluminum bronze
bushing conforming to ASTM B 148]. Hinge pin shall be of [forged steel conforming to ASTM A 668/A 668M] [stainless
steel conforming to [ASTM A 276] [ASTM A 564/A 564M]]. [In addition to welds specifically indicated on the drawings
for nondestructive testing, [_____] percent of the welds in the hinge assembly components shall receive nondestructive
testing. The location of these additional welds for testing shall be directed by the Contracting Officer.]
[Welded hinge assembly components shall be stress-relieved by heat-treating after all welding is completed.
Stress-relieving shall be performed prior to machining.]
2.3.7.3 Pintle Assembly
Pintle assembly shall consist of pintle base anchor frame, pintle base, pintle socket seal retainer ring assembly,
pintle, and pintle socket which shall be an integral component of the gate leaf. Pintle base anchor frame shall
be a welded structural steel frame [with high strength anchor bolts conforming to ASTM A 722/A 722M for prestressed
anchorage of the pintle base]. Pintle base shall be of [cast steel conforming to ASTM A 27/A 27M] [structural
steel conforming to ASTM A 36/A 36M]. Pintle shall be of [cast alloy steel] [forged alloy steel with bearing
surfaces of corrosion-resisting steel deposited in weld passes to a thickness of not less than 3 mm 1/8 inch
and machined the required shape]. The pintle ball pintle shall receive a 0.4 micrometer 16 microinchfinish and
shall be fitted into the bushing of the pintle socket by scraping the bushing until uniform contact is attained
over the entire bearing surface as determined by testing with carbon paper or other approved coloring. The pintle
ball shall be match-marked with the bushing when fitted and so erected in the field.
2.3.7.4 Seal Assemblies
Seal assemblies shall consist of rubber seals, stainless steel retainer and spacer bars, and fasteners. Rubber
seals shall be continuous over the full length. Seals shall be accurately fitted and drilled for proper installation.
Bolt holes shall be drilled in the rubber seals by using prepared templates or the retainer bars as templates.
Splices in seals shall be fully molded, develop a minimum tensile strength of 50 percent of the unspliced seal,
and occur only at locations shown. All vulcanizing of splices shall be done in the shop. The vulcanized splices
between molded corners and straight lengths shall be located as close to the corners as practicable. Splices
shall be on a 45 degree bevel related to the "thickness" of the seal. The surfaces of finished splices shall
be smooth and free of irregularities. Stainless steel retainer bars shall be field-spliced only where shown
and shall be machine-finished after splicing.
2.3.7.5 Appurtenant Items
Seal plates, seal shapes, pintle socket seal retainer ring assembly, bumpers, fenders, [walkways,] [bridgeways,]
and other appurtenant items shall conform to details specified and shown.
2.3.8 Shop Assembly
Shop assembly requirements for sector gates and appurtenant items shall be as shown and specified herein and
in Section
05 50 03.00 10
05 50 03.00 10
05 50 03.00 10 METALWORK FABRICATION, MACHINE WORK, MISCELLANEOUS PROVISIONS. Sector gates and appurtenant
items shall be assembled completely in the shop, unless otherwise approved, to assure satisfactory field installation.
Adjoining components shall be fitted and bolted together to facilitate field connections. The matchmarking of
unassembled items shall be carefully preserved until the items are assembled. Mating surfaces and machined surfaces
shall be covered with a rust preventive until assembly. Assembled components shall be shop-welded in their final
positions as much as delivery and field installation conditions will permit. Rubber seals shall be fitted and
drilled to match the seal retainers, match-marked, and removed for shipment. Shop assembly and disassembly work
shall be performed in the presence of the Contracting Officer unless otherwise approved. The presence of the
Contracting Officer will not relieve the Contractor of any responsibility under this contract.
2.4 TESTS, INSPECTIONS, AND VERIFICATIONS
Tests, inspections, and verifications for materials shall conform to the requirements specified and in Section
05 50 03.00 10
05 50 03.00 10
05 50 03.00 10 METALWORK FABRICATION, MACHINE WORK, AND MISCELLANEOUS PROVISIONS.
2.4.1 [Testing of Rubber Seals
NOTE: If fluorocarbon (Teflon) clad seals are not used, delete this paragraph.
The fluorocarbon film of rubber seals shall be tested for adhesion bond in accordance with ASTM D 413 using either
the machine method or the deadweight method. A 25 mm 1 inch long piece of seal shall be cut from the end of
the seal which has been masked and subjected to tension at an angle approximately 90 degrees to the rubber surface.
There shall be no separation between the fluorocarbon film and the rubber when subjected to the following loads:
THICKNESS OF MACHINE METHOD AT DEADWEIGHT
FLUOROCARBON FILM 50 MM PER MINUTE METHOD
[1.524 mm 13.6 kg per 13.6 kg per
25 mm width 25 mm width]
[0.726 mm 13.6 kg per 13.6 kg per
25 mm width 25 mm width]
THICKNESS OF MACHINE METHOD AT DEADWEIGHT
FLUOROCARBON FILM 2 INCHES PER MINUTE METHOD
[0.030 inch 30 pounds per inch width 30 pounds per
inch width]
[0.060 inch 30 pounds per inch width 30 pounds per
inch width]]
PART 3 EXECUTION
3.1 INSTALLATION
Installation shall conform with the requirements specified herein and in Section
05 50 03.00 10
05 50 03.00 10
05 50 03.00 10 METALWORK FABRICATION,
MACHINE WORK, MISCELLANEOUS PROVISIONS. Sector gates and appurtenant items shall be assembled for installation
in strict accordance with the contract drawings, approved installation drawings, and shop match-markings. Bearing
surfaces requiring lubrication shall be thoroughly cleaned and lubricated with an approved lubricant before assembly
and installation. Components to be field-welded shall be in correct alignment before welding is commenced.
3.1.1 Embedded Metals
Seal shapes, seal plates, frames, bases and other embedded metal items required for proper and complete installation
shall be accurately installed to the alignment and grade required to ensure accurate fitting and matching of
components. Embedded metals shall be given a primer coat of the required paint on all surfaces prior to installation
in concrete forms. Anchors for embedded metals shall be installed as shown. Items requiring two concrete pours
for installation shall be attached to the embedded anchors after the initial pour, adjusted to the proper alignment,
and concreted in place with the second pour. Welded field splices in sealing surfaces of embedded items shall
be ground smooth.
3.1.2 Hinge Assembly Embedded Anchorages
The hinge assembly embedded anchorages consisting of the hinge bracket support anchor frame and attached hinge
bracket support anchor bolts shall be aligned accurately, leveled, and blocked rigidly in place to prevent displacement
before concrete is placed. Hinge bracket support anchor bolts shall be coated with asphalt mastic prior to the
placement of first-pour concrete. Hinge bracket support shall be connected to anchor bolts and embedded in second-pour
concrete. Anchor bolts shall be prestressed as shown on contract drawings and approved field installation drawings
after the concrete has attained the specified strength. A record of the prestressing operations shall be compiled
and submitted.
3.1.3 Pintle Base Anchor Frame and Pintle Base
NOTE: Design options provided in this paragraph consist of the pintle base
bearing directly on an anchor frame embedded in second-pour concrete and anchored
with bolts embedded in first-pour concrete, the pintle base bearing directly
on second-pour concrete and anchored with bolts attached to an anchor frame
embedded in first-pour concrete, and the prestressing of pintle base anchor
bolts when attached to an anchor frame embedded in first-pour concrete.
[Anchor bolts for the pintle base anchor frame shall be embedded in first-pour concrete. Pintle base anchor
frame shall be attached to the anchor bolts, aligned, leveled, blocked rigidly to prevent displacement, and embedded
in second-pour concrete. Pintle base shall be bolted to the pintle base anchor frame.] [Pintle base anchor
frame shall be embedded in first-pour concrete. Pintle base shall be attached to the pintle base anchor bolts
extending from the embedded anchor frame, aligned, leveled, blocked rigidly to prevent displacement, and embedded
in second-pour concrete.] [Pintle base anchor bolts shall be prestressed as shown on contract drawings and approved
field installation drawings. A record of the prestressing operations shall be compiled and submitted.] Concrete
pours shall be allowed to set for 72 hours and must attain the specified before any loading is applied.
3.1.4 Pintle
Surfaces of the pintle base shall be cleaned thoroughly prior to installing the pintle. The pintle shaft shall
be set in the pintle base and secured by lock-bolting.
3.1.5 Gate Leaf
Gate leaf components not assembled in the shop shall be assembled in the field as required for installation.
Pintle socket seal retainer ring assembly shall be attached to the pintle socket and the pintle ball shall be
coated with grease prior to setting the gate leaf in place. Pintle grease pipes shall be tapped into pintle
bushing in correct register with bushing grease grooves. Grease pipes shall be flushed prior to connecting to
bearings. All necessary precautions shall be taken to avoid distortion of the gate leaf or any component parts.
Special care shall be exercised during installation to prevent any sag of the sector gate leaf due to compression
of blocking or other causes.
3.1.6 Hinge Bracket and Hinge Pin
Hinge bracket shall be attached to the hinge bracket support after the gate leaf has been set in place. Hinge
pin shall be inserted to connect the hinge pin barrel of the hinge bracket to the hinge pin housing of the gate
leaf. Hinge bracket shall be adjusted so that the center of the hinge pin is in vertical alignment with the
center of the pintle and each gate leaf swings without interference and any point on the moving gate leaf remain
in a plane throughout the range of movement.
3.1.7 Painting
Exposed parts of gates and appurtenances, except machined surfaces, corrosion-resistant surfaces, surfaces of
anchorages embedded in concrete, [cathodic protection system anodes,] and other specified surfaces shall be painted
as specified in Section
09 97 02
09 97 02
09 97 02 PAINTING: HYDRAULIC STRUCTURES.
3.1.8 Seal Assemblies
Rubber seal assemblies shall be installed after the embedded metal components have been concreted in place and
the gate installation, including painting, completed. Rubber seals shall be fastened securely to metal retainers.
Before operating the gates, a suitable lubricant shall be applied to the rubber seal rubbing plates to protect
the rubber.
3.2 CATHODIC PROTECTION SYSTEM
3.3 OPERATING MACHINERY
Operating machinery shall conform to Section [
_____
_____
_____] [SECTOR GATE OPERATING MACHINERY].
3.4 FIELD TESTS AND INSPECTIONS
3.4.1 [Skinplate Watertightness Test
NOTE: Skinplate watertightness tests should be deleted when complete or spot
radiographic or ultrasonic examination of the skinplate is required by the specifications.
After the gate leaves are installed but prior to painting and mounting of seals, skinplate welds shall be tested
for watertightness by applying air pressure with a hose, using a minimum air pressure of 400 kPa 60 psi at the
nozzle, to one face of the skinplate with a light coating of soapsuds on the opposite face. Disclosed leaks
shall be sealed with light welds.]
3.4.2 Acceptance Trial Operation
After completion of the gate installation, the Contracting Officer will examine the gates for final acceptance.
The gates will be examined first to determine whether or not the workmanship conforms to the specification requirements.
The Contractor will then be required to operate the gates from the fully-opened to the fully-closed position
a sufficient number of times to demonstrate to the Contracting Officer's satisfaction that all parts are functioning
properly. The workmanship in the fabrication and installation of gates shall be such that the gates in the closed
position will form a watertight barrier across the opening. Required repairs or replacements to correct defects,
as determined by the Contracting Officer, shall be made at no cost to the Government. The trial operation shall
be repeated after defects are corrected. Prior to final acceptance of the gates, the Contractor shall provide
temporary restraints to prevent unauthorized operation of the gates.
3.5 PROTECTION OF FINISHED WORK
-- End of Section --