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USACE / NAVFAC / AFCESA / NASA UFGS-11285 (August 2004)
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MasterFormatTM 2004 - 35 20 16.33
Superseding
UFGS-11285A (January 1994)
UNIFIED FACILITIES GUIDE SPECIFICATIONSReferences are in agreement with UMRL dated 23 June 2005
Section Table of Contents
SECTION 11285
MITER GATES
08/04
PART 1 GENERAL
1.1 REFERENCES
1.2 UNIT PRICES
1.2.1 Furnishing and Installing Miter Gates
1.2.1.1 Payment
1.2.1.2 Unit of Measure
1.2.2 Furnishing Miter Gates
1.2.2.1 Payment
1.2.2.2 Unit of Measure
1.2.3 Installing Miter Gates
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 Rubber Seals
1.5.2 [Epoxy Filler
1.6 [SAFETY PROVISIONS FOR ZINC FILLER
PART 2 PRODUCTS
2.1 MATERIALS
2.1.1 Metals
2.1.1.1 Structural Steel
2.1.1.2 Structural Steel Plates
2.1.1.3 Steel Pipe
2.1.1.4 Stainless Steel Bars and Shapes
2.1.1.5 Stainless Steel Plate, Sheet, and Strip
2.1.2 Rubber Seals
2.1.2.1 Physical Characteristics
2.1.2.2 [Fabrication
2.1.3 [Epoxy Filler
2.1.4 [Zinc Filler
2.1.5 Bumpers and Fenders
2.1.6 Asphalt Saturated Preformed Filler Strips
2.1.7 Asphalt Cement
2.1.8 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 Wall Quoin
2.3.7.3 Quoin and Miter Contact [Blocks] [Posts]
2.3.7.4 Pintle Assembly
2.3.7.5 Gudgeon Anchorage
2.3.7.6 Seal Assemblies
2.3.7.7 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 Pintle Assembly
3.1.3 Gudgeon Embedded Anchorage
3.1.4 Wall Quoin
3.1.5 Gate Leaf
3.1.6 Diagonals
3.1.7 Gate Leaf Quoin and Miter Contact [Blocks] [Posts]
3.1.7.1 Placing [Epoxy] [Zinc] Filler
3.1.7.2 Adjusting Contact [Blocks] [Posts]
3.1.8 Miter Guide
3.1.9 Painting
3.1.10 Seal Assemblies
3.2 CATHODIC PROTECTION SYSTEM
3.3 OPERATING MACHINERY
3.4 FIELD TESTS AND INSPECTIONS
3.4.1 [Skin Plate Watertightness Test
3.4.2 Acceptance Trial Operation
3.5 PROTECTION OF FINISHED WORK
SECTION 11285
MITER GATES
NOTE: This guide specification covers the requirements for the fabrication,
assembly, delivery, and installation of miter gates and appurtenant items as
specified and shown.
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 | | (2004) Structural Welding Code - Steel |
| |
| AWS D1.2 | | (2003) Structural Welding Code - Aluminum |
| AMERICAN WOOD-PRESERVERS' ASSOCIATION (AWPA) |
| |
| AWPA C2 | | (2001) 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 167 | | (2004) Stainless and Heat-Resisting Chromium-Nickel
Steel Plate, Sheet, and Strip |
| |
| ASTM A 176 | | (1999; R 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 276 | | (2004) 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 | | (2004) 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 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 | | (2004) 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 B 6 | | (2003) Zinc |
| |
| ASTM D 1751 | | (2004) Preformed Expansion Joint Filler for
Concrete Paving and Structural Construction
(Nonextruding and Resilient Bituminous Types) |
| |
| ASTM D 2240 | | (2004) Rubber Property - Durometer Hardness |
| |
| ASTM D 3019 | | (1994; R 2000e1) Lap Cement Used with Asphalt
Roll Roofing Non Fibered, Asbestos Fibered,
and Non Asbestos Fibered |
| |
| 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 0127001025 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 01270.
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 Miter Gates
1.2.1.1 Payment
Payment will be made for costs associated with furnishing and installing miter gates and appurtenant items, which
includes full compensation for the materials, fabrication, delivery, installation, and testing of miter gates
and appurtenant items including gate leaves, diagonals, strut connections, miter guides, miter latches, recess
latch strikes, quoin and miter contact blocks, gudgeon top anchorages, pintle assemblies, [walkways,] [bridgeways,]
gudgeon embedded anchorages, wall quoins, sill assemblies, seal assemblies, recess latches, bumpers, fenders,
and all other items necessary for complete installation.
1.2.1.2 Unit of Measure
Unit of measure: lump sum.
1.2.2 Furnishing Miter Gates
1.2.2.1 Payment
Payment will be made for costs associated with furnishing miter gates and appurtenant items, which includes full
compensation for the materials, fabrication, and delivery of miter gates and appurtenant items including gate
leaves, diagonals, strut connections, miter guides, miter latches, recess latch strikes, quoin and miter contact
blocks, gudgeon top anchorages, pintle assemblies, [walkways,] [bridgeways,] gudgeon embedded anchorages, wall
quoins, sill assemblies, seal assemblies, recess latches, 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 Miter Gates
1.2.3.1 Payment
Payment will be made for costs associated with the installation of miter gates and appurtenant items, which includes
full compensation for the complete installation and testing of miter 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 01330 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
01330
01330
01330 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Detail Drawings[; G][; G, [_____]]
Detail drawings shall be submitted as specified herein and in Section
05055A
05055A
05055A METALWORK FABRICATION,
MACHINE WORK, MISCELLANEOUS PROVISIONS.
Diagonals Prestressing[; G][; G, [_____]]
Diagonal prestressing plan shall be submitted and approved prior to initiating the prestressing
operations. Diagonal prestressing record shall be submitted prior to completion of the contract.
Gudgeon Embedded Anchorage[; G][; G, [_____]]
Gudgeon embedded anchorage prestressing plan shall be submitted and approved prior to initiating
the anchorage operations. Gudgeon embedded anchorage prestressing record shall be submitted
prior to completion of the contract.
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
05055A
05055A
05055A METALWORK FABRICATION, MACHINE WORK, MISCELLANEOUS PROVISIONS.
Diagonals Prestressing
Diagonal prestressing records shall be submitted immediately after completion of the prestressing
operations.
Gudgeon Embedded Anchorage
Gudgeon embedded anchorage prestressing records shall be submitted immediately after completion
of the prestressing operations.
Welding
Schedules of welding procedures for structural steel shall be submitted as specified in Section
05055A
05055A
05055A METALWORK FABRICATION, MACHINE WORK, MISCELLANEOUS PROVISIONS.
SD-04 Samples
Materials[; 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.
SD-07 Certificates
Epoxy Filler
Manufacturer's certificate for epoxy filler shall be submitted with the material delivered
to the site.
1.4 QUALIFICATION OF WELDERS AND WELDING OPERATORS
Qualification of welders and welding operators shall conform to the requirements of Section
05055A
05055A
05055A METALWORK
FABRICATION, MACHINE WORK, MISCELLANEOUS PROVISIONS.
1.5 DELIVERY, STORAGE, AND HANDLING
Delivery, handling, and storage of materials and fabricated items shall conform to the requirements specified
[herein and] in Section
05055A
05055A
05055AMETALWORK 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.]
1.5.1 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.
1.5.2 [Epoxy Filler
Epoxy filler shall be delivered from the manufacturer just prior to use in the work to insure receipt of recently
manufactured material and shall be stored under cover, out of direct sunlight, at a temperature between 20 to
30 degrees C 65 to 85 degrees F.]
1.6 [SAFETY PROVISIONS FOR ZINC FILLER
The following special safety provisions are required for heating and placing zinc filler:
a. Workers shall wear protective clothing including hard hats with fine wire mesh screen, goggles, leather
sleeves, chaps, apron, and leather gloves.
b. Workers shall wear air-line respirators certified by National Institute for Occupational Safety and
Health (NIOSH) or Mine Safety and Health Administration (MSHA). In enclosed spaces, both local exhaust
ventilation and air-line respirators are required. Local exhaust ventilation shall consist of movable
hoods placed close to the work to remove fumes at the source.
c. Ladles, equipment, and material shall be pre-heated before being used so that they will be moisture-free.
d. Heating devices and ladles shall be placed on a level, firm foundation, and protected against traffic,
accidental tipping, or similar hazard.
e. Hot zinc shall not be carried up or down ladders.
f. Buckets or vessels used for handling and transporting hot zinc shall be substantially constructed
and shall not be filled higher than 100 mm 4 inches from the top.]
PART 2 PRODUCTS
2.1 MATERIALS
Materials orders, materials lists and materials shipping bills shall conform with the requirements of Section
05055A
05055A
05055A 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
05502A
05502A
05502A METALS:
MISCELLANEOUS, STANDARD ARTICLES, SHOP FABRICATED ITEMS.
2.1.1.1 Structural Steel
Structural steel shall conform to ASTM A 36/A 36M.
2.1.1.2 Structural Steel Plates
Structural steel plates shall conform to [ASTM A 36/A 36M] [ASTM A 572/A 572M, Grade 50] [ASTM A 588/A 588M,
Grade 50].
2.1.1.3 Steel Pipe
Steel pipe shall conform to ASTM A 53/A 53M, Type S, Grade B, seamless, black, nominal size and weight class
or outside diameter and nominal wall thickness as shown, [plain] [threaded] [threaded and coupled] ends.
2.1.1.4 Stainless Steel Bars and Shapes
Stainless steel bars and shapes shall conform to 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.
2.1.1.5 Stainless Steel Plate, Sheet, and Strip
Stainless steel plate, sheet, and strip shall conform to 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.
2.1.2 Rubber Seals
NOTE: If fluorocarbon (Teflon) clad seals are not used, omit paragraphs FABRICATION
and ZINC FILLER.
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% (min.) ASTM D 412
300% 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 2,500 psi (min.) ASTM D 412
Elongation at Break 450% (min.) ASTM D 412
300% 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 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 [Epoxy Filler
Epoxy filler shall be an approved epoxy resin formulation equal to "Nordback," a product of Nordberg Mfg. Co.,
or an approved equal, with a specific gravity of 1.70 to 1.75, minimum compressive strength after 72 hours at
20 degrees C 70 degrees F of 114 MPa 16,500 psi, and maximum shrinkage of 0.15 percent. The manufacturer must
certify that the material meets or exceeds the specified physical properties.]
2.1.4 [Zinc Filler
ASTM B 6.]
2.1.5 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.]
2.1.6 Asphalt Saturated Preformed Filler Strips
ASTM D 1751.
2.1.7 Asphalt Cement
ASTM D 3019.
2.1.8 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
herein and in Section
05502A
05502A
05502A METALS: MISCELLANEOUS, STANDARD ARTICLES, SHOP FABRICATED ITEMS.
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 herein and in Section
05055A
05055A
05055A 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 gate leaf diagonals, which shall include descriptions of connections, riggings, anchorages,
and measuring equipment; methods for installing quoin and miter blocks, including checking and maintaining alignments
of the blocks during concreting and placement of [epoxy] [zinc] filler; [procedures and equipment used for heating
and placing of the zinc filler;] 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
05055A
05055A
05055A 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 on the drawings. 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 [cathodic protection system devices and other] appurtenances as required.
2.3.3 Welding
NOTE: List applicable welds requiring radiographic examination.
Welding shall conform with the requirements of
AWS D1.1/D1.1M,
AWS D1.2, the requirements specified herein and
in Section
05055A
05055A
05055A 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, 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
Bolted connections shall conform with the requirements specified in Section
05055A
05055A
05055A METALWORK FABRICATION, MACHINE
WORK, MISCELLANEOUS PROVISIONS.
2.3.5 Machine Work
Machine work shall conform with the requirements specified in Section
05055A
05055A
05055A METALWORK FABRICATION, MACHINE WORK,
MISCELLANEOUS PROVISIONS.
2.3.6 Miscellaneous Provisions
Miscellaneous provisions for fabrication shall conform with the requirements specified herein and in Section
05055A
05055A
05055A METALWORK FABRICATION, MACHINE WORK, MISCELLANEOUS PROVISIONS.
2.3.7 Fabrications
2.3.7.1 Gate Leaf
Gate leaf shall be of welded structural steel fabrication consisting of horizontal girders, [vertical beams,]
[vertical girders,] intercostals, diaphragms, quoin post, gudgeon pin hood, operating strut connections, skin
plate, and adjustable diagonals. Gate leaf shall be shop-fabricated. Contractor proposed shop-fabrication of
gate leaf in separate segments to facilitate handling and shipping must be approved by the Contracting Officer
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 framing elements 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 framing members 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 girders, gudgeon pin hood, verticals and skin plate of the gate leaf 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 quoin and miter contact [blocks] [posts], miter guide assembly, pintle
assembly, gudgeon anchorage, seal assembly, and other appurtenant components as required for complete installation,
specified herein and shown.
2.3.7.2 Wall Quoin
Wall quoin shall consist of a welded structural steel frame with adjustable stainless steel base anchors and
adjustable stainless steel quoin contact [block] [post].
2.3.7.3 Quoin and Miter Contact [Blocks] [Posts]
Quoin and miter contact [blocks] [posts] shall be of stainless steel bars conforming to ASTM A 276 or ASTM A 564/A 564M
. Splices in contact [blocks] [posts] shall be made by an offset method so that there will not be a continuous
joint across the [block] [post]. [Splices in gate leaf contact [block] [post] shall occur only at the centerlines
of horizontal girders.] Splice locations shall match those of the opposing [block] [post]. Contact faces of
contact [blocks] [posts] shall be milled at splices to assure watertight joints. Contact [blocks] [posts] shall
be provided with adjusting bolts as shown.
2.3.7.4 Pintle Assembly
Pintle assembly shall consist of pintle socket, pintle, and pintle base as shown. Pintle socket shall be of
cast nickel-alloy steel. Pintle socket shall be press-fitted with an aluminum bronze bushing with bearing surfaces
finished truly hemispherical. Pintle shall be of [cast alloy] [forged alloy] steel with bearing surfaces of
corrosion-resisting steel. Pintle ball shall receive a 0.4 micrometer 16 microinch finish and shall be fitted
into the bushing by scraping 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. Pintle base shall be of cast steel. Bolt holes for attaching pintle
socket to gate leaf shall be drilled and reamed after the pintle socket is assembled with gate leaf. Pintle
socket shall be connected to the bottom of the lower girder web of the gate leaf with stainless steel bolts.
2.3.7.5 Gudgeon Anchorage
Gudgeon anchorage shall consist of gudgeon pin barrel, gudgeon anchorage links, gudgeon pin, and gudgeon embedded
anchorage. Gudgeon pin barrel shall be of welded [structural steel plates] [forged alloy steel plates conforming
to ASTM A 668/A 668M] and shall be fitted with a bronze bushing. Gudgeon anchorage links and gudgeon pin shall
be of forged alloy steel conforming to ASTM A 668/A 668M. Gudgeon anchorage links shall be pin connected to
the gudgeon embedded anchorage and shall have a threaded section for adjustment of the gate leaf. The threaded
section shall have right and left threads, a hexagonal sleeve nut with 13 mm1/2 inch threads, and a jam nut with
standard threads at each end of the sleeve nut. The gudgeon embedded anchorage shall consist of a structural
steel frame with end-restrained anchor bolts conforming to [ASTM A 325M.ASTM A 325.] [ASTM A 490M.ASTM A 490M
.]
2.3.7.6 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 machine-finished after splicing.
2.3.7.7 Appurtenant Items
Sill assemblies, latches, bumpers fenders, seal plates and shapes, and other appurtenant items shall conform
to details specified and shown.
2.3.8 Shop Assembly
Shop assembly requirements for miter gates and appurtenant items shall be as shown and specified herein and in
Section
05055A
05055A
05055A METALWORK FABRICATION, MACHINE WORK, MISCELLANEOUS PROVISIONS. Miter gates and appurtenant items
shall be assembled completely in the shop, unless otherwise approved by the Contracting Officer, 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 by the Contracting Officer. 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 herein and in
Section
05055A
05055A
05055A METALWORK FABRICATION, MACHINE WORK, AND MISCELLANEOUS PROVISIONS.
2.4.1 Testing of Rubber Seals
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 50 MM PER MINUTE METHOD
FILM
[0.762 mm 13.6 kg per 13.6 kg per
25 mm width 25 mm width]
[1.524 mm 13.6 kg per 13.6 kg per
25 mm width 25 mm width]
THICKNESS OF MACHINE METHOD AT DEADWEIGHT
FLUOROCARBON 2 INCHES PER MINUTE METHOD
FILM
[0.030 inch 30 pounds per 30 pounds per
inch width inch width]
[0.060 inch 30 pounds per 30 pounds per
inch width inch width]
PART 3 EXECUTION
3.1 INSTALLATION
Installation shall conform with the requirements specified herein and in Section
05055A
05055A
05055A METALWORK FABRICATION,
MACHINE WORK, MISCELLANEOUS PROVISIONS. Miter 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
Sill assemblies, 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 Pintle Assembly
Base anchors for the pintle assembly shall be embedded in first-pour concrete. The pintle assembly base plate
shall be attached to base anchors, adjusted to the exact elevation and center-to-center distance shown, leveled,
blocked rigidly to prevent displacement, and embedded in second-pour concrete. The concrete shall be allowed
to set 72 hours and must reach a minimum compressive strength of [_____] MPa psi before loading is applied.
[The space in the floating pintle base not occupied by the pintle shoe shall be filled completely with sponge
rubber before the gate leaf is set in place.]
3.1.3 Gudgeon Embedded Anchorage
The gudgeon embedded anchorage, except for anchor bolts and horizontal anchor arms, shall be covered with asphalt
saturated preformed strips applied with asphalt cement prior to being embedded in concrete. Anchor bolts shall
be coated with asphalt mastic. The gudgeon embedded anchorage shall be aligned, leveled, and blocked rigidly
in place to prevent displacement before concrete is placed. Concrete shall be placed in a manner not to damage
the preformed strips. Anchor bolts shall be prestressed after the concrete has attained the specified strength
in accordance with contract drawings and approved field installation drawings. A record of the gudgeon embedded
anchorage prestressing operations shall be compiled and submitted in accordance with paragraph SUBMITTALS.
3.1.4 Wall Quoin
Base anchors for the wall quoin shall be embedded in first-pour concrete. The wall quoin shall be attached to
base anchors prior to setting the gate leaf in place. After the gate leaf is set in place, the wall quoin shall
be plumbed and adjusted in relation to the gate leaf quoin so as to provide for continuous contact between the
sealing surfaces of the wall and gate leaf quoin contact [blocks] [posts] over the full height of the gate leaf.
This adjustment shall be made almost entirely by moving the wall quoin so that the gap for the [epoxy] [zinc]
filler behind the gate leaf quoin contact [block] [post] remains near the nominal dimension. After final adjustments
have been made, the wall quoin shall be anchored firmly and the second-pour concrete shall be placed in the blockout.
3.1.5 Gate Leaf
Gate leaf components not assembled in the shop shall be assembled in the field as required for installation.
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 miter
ends of the gate leaf due to compression of blocking or other causes. After the gate leaf has been set in place
and the components of gudgeon anchorage are connected to the gate leaf, the gate leaf shall be plumbed and brought
into correct position by adjusting the sleeve nuts of the diagonals and the gudgeon anchorage links.
3.1.6 Diagonals
Gate leaf diagonals shall be attached to the gate leaf after the leaf is set in place. Diagonals prestressing
shall be performed before the final adjustment of the quoin and miter contact [blocks] [post] are made. Prestressing
of diagonals shall be as specified, shown, and as approved on the prestressing plan developed by the Contractor.
The plan for prestressing the diagonals shall describe the method of prestressing, including the materials, connections,
rigging, anchorages, and stress measuring equipment. The Contractor shall compile a record of the prestressing
operations consisting of the information indicated in the following table:
STRESS DATA TABLE
Gate Leaf Location:____________________________Date ___________
: 1 : 2 : 3 : 4 : 5
Diagonal : Strain Gage : Readings : E : D : d
: Initial : Final : (mm) : (mm) : (mm)
[_____] : [_____] : [_____] : [_____] : [_____] : [_____]
[_____] : [_____] : [_____] : [_____] : [_____] : [_____]
[_____] : [_____] : [_____] : [_____] : [_____] : [_____]
[_____] : [_____] : [_____] : [_____] : [_____] : [_____]
STRESS DATA TABLE
Gate Leaf Location:__________________________Date __________
: 1 : 2 : 3 : 4 : 5
Diagonal : Strain Gage : Readings : E : D : d
: Initial : Final : (in.) : (in.) : (in.)
[_____] : [_____] : [_____] : [_____] : [_____] : [_____]
[_____] : [_____] : [_____] : [_____] : [_____] : [_____]
[_____] : [_____] : [_____] : [_____] : [_____] : [_____]
[_____] : [_____] : [_____] : [_____] : [_____] : [_____]
1. Initial strain gage readings shall be made after slack is removed.
2. Final strain gage readings shall be made after prestressing is complete.
3. E is the total elongation over the full length of the diagonal, computed from the strain gage readings.
4. D is the prestress deflection of the leaf as shown on the drawings.
5. d is the field deflection of the leaf measured after completion of the prestress operation; it is the deflection
when final strain gage readings are taken.
3.1.7 Gate Leaf Quoin and Miter Contact [Blocks] [Posts]
After the wall quoin has been adjusted and concreted in place and final adjustments made to the gudgeon anchorage
links, gate leaf quoin and miter contact [blocks] [posts] shall be adjusted to provide continuous contact over
the full height of the gate leaf in the mitered position. After the gate leaf diagonals are prestressed and
final adjustments of gate leaf quoin and miter contact [blocks] [posts] have been made with the gate leaf in
the mitered position, the gate leaf shall be swung out of miter and [epoxy] [zinc] filler poured behind the quoin
and miter contact [blocks] [posts]. Prior to pouring of the filler, the surfaces to receive the filler shall
be cleaned free of dirt, rust, and other foreign materials. The adjusting and holding bolts shall be coated
with grease or other bond breaker to prevent adherence of the filler.
3.1.7.1 Placing [Epoxy] [Zinc] Filler
[A field test to determine the indentation hardness of the epoxy filler compound shall be conducted prior to
placement. The field test procedures are as follows:
a. Cast a 50 mm 2 inch cube sample of mixed epoxy filler compound in a mold and cure at room temperature
(20 to 25 degrees C70 to 80 degrees F) for 24 plus or minus 8 hours.
b. Remove from mold and cut sample to expose interior surface.
c. Sand exposed interior surfaces to remove saw marks and provide a smooth surface.
d. Using a Type D Durometer conforming to ASTM D 2240, measure the hardness across the exposed interior
surface, taking a minimum of three readings on each half of the sample. Care must be taken during the
durometer reading to insure the spring loaded pin used to penetrate the surface is not in a depressed
surface caused by either residual saw marks or an exposed air bubble. The average reading should be
at least 85, with no individual reading below 82. If the durometer readings fall below the required
minimum values, the material will be rejected.
The manufacturer's instructions for placing the epoxy filler shall be followed explicitly. Special precautions
must be taken to prevent leakage of the filler during placement. The complete masses of the metals whose surface
areas are to receive the epoxy filler should have a temperature of 15 to 30 degrees C 60 to 90 degrees F. The
epoxy filler shall be kept free from moisture or other foreign materials during mixing and placement and for
at least 48 hours after placement.]
[Immediately preceding the pouring of the zinc filler, the adjacent metal components shall be pre-heated to a
temperature of 100 to 150 degrees C212 to 300 degrees F by an approved method which does not buckle the metal
components. The zinc filler shall then be poured at a temperature which will insure that it will completely
fill all interstices. Pouring temperature of zinc filler shall be maintained between 430 and 480 degrees C 810
and 900 degrees F to minimize volatilization and oxidation of the zinc.]
3.1.7.2 Adjusting Contact [Blocks] [Posts]
After the [epoxy has set] [zinc has cooled], quoin and miter contact [blocks] [posts] shall be drawn up against
the filler by tightening of the adjusting bolts. After the contact [blocks] [posts] are adjusted, the gate leaves
shall swing into the mitered position without interference of the quoin contact [blocks] [posts] and the gate
leaf quoin contact [block] [post] shall make tight contact with the wall quoin contact [block] [post].
3.1.8 Miter Guide
Miter guide shall be installed after the contact [blocks] [posts] have been properly set. The guide bracket
and roller bracket shall be mounted on gate leaves with leaves in the mitered position. The roller shall be
centered accurately in the saddle of the contact [blocks] [posts] and shall be in full contact with the [blocks]
[posts]. Adjustment of the miter guide shall be accomplished by adjusting the guide bracket and roller bracket
so that the gap behind the contact [blocks] [posts] for the [epoxy] [zinc] filler is kept at the nominal dimension.
Proper adjustment of the brackets should allow either gate leaf to be mitered or opened without moving the other
leaf. After final adjustments have been made, bolt holes shall be drilled in the brackets and gate leaves, brackets
shall be bolted securely in place, and [epoxy] [zinc] filler shall be placed behind the contact [blocks] [posts].
3.1.9 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
09964
09964
09964 PAINTING: HYDRAULIC STRUCTURES.
3.1.10 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 gate(s), a suitable lubricant shall be applied to the rubber seal rubbing plates to protect
the rubber.
3.2 CATHODIC PROTECTION SYSTEM
The cathodic protection system shall conform to Section [
_____
_____
_____] [CATHODIC PROTECTION SYSTEMS FOR LOCK MITER GATES].
3.3 OPERATING MACHINERY
Operating machinery shall conform to Section [
_____
_____
_____] [LOCK MITER GATE OPERATING MACHINERY].
3.4 FIELD TESTS AND INSPECTIONS
3.4.1 [Skin Plate Watertightness Test
NOTE: Skin plate watertightness tests should not be required when complete
or spot radiographic or ultrasonic examination of the skinplate is required
by the specifications.
After the gate leaf diagonals are prestressed but prior to painting and mounting of seals, skin plate 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 skin plate 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
Protection of finished work shall conform to the requirements of Section
05055A
05055A
05055A METALWORK FABRICATION, MACHINE
WORK, MISCELLANEOUS PROVISIONS.
-- End of Section --