USACE / NAVFAC / AFCESA / NASA UFGS-35 20 16.46 (January 2008)
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Preparing Activity: USACE (CW) Superseding
UFGS-35 20 16.46 (April 2006)
UNIFIED FACILITIES GUIDE SPECIFICATIONS
References are in agreement with UMRL dated January 2009
SECTION 35 20 16.46
TAINTER GATES AND ANCHORAGES
01/08
NOTE: This guide specification covers the requirements for fabrication, assembly,
delivery, and installation of tainter gates, anchorage assemblies, and appurtenant
items.
Edit this guide specification for project specific requirements by adding, deleting,
or revising text. For bracketed items, choose applicable items(s) or insert
appropriate information.
Remove information and requirements not required in respective project, whether
or not brackets are present.
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).
PART 1 GENERAL
1.1 UNIT PRICES
NOTE: Delete paragraph UNIT PRICES and incorporate appropriately edited paragraphs
from below into Section 01 22 00.00 10 MEASUREMENT AND PAYMENT.
1.1.1 Alternate 1
a. "Furnishing Tainter Gates and Appurtenant Items"
(1) Payment will be made for costs associated with furnishing tainter gates and appurtenant
items, which includes full compensation for materials, fabrication, shop assembly, and delivery
of tainter gates, including gates, trunnions, trunnion yokes, trunnion pins, and appurtenant
items, including cable attachment brackets, seal assemblies, side seal plates, dogging brackets,
sill beams, stop beams, and other items necessary for complete installation.
(2) Unit of measure: lump sum.
b. "Furnishing Tainter Gate Anchorage Assemblies"
(1) Payment will be made for costs associated with furnishing tainter gate anchorage assemblies,
which includes full compensation for materials, fabrication, and delivery of tainter gate anchorage
assemblies, including tainter gate trunnion girders and prestressing assemblies for anchoring
trunnion girders to piers [and trunnion yokes to trunnion girders, and other items necessary
for complete installation].
(2) Unit of measure: lump sum
c. "Installing Tainter Gate Anchorage Assemblies"
(1) Payment will be made for cost associated with the complete installation of tainter gates
anchorage assemblies.
(2) Unit of measure: lump sum.
1.1.2 Alternate 2
a. "Furnishing and Installing Tainter Gates and Appurtenant Items"
(1) Payment will be made for costs associated with furnishing and installing tainter gates
and appurtenant items, which includes full compensation for materials, fabrication, shop assembly,
delivery, and installation of tainter gates, including gates, trunnions, trunnion yokes, trunnion
pins, and appurtenant items, including cable attachment brackets, seal assemblies, side seal
plates, dogging brackets, sill beams, stop beams, and other items necessary for complete installation.
(2) Unit of measure: lump sum.
b. "Furnishing and Installing Tainter Gate Anchorage Assemblies"
(1) Payment will be made for costs associated with furnishing and installing tainter gate anchorage
assemblies, which includes full compensation for materials, fabrication, delivery, and installation
of tainter gate anchorage assemblies, including tainter gate trunnion girders and prestressing
assemblies for anchoring trunnion girders to piers [and trunnion yokes to trunnion girders,
and other items necessary for complete installation].
(2) Unit of measure: lump sum.
1.1.3 Alternate 3
"Furnishing and Installing Tainter Gates, Appurtenant Items, and Tainter Gate Anchorage Assemblies"
(1) Payment will be made for costs associated with furnishing and installing tainter gates,
appurtenant items, and tainter gate anchorage assemblies, which includes full compensation for
materials, fabrication, shop assembly, delivery, and installation of tainter gates, including
gates, trunnions, trunnion yokes, trunnion pins; appurtenant items, including cable attachment
brackets, seal assemblies, side seal plates, dogging brackets, sill beams, and stop beams; and
tainter gate anchorage assemblies, including tainter gate trunnion girders and prestressing
assemblies for anchoring trunnion girders to piers [and trunnion yokes to trunnion girders,
and other items necessary for complete installation].
(2) Unit of measure: lump sum.
1.2 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(2008) Structural Welding Code - SteelAWS D1.2/D1.2M(2008) Structural Welding Code - Aluminum][ASTM INTERNATIONAL (ASTM)ASTM A 148/A 148M(2008) Standard Specification for Steel Castings, High Strength, for Structural PurposesASTM A 167(1999; R 2004) Standard Specification for Stainless and Heat-Resisting Chromium-Nickel Steel Plate, Sheet, and StripASTM A 176(1999; R 2004) Standard Specification for Stainless and Heat-Resisting Chromium Steel Plate, Sheet, and StripASTM A 240/A 240M(2008) Standard Specification for Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General ApplicationsASTM A 27/A 27M(2008) Standard Specification for Steel Castings, Carbon, for General ApplicationASTM A 276(2008a) Standard Specification for Stainless Steel Bars and ShapesASTM A 307(2007b) Standard Specification for Carbon Steel Bolts and Studs, 60 000 PSI Tensile StrengthASTM A 320/A 320M(2008) Standard Specification for Alloy/Steel Bolting Materials for Low-Temperature ServiceASTM A 325(2007a) Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile StrengthASTM A 36/A 36M(2008) Standard Specification for Carbon Structural SteelASTM A 490(2008a) Standard Specification for Structural Bolts, Alloy Steel, Heat Treated, 150 ksi Minimum Tensile StrengthASTM A 501(2007) Standard Specification for Hot-Formed Welded and Seamless Carbon Steel Structural TubingASTM A 53/A 53M(2007) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and SeamlessASTM A 564/A 564M(2004) Standard Specification for Hot-Rolled and Cold-Finished Age-Hardening Stainless Steel Bars and ShapesASTM A 572/A 572M(2007) Standard Specification for High-Strength Low-Alloy Columbium-Vanadium Structural SteelASTM A 588/A 588M(2005) Standard Specification for High-Strength Low-Alloy Structural Steel with 50 ksi (345 MPa) Minimum Yield Point, with Atmospheric Corrosion ResistanceASTM A 668/A 668M(2004) Standard Specification for Steel Forgings, Carbon and Alloy, for General Industrial UseASTM A 722/A 722M(2007) Standard Specification for Uncoated High-Strength Steel Bar for Prestressing ConcreteASTM B 148(1997; R 2003e1) Standard Specification for Aluminum-Bronze Sand CastingsASTM B 22(2008) Standard Specification for Bronze Castings for Bridges and TurntablesASTM C 109/C 109M(2008) Standard Test Method for Compressive Strength of Hydraulic Cement Mortars (Using 2-in. or (50-mm) Cube Specimens)ASTM C 150(2007) Standard Specification for Portland CementASTM C 939(2002) Flow of Grout for Preplaced-Aggregate Concrete (Flow Cone Method)ASTM C 940(1998a; R 2003) Expansion and Bleeding of Freshly Mixed Grouts for Preplaced-Aggregate Concrete in the LaboratoryASTM D 2240(2005) Standard Test Method for Rubber Property - Durometer HardnessASTM D 395(2003; R 2008) Standard Test Methods for Rubber Property - Compression SetASTM D 412(2006ae1e2) Standard Test Methods for Vulcanized Rubber and Thermoplastic Elastomers - TensionASTM D 413(1998; R 2007) Rubber Property - Adhesion to Flexible SubstrateASTM D 471(2006; R 2008) Standard Test Method for Rubber Property - Effect of LiquidsASTM D 572(2004) Rubber Deterioration by Heat and Oxygen]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 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Detail Drawings[; G][; G, [_____]]
Detail drawings as specified herein and in Section 05 50 14 STRUCTURAL METAL FABRICATIONS.
SD-03 Product Data
Materials
System of identification which shows the disposition of specific lots of approved materials
and fabricated items in the work, before completion of the contract.
Materials orders, materials lists and materials shipping bills as specified in Section
05 50 14 STRUCTURAL METAL FABRICATIONS.
Prestressing Assemblies[; G][; G, [_____]]
Prestressing records immediately after the work is completed. Descriptions of the proposed
method for installing the prestressing assemblies, for approval, 30 days prior to the start
of prestressing operations.
Grout Admixture[; G][; G, [_____]]
Manufacturer's description of grout admixture, for approval, 30 days prior to the use of the
material in the work.
Welding[; G][; G, [_____]]
Schedules of welding procedures for structural steel as specified in Section 05 50 14 STRUCTURAL
METAL FABRICATIONS.
SD-04 Samples
Materials[; G][; G, [_____]]
Manufactured Units[; G][; G, [_____]]
Fabrications[; G][; G, [_____]]
Samples for approval 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 with all materials delivered to the site.
SD-07 Certificates
Anchorages and Couplers
Certificates for anchorages and couplers 30 days prior to the start of prestressing operations.
Certification of Prestressing Technicians
Certificates of prestressing technicians 30 days prior to the start of prestressing operations.
1.4 QUALITY ASSURANCE
1.4.1 Qualification of Welders and Welding Operators
Provide qualification of welders and welding operators conforming to the requirements of Section 05 50 14 STRUCTURAL
METAL FABRICATIONS.
1.4.2 Certification of Prestressing Technicians
Submit certificates, for prestressing technicians who will use the proposed system in the work, certifying by
name that the technicians are trained and skilled in the use of the proposed system.
1.4.3 Manufactured Units and Fabricated Items
Samples of manufactured units and shop fabricated 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 identified and its location
recorded.
1.5 DELIVERY, STORAGE, AND HANDLING
1.5.1 General
Perform delivery, handling, and storage of materials and fabricated items in conformance with the requirements
specified herein and in Section 05 50 14 STRUCTURAL METAL FABRICATIONS. Do not allow prestressing steel materials
to come in contact with the earth. Protective wrappings and coverings shall not be removed until immediately
prior to use in the work. Each prestressing tendon shall be closely inspected prior to use in the work. Tendons
with nicks, pits, bends or damaged threaded ends shall not be used in the work.
1.5.2 Rubber Seals
Store rubber seals in a place which permits free circulation of air, maintains a temperature of 21 degrees C
70 degrees F or less, and prevents the rubber from being exposed to the direct rays of the sun. Keep rubber
seals 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
Provide materials orders, materials lists, and materials shipping bills conforming with the requirements of Section
05 50 14 STRUCTURAL METAL FABRICATIONS.
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 on the drawings and specified herein and
in Section 05 50 15 CIVIL WORKS FABRICATIONS.
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 on the drawings, [plain] [threaded] [threaded and coupled] ends.] [ASTM A 501, seamless,
outside diameter and nominal wall thickness as shown on the drawings.]
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 per cent, and chemical composition which
results in satisfactory weldability.
2.1.1.6 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.
2.1.1.7 Stainless Steel Plate, Sheet, and Strip
ASTM A 167, UNS S 30400; ASTM A 176, UNS S 40500 or U NS 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.
2.1.1.8 Bronze Castings
ASTM B 22, Copper Alloy UNS No. C91300.
2.1.1.9 Aluminum-Bronze Castings
ASTM B 148, Copper Alloy UNS No. [_____].
2.1.1.10 Prestressing Steel Bar Tendons
ASTM A 722/A 722M, Type [_____], including Supplementary Requirements, except the degree of bending for bend
tests shall be 180 degrees. Certified manufacturing records and test reports for tendons shall be provided,
identified with specific lots, and approved prior to use of tendons in the work. Manufacturing records for tendons
shall include mixing casting, cooling, rolling, cold-stressing to 80 percent of the minimum ultimate strength,
and stress-relieving. Test reports shall include chemical analyses, mechanical properties testing and stress-strain
curves, mechanical coupling demonstration, and product analyses of finished tendons representing each heat.
2.1.1.11 Steel Bars for Concrete Reinforcement
Steel bars for concrete reinforcement other than steel bar prestressing tendons shall be as specified in Section
03 20 02 STEEL BARS AND WELDED WIRE FABRIC FOR CONCRETE REINFORCEMENT FOR CIVIL WORKS.
2.1.1.12 Anchorages and Couplers
Anchorages and couplers for prestressing tendons shall be of metal of proven corrosion resistance and compatibility
with tendons and shall be tested by an approved method and certified to be capable of developing the minimum
ultimate strength of tendons without excessive slip. Anchorages shall be plate, bar, or other positive connecting
type which allows complete placement and consolidation of concrete around and within its confines and exerts
uniform bearing on the concrete. Couplers shall be provided with housing or enclosures which are long enough
to permit the necessary movements and fittings which allow complete grouting of all components.
2.1.1.13 Ducts
Ducts for encasing prestressing tendons shall be of the type [shown on the drawings] [approved by the Contracting
Officer]. Ducts shall retain shape under the weight of concrete and shall not permit the entrance of cement
paste from concrete.
2.1.2 Concrete
As specified in Section 03 31 01.00 10 CAST-IN-PLACE STRUCTURAL CONCRETE FOR CIVIL WORKS [and Section
03 45 33 PRECAST[ PRESTRESSED] STRUCTURAL CONCRETE].
2.1.3 Asphalt Mastic
Asphalt Mastic shall conform to [_____].
2.1.4 Premolded Expansion Joint Sheets
As specified in Section 03 15 14.00 10 EXPANSION, CONTRACTION AND CONSTRUCTION JOINTS IN CONCRETE FOR CIVIL WORKS.
2.1.5 Gaskets for Seal Assemblies
Rubber gasket sheets for seal assemblies shall have nominal Shore A durometer value of [40][55][80] with dimensions
as shown on the drawings.
2.1.6 Rubber Seals
NOTE: If fluorocarbon (Teflon) clad seals are not used, delete paragraph FABRICATION
below.
2.1.6.1 General
Rubber seals shall be [fluoro-carbon (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. Physical characteristics of the seals
shall meet the following requirements:
TEST METHOD
PHYSICAL TEST TEST VALUE SPECIFICATION
Tensile Strength 1.38 MPa (min.) ASTM D 412
Elongation at Break 450% (min.) ASTM D 412
300% Modulus 6.21 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% (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 C for 22 hours 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
W1 (W1 is defined in ASTM D 471). The immersion temperature shall be 70 degrees C plus or minus 1 degree C and
the duration of immersion shall be 166 hours.
2.1.6.2 [Fabrication
Rubber seals shall have a fluoro-carbon 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 fluoro-Carbon 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 on the drawings 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 fluoro-carbon film shall be masked during bonding to prevent a bond for a length sufficient to hold the film
securely during testing.]
2.1.7 Cement for Grout
ASTM C 150, Type I or II.
2.1.8 Grout Admixture
Grout admixture shall be a shrinkage compensating type which produces 2 percent maximum and 10 percent maximum
unconfined expansion of the grout when tested in accordance with ASTM C 940, shall not contain chlorides, fluorides,
or nitrates and may be dispensed in solid or liquid form. Complete manufacturer's description of the grout admixture
shall be submitted for approval.
2.2 MANUFACTURED UNITS
Bolts, nuts, washers, screws and other manufactured units shall conform with the requirements shown on the drawings
and specified herein and in Section 05 50 15 CIVIL WORKS FABRICATIONS.
2.2.1 Bolts, Nuts and Washers
High-strength bolts, nuts, and washers shall conform to ASTM A 325, Type [_____], [hot-dip galvanized] or ASTM 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 13-mm 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 GROUT
Grout shall be a mixture of Portland cement specified in paragraph CEMENT FOR GROUT, shrinkage compensating admixture
specified in paragraph GROUT ADMIXTURE, and potable water. Final mix proportions shall be based on test results
of sample mixtures. The water content of grout shall be the minimum necessary for proper placement but the water-cement
ratio shall not exceed 0.50 by weight. The fluidity of grout shall be determined in accordance with ASTM C 939
. The efflux time of a grout sample immediately after mixing shall not be less than 11 seconds. The minimum
7-day compressive strength of 50-mm 2-inch grout cubes molded, cured and tested in accordance with ASTM C 109/C 109M
shall be 17.2 MPa 2500 psi.
2.4 FABRICATION
2.4.1 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 05 50 14 STRUCTURAL METAL FABRICATIONS.
2.4.1.1 Fabrication Drawings
Show on the fabrication drawings complete details of materials, tolerances, connections, machined surface finishes,
and proposed welding sequences which clearly differentiate shop welds and field welds.
2.4.1.2 Shop Assembly Drawings
Provide on the shop assembly drawings details for connecting the adjoining fabricated components in the shop
to assure satisfactory field installation.
2.4.1.3 Delivery Drawings
Provide on the delivery drawings descriptions of methods of delivering components to the site, including details
for supporting fabricated components during shipping to prevent distortion or other damages.
2.4.1.4 Field Installation Drawings
Provide on the field installation drawings 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 installation of prestressing assemblies, including proposed stressing sequences and stressing
calculations for anchorage assemblies.
2.4.2 Structural Fabrication
Structural fabrication shall conform with the requirements shown on the drawings and specified herein and in
Section 05 50 14 STRUCTURAL METAL FABRICATIONS. Components shall be shop-fabricated of the materials specified
and shown on the drawings. Dimensional tolerances shall be as specified and shown on the drawings. Splices
shall occur only where shown on the drawings or approved by the Contracting Officer. 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.
2.4.3 Welding
NOTE: List applicable welds requiring radiographic examination.
Welding shall conform with the requirements [of AWS D1.1/D1.1M, AWS D1.2/D1.2M,] specified herein, and in Section
05 50 14 STRUCTURAL METAL FABRICATIONS. 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 on the drawings. Stress-relieving of components shall be performed prior to the attachment
of miscellaneous appurtenances.]
2.4.4 Bolted Connections
Bolted connections shall conform with the requirements specified in Section 05 50 14 STRUCTURAL METAL FABRICATIONS.
2.4.5 Machine Work
Machine work shall conform with the requirements specified in Section 05 50 14 STRUCTURAL METAL FABRICATIONS.
2.4.6 Miscellaneous Provisions
Miscellaneous provisions for fabrication shall conform with the requirements specified herein and in Section
05 50 14 STRUCTURAL METAL FABRICATIONS.
2.4.7 Fabrications
2.4.7.1 Gates
Gates shall be of welded fabrication except for bolted appurtenances as shown on the drawings. Structural steel
framing members 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]. Gates 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 gates shall not vary from the nominal dimension by more than 6 mm 1/4 inch. The surfaces of framing
elements which support skin plates shall be in true alignment within 5 mm 3/16 inch so that skin plates will
be in full bearing on all contact surfaces before being welded. The outside faces of skin plates after being
welded to framing elements shall not vary from the surface established on the drawings by more than 5 mm 3/16
inch. Splices in skin plates shall be located only where shown on the drawings. Trunnions shall be an integral
part of the gate framing and shall be stress-relieved by heat treatment after welding. The machining of trunnion
hubs and bushings shall be performed after welding of the hubs is completed. The classification of fit between
trunnion hubs and bushings shall be as shown on the drawings. Dowel holes and grease holes shall be drilled
in bushings after installation in trunnion hubs. Gates shall be provided with seal assemblies and other appurtenant
items as shown on the drawings.
2.4.7.2 Trunnion Pins
Trunnion pins shall be of [[cast steel conforming to [ASTM A 27/A 27M] [ASTM A 148/A 148M]] [alloy steel forging
conforming to [ASTM A 668/A 668M] clad with corrosion resisting steel [weldment] [shrunk-on sleeve] as shown
on the drawings. The clad surface shall be machined after completion of all welding. The thickness of the cladding
after final machining shall be not less than 25 mm 1 inch thick] [corrosion resisting steel as shown on the drawing]].
2.4.7.3 Trunnion Yokes
Trunnion yokes shall be provided complete with adjusting plates and bolts and thrust washers. Yokes shall be
stress-relieved by heat treatment and machined to the class to fit shown on drawings after fabrication welding
is completed.
2.4.7.4 Prestressing Anchorage Assemblies
Prestressing assemblies shall consist of prestressing tendons, anchorages, ducts, grout and other appurtenances
as required and shown on the drawings.
a. Prestressing tendons shall be as specified in paragraph PRESTRESSING STEEL BAR TENDONS.
b. Anchorages shall be as specified in paragraph ANCHORAGES AND COUPLERS.
c. Ducts shall be as specified in paragraph DUCTS.
d. Grout shall be as specified in paragraph GROUT.
2.4.7.5 Trunnion Girders
Trunnion girders shall be [[cast-in-place] [precast] concrete girders of the 28-day compressive strength shown
on the drawings and post-tensioned with prestressing anchorage assemblies. The ducts of the anchorage assemblies
shall be cast in the girders in the positions and alignments shown on the drawings. The installation of prestressing
assemblies shall be as specified in paragraph PRESTRESSING ANCHORAGE ASSEMBLIES. Reinforcement steel, premolded
expansion joint sheets, blockouts and other components of the girders shall be as specified and indicated on
the drawings] [structural steel as shown on the drawings].
2.4.7.6 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 on the drawings. 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 on the drawings and shall be machine-finished after splicing.
2.4.7.7 Appurtenant Items
Cable attachment brackets, dogging brackets, side seal plates, sill beams, stop beams and other appurtenant
items shall conform to the requirements specified and shown on the drawings. The sealing surfaces of side seal
plates and sill beams shall be flush, straight, and free from offsets, warps, twists or other distortions.
2.4.8 Shop Assembly
Shop assembly requirements for tainter gates, anchorage assemblies and appurtenant items shall be as shown on
the drawings and specified herein and in Section 05 50 14 STRUCTURAL METAL FABRICATIONS. Gates shall be assembled
completely in the shop to assure satisfactory field installation. Adjoining components and appurtenant items
shall be fitted and bolted together to facilitate field connections. Assembled components shall be shop-welded
in their final positions as much as delivery and field installation conditions permit. Rubber seals shall be
fitted and drilled to match the seal retainers on the gates, match-marked and removed for shipment. Drilled
slots for attaching seals shall allow a minimum adjustment of plus/minus 10 mm 3/8 inch. Shop assembly and disassembly
work shall be performed in the presence of the Contracting Officer unless otherwise waived in writing by the
Contracting Officer. The presence of the Contracting Officer during assembly or disassembly will not relieve
the Contractor of any responsibility under this contract.
2.5 TESTS, INSPECTIONS, AND VERIFICATIONS
2.5.1 General
Tests, inspections, and verifications for materials shall conform to the requirements specified herein and in
Section 05 50 14 STRUCTURAL METAL FABRICATIONS.
2.5.2 Testing of Rubber Seals
NOTE: If fluoro-carbon (Teflon) clad seals are not used, delete this paragraph.
The fluoro-carbon 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 fluoro-carbon film and the rubber when subjected to the following
loads:
THICKNESS OF MACHINE METHOD AT DEADWEIGHT
FLOURO-CARBON FILM 50 mm PER MINUTE METHOD
[0.762 5.25 N per mm width 5.25 N per
mm width]
[1.524 5.25 N per mm width 5.25 N per
mm width]
THICKNESS OF MACHINE METHOD AT DEADWEIGHT
FLOURO-CARBON FILM 2 INCHES PER MINUTE METHOD
[0.030 30 pounds per inch width 30 pounds per
inch width]
[0.060 30 pounds per inch width 30 pounds per
inch width]
PART 3 EXECUTION
3.1 INSTALLATION
Perform installation conforming with the requirements specified herein and in Section 05 50 14 STRUCTURAL METAL
FABRICATIONS. 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 Trunnion Girders
Trunnion girders shall be anchored to concrete piers as specified and shown on the drawings. [The installation,
post-tensioning and grouting of prestressing assemblies for anchoring trunnion girders shall conform to the requirements
specified in paragraph PRESTRESSING ASSEMBLIES.]
3.1.3 Trunnion Yokes
Trunnion yokes shall be installed and adjusted in strict accordance with the procedure shown on the drawings.
[The final alignment of trunnion yokes shall be performed after the prestressing tendons of the anchoring prestressing
assemblies have been post-tensioned partially as specified in paragraph POST-TENSIONING.] Special precautions
shall be exercised to align the trunnion yokes so that the center lines of trunnion pins at the opposite ends
of each gate are concentrically located on the established horizontal line. The eccentricity of the actual centerline
of each trunnion pin with respect to the established horizontal line shall not be more than 0.8 mm 1/32 inch.
The horizontal distance between trunnion yokes shall not vary more than 3 mm 1/8 inch from the established dimension.
[Second-pour, high-strength concrete fills shall be placed between the bases of trunnion yokes and trunnion girders
[and concrete non-shrink grout fills shall be placed between the yokes of trunnion yokes and the abutting faces
of concrete piers] after the successful completion of the trial operation specified in paragraph TRIAL OPERATIONS
and the final alignment of trunnion yokes.] [Complete tensioning of the prestressing tendons shall be performed
after the concrete fills have attained the minimum [strengths] [strength]. The installation, post tensioning
and grouting of prestressing assemblies for anchoring trunnion yokes to trunnion girders shall conform to the
requirements specified in paragraph PRESTRESSING ASSEMBLIES.]
3.1.4 Gates
NOTE: The water-tightness tests on the skinplates should be deleted when complete
or spot radiographic or ultrasonic examination of the skinplates is required
by the specifications.
The trunnion lubrication system lines shall be purged, filled with grease and connected to each trunnion assembly
prior to installing gates. The bearing surfaces of trunnion pins and bushings shall be cleaned and coated with
grease prior to installing the trunnion pins. Gates shall be assembled in the field in strict conformity with
shop match markings. Controlling dimensions and alignments shall be checked and corrected as required before
starting field welding. Welding shall be done in a manner such that distortion of gates is prevented. Erection
bolts, lugs and ties shall be removed after welding is completed. Holes and depressions shall be filled with
weld metal and surface projections shall be removed by grinding. [Skinplate welds shall be tested for water-tightness
after the gates are installed but prior to painting and mounting of seals by coating one face of the skinplate
with soapsuds and applying air pressure with a hose using a minimum air pressure of 414 kPa 60 psi at the nozzle
to the opposite face.] Disclosed leaks shall be sealed with light welds.
3.1.5 Prestressing Assemblies
The proposed method and equipment for installing prestressing anchorage assemblies, including riggings, tensioning
jacks, gages, dynamometers and load cells or other devices for measuring stress loads, shall provide for the
accurate installation of the assemblies and shall be selected by the Contractor and submitted for approval.
3.1.5.1 Ducts
Ducts shall be accurately placed, aligned and adequately supported at close intervals to limit sag and deviation
from established lines when tendons are inserted and concrete is placed. Ducts shall have grout openings at
both ends and grout vents as required. Connections and other joints in ducts shall be watertight. Openings
shall be adequately protected to prevent the entry of water, concrete or debris. Ducts shall not have blockages,
dents or other defects which could cause increased friction between tendons and ducts or restrict grout flow.
3.1.5.2 Steel Bar Prestressing Tendons
Steel bar prestressing tendons shall be inspected before being placed in ducts to assure that they are not bent,
nicked, scored or have damaged threaded ends. Tendons should not be placed in ducts until all welding has been
completed on templates, supports or other items near or in contact with the tendons.
3.1.5.3 Anchorages
Anchorages for steel bar prestressing tendons shall be set in a plan normal to the axis of the tendon so that
uniform bearing on the concrete is assured and shall be positively connected to tendons. Ends of tendons shall
extend beyond anchorages to accommodate testing. End extensions shall be removed after tests are completed and
approved.
3.1.5.4 Post-Tensioning
Complete records of the prestressing operation shall be compiled and submitted as required in paragraph GROUT
RECORDS. Tensioning of the steel bar prestressing tendons shall be as specified and shown on the drawings.
Tendons shall be tensioned a minimum of [_____] days after the casting of concrete piers [and girders]. Tensioning
shall not be started until tests on concrete cylinders made and cured under the same conditions as the piers
[and girders] indicate that the concrete has attained the required minimum strength. The tensioning operation
shall be conducted in a manner so that the load being applied and the elongation of the tendon may be measured
at all times. Elongation measurements shall be accurate to 0.25 mm 0.01 inch. Jack gage readings shall be accurate
to the nearest 500 kPa 100 psi. If the stress in a tendon determined by gage pressure differ from the stress
determined by elongation measurement in excess of 5 percent the cause of the difference shall be determined and
corrected before proceeding with the tensioning operation. [Longitudinal tendons in concrete trunnion girders
shall be tensioned prior to the placement of the second-pour, high-strength concrete fills for the sections of
piers adjacent to the face of trunnion girders.] [The transverse tendons which anchor trunnion girders to piers
shall be tensioned after the second-pour concrete fills for the piers have attained the minimum required strength.]
[The transverse tendons which anchor trunnion yokes to trunnion girders shall be partially tensioned prior to
the trial operation of tainter gates as specified below in paragraph TRIAL OPERATIONS and prior to the final
adjustment of trunnion yokes as specified and shown on the drawings. Complete tensioning of these tendons shall
not be performed until after the trunnion yokes have been adjusted and the second-pour, high-strength concrete
fills between the base of trunnion yokes and the trunnion girders [and the concrete grout fills between the yokes
of trunnion yokes and the piers] have attained the required minimum [strength] [strengths].] Exposed ends of
prestressing components shall be protected from damage during the tensioning operations; take the safety measures
necessary to prevent accidents caused by failure of prestressing components.
3.1.5.5 Verification of Prestressing Forces
Individual prestressing tendons selected by the Contracting Officer shall be tested to verify the sustentation
of prestress forces by being subjected to a force equal to the design force between 7 and 14 days after the complete
tensioning of all tendons. Tendons which sustain the applied force without being unseated will be considered
to be satisfactory. The number of tendons tested shall not exceed 10 percent of all tendons unless a tested
tendon is unable to sustain the required test force. If a tested tendon is unable to sustain the required test
force all tendons shall be tested and retensioned if required to the initial prestress. Retensioned tendons
shall be retested after 7 days at no additional cost to the Government.
3.1.5.6 Grouting
Prestressing assemblies shall be grouted immediately after complete tensioning of prestressing tendons and verification
of prestressing forces. Grout shall conform to the requirements specified in paragraph GROUT. Grouting equipment
shall provide continuous mechanical mixing and placing of grout, measure grout mix volume and measure volume
of grout placed within 2500 cubic mm 0.1 cubic foot. Grout pump shall be a positive displacement type and have
the capacity to develop a pressure of 1.38 MPa 200 psi. Stand-by water flushing equipment shall be provided
for flushing out ducts partially grouted and stopped due to blockage or equipment breakdown. Ducts for prestressing
tendons shall be flushed free of water, dirt or any other foreign substance and shall be blown out with compressed
air until no water comes through just prior to grouting. Ducts shall be pressure grouted at a minimum pressure
of 690 kPa 100 psi immediately after post-tensioning has been completed. Grouting shall continue until all air
within the duct has been displaced with grout. Once the grouting of a system of prestressing tendons and ducts
has been started the grouting operation shall be continuous until that system has been completely grouted. Grout
placement records shall be compiled.
3.1.6 Appurtenant Items
Side seal plates, sill beams, stop beams and other items to be embedded in second-pour concrete shall be attached
to anchors, aligned, leveled and rigidly blocked to prevent displacement during the placement of concrete. Side
seal plates shall be aligned in planes normal to the axis of rotation of the gates and shall be checked before
being embedded in concrete to ensure that they do not vary more than 2.5 mm 3/32-inch from the established alignment
in an arc length of 3.6 m 12 feet. Welded field splices in exposed metals shall be ground smooth to assure proper
sealing. Metal supports for rubber seals shall be continuous and free of waves, winds and distortions. Rubber
seals shall be installed after the [skinplate water-tightness test and] gate painting operations have been completed.
Seals shall be adjusted after installation so that they are slightly compressed in the closed, unwatered condition
to prevent excessive depression and wear in the closed, watered condition. [The heating system for seals shall
be installed as shown on the drawings and specified in Section [_____] CREST-GATE-SEAL.]
3.1.7 Trial Operations
Gates shall be trial operated after the complete installation of gates and appurtenant items. Trial operations
shall be performed and approved prior to placing the second-pour, high-strength concrete fills around embedded
appurtenant items [and between trunnion yokes and trunnion girders and prior to the complete tensioning of the
prestressing tendons anchoring the trunnion yokes]. Hoist lifting cables shall be adjusted and trunnion bushings
shall be lubricated through the permanent lubrication fittings with an approved, extreme-pressure lubricant before
operating the gates. Gates shall move smoothly and without binding or lateral sway when raised and lowered through
the complete range of travel. Defects disclosed from trial operations shall be corrected and trial operations
repeated by the Contractor at no cost to the Government. Trial operations shall be repeated after complete tensioning
and grouting of all prestressing assemblies.
3.1.8 Second-Pour, High-Strength Concrete [and Concrete Grout] Fills
NOTE: The zones and strengths of high-strength concrete and concrete grout should
be shown on the drawings.
The second-pour, high-strength concrete fills for the sections of piers adjacent to the face of trunnion girders
[and the space between the base of trunnion yokes and trunnion girders] [and the concrete grout fills between
the yokes of trunnion yokes and the piers] shall be as shown on the drawings and as specified in Section
03 31 01.00 10 CAST-IN-PLACE STRUCTURAL CONCRETE FOR CIVIL WORKS.
3.1.9 Painting
Exposed parts of gates and appurtenances, except machined surfaces, stainless steel 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 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 gates, 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 [26 42 17.00 10 CATHODIC PROTECTION SYSTEM (IMPRESSED
CURRENT)] [26 42 19.10 CATHODIC PROTECTION SYSTEMS (IMPRESSED CURRENT) FOR LOCK MITER GATES].
3.3 OPERATING MACHINERY
Operating machinery shall conform to Section [_____] TAINTER 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 414 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, 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 05 50 14 STRUCTURAL METAL FABRICATIONS.