USACE / NAVFAC / AFCESA / NASA UFGS-35 51 13.00 20 (April 2006) ------------------------------ Preparing Activity: NAVFAC Replacing without change UFGS-03420N (August 2004) UNIFIED FACILITIES GUIDE SPECIFICATIONS References are in agreement with UMRL dated January 2009 SECTION 35 51 13.00 20 CONCRETE FLOATING PIER FOR SMALL CRAFT 04/06 NOTE: This guide specification covers the requirements for precast non-prestressed concrete floating piers and associated hardware and accessories. 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 suggestion on this specification are welcome and should be directed to the technical proponent of the specification. A listing of the 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 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 in the text by the basic designation only. ACI INTERNATIONAL (ACI)ACI 211.2(1998; R 2004) Standard Practice for Selecting Proportions for Structural Lightweight ConcreteACI 304R(2000) Guide for Measuring, Mixing, Transporting, and Placing ConcreteACI 305R(1999; Errata 2006) Hot Weather ConcretingACI 306.1(1990; R 2002) Standard Specification for Cold Weather ConcretingACI 309R(2005) Guide for Consolidation of ConcreteACI 318/318R(2008; Errata 2008) Building Code Requirements for Structural Concrete and CommentaryACI 318M(2008) Metric Building Code Requirements for Structural Concrete and CommentaryAMERICAN WELDING SOCIETY (AWS)AWS D1.4/D1.4M(2005; Errata 2005) Structural Welding Code - Reinforcing SteelAMERICAN WOOD PROTECTION ASSOCIATION (AWPA)AWPA C1(2003) All Timber Products - Preservative Treatment by Pressure ProcessesAWPA C18(2003) Standard For Pressure Treated Material in Marine ConstructionAWPA C2(2003) Lumber, Timber, Bridge Ties and Mine Ties - Preservative Treatment by Pressure ProcessesAWPA C28(2003) Standard for Preservative Treatment of Structural Glued Laminated Members and Lamination Before Gluing of Southern Pine, Coastal Douglas Fir, Hemfir and Western Hemlock by Pressure ProcessesAWPA C33(2003) Standard for Preservative Treatment of Structural Composite Lumber by Pressure ProcessesAWPA P5(2005) Standard for Waterborne PreservativesASTM INTERNATIONAL (ASTM)ASTM A 123/A 123M(2008) Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel ProductsASTM A 153/A 153M(2005) Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel HardwareASTM A 185/A 185M(2007) Standard Specification for Steel Welded Wire Reinforcement, Plain, for ConcreteASTM A 27/A 27M(2008) Standard Specification for Steel Castings, Carbon, for General ApplicationASTM A 307(2007b) Standard Specification for Carbon Steel Bolts and Studs, 60 000 PSI Tensile StrengthASTM A 36/A 36M(2008) Standard Specification for Carbon Structural SteelASTM A 47/A 47M(1999; R 2004) Standard Specification for Steel Sheet, Aluminum-Coated, by the Hot-Dip ProcessASTM A 497/A 497M(2007) Standard Specification for Steel Welded Wire Reinforcement, Deformed, for ConcreteASTM A 563(2007a) Standard Specification for Carbon and Alloy Steel NutsASTM A 563M(2007) Standard Specification for Carbon and Alloy Steel Nuts (Metric)ASTM A 615/A 615M(2008b) Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete ReinforcementASTM A 706/A 706M(2008a) Standard Specification for Low-Alloy Steel Deformed and Plain Bars for Concrete ReinforcementASTM A 780(2001; R 2006) Standard Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized CoatingsASTM C 1107/C 1107M(2008) Standard Specification for Packaged Dry, Hydraulic-Cement Grout (Nonshrink)ASTM C 150(2007) Standard Specification for Portland CementASTM C 260(2006) Standard Specification for Air-Entraining Admixtures for ConcreteASTM C 272(2001; R 2007) Water Absorption of Core Materials for Structural Sandwich ConstructionsASTM C 330(2005) Standard Specification for Lightweight Aggregates for Structural ConcreteASTM C 494/C 494M(2008a) Standard Specification for Chemical Admixtures for ConcreteASTM C 578(2008b) Standard Specification for Rigid, Cellular Polystyrene Thermal InsulationASTM C 595(2008) Standard Specification for Blended Hydraulic CementsASTM C 618(2008a) Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in ConcreteASTM C 94/C 94M(2007) Standard Specification for Ready-Mixed ConcreteASTM C 989(2006) Standard Specification for Ground Granulated Blast-Furnace Slag for Use in Concrete and MortarsASTM D 1535(2008) Specifying Color by the Munsell SystemASTM D 1894(2008) Static and Kinetic Coefficients of Friction of Plastic Film and SheetingASTM D 2240(2005) Standard Test Method for Rubber Property - Durometer HardnessASTM D 256(2006e1) Determining the Izod Pendulum Impact Resistance of PlasticsASTM D 4020(2005) Ultra-High-Molecular-Weight Polyethylene Molding and Extrusion MaterialsASTM D 5456(2008) Evaluation of Structural Composite Lumber ProductsASTM D 570(1998; R 2005) Standard Test Method for Water Absorption of PlasticsASTM D 638(2008) Standard Test Method for Tensile Properties of PlasticsASTM D 792(2008) Density and Specific Gravity (Relative Density) of Plastics by DisplacementASTM F 844(2007a) Washers, Steel, Plain (Flat), Unhardened for General UseASTM G 109(2007) Determining the Effects of Chemical Admixtures on the Corrosion of Embedded Steel Reinforcement in Concrete Exposed to Chloride Environments E(2000)EUROPEAN COMMITTEE FOR STANDARDIZATION (CEN/CENELEC)EN 60309-1(1999; Amendment 2004; Amendment 2007) Plugs, Socket-Outlets and Couplers for Industrial Purposes Part 1: General Requirements - IEC 60309-1EN 60309-2(1999; Amendment 2004; Amendment 2007) Plugs, Socket-Outlets and Couplers for Industrial Purposes Part 2: Dimensional Interchangeability Requirements for Pin and Contact-Tube Accessories - IEC 60309-2EN 60529(1991; Amendment 2000) Degrees of Protection Provided By Enclosures (IP Code)INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)IEEE C57.12.29(2005) Pad-Mounted Equipment - Enclosure Integrity for Coastal EnvironmentsNATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)NEMA ICS 6(1993; R 2006) Standard for Industrial Controls and Systems EnclosuresPRECAST/PRESTRESSED CONCRETE INSTITUTE (PCI)PCI MNL-116(1999) Manual for Quality Control for Plants and Production of Structural Precast Concrete ProductsPCI MNL-120(2004) Design Handbook - Precast and Prestressed ConcreteSOCIETY OF AUTOMOTIVE ENGINEERS INTERNATIONAL (SAE)SAE AMS-QQ-A-200/8(1997; R 2007) Aluminum Alloy 6061, Bar, Rod, Shapes, Tube, and Wire, ExtrudedU.S. DEPARTMENT OF DEFENSE (DOD)MIL-I-24768/14INSULATION, PLASTIC, LAMINATED, THERMOSETTING, COTTON-FABRIC-BASE, PHENOLIC-RESIN (FBG)U.S. GENERAL SERVICES ADMINISTRATION (GSA)FS A-A-55619B(2003) Casters, Industrial, Heavy DutyUNDERWRITERS LABORATORIES (UL)UL 1686(2007) Pin and Sleeve ConfigurationsUL 231(2008) Power OutletsUL 489(2002; Rev thru Jun 2006) Standard for Molded-Case Circuit Breakers, Molded-Case Switches and Circuit-Breaker EnclosuresUL 943(2006; Rev thru Feb 2008) Ground-Fault Circuit-InterruptersUL 98(2004; Rev thru Apr 2006) Enclosed and Dead-Front Switches1.2 MODIFICATIONS TO REFERENCES In the ACI publications, the advisory provisions shall be considered to be mandatory, as though the word "shall" has been substituted for "should" wherever it appears; reference to the "Building Official," the "Structural Engineer" and the "Architect/Engineer" shall be interpreted to mean the Contracting Officer. 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.][for 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 Drawings of Precast Floats}; _{G, [_____] Gangways} [_{Receptacle Stations}; _{G, [_____]} ] _{SD-03 Product Data} Anchorage and lifting _inserts and devices [_{Receptacle Stations}; _{G, [_____]} ] _{Guide Pile Caps SD-05 Design Data} Precast Concrete Floats _{Design Calculations}; _{G, [_____] Gangway Design Concrete Mix Design SD-06 Test Reports Contractor-Furnished Mix Design} Submit copies of test reports showing that the mix has been successfully tested to produce concrete with the properties specified and will be suitable for the job conditions. Obtain approval before concrete placement. _{SD-07 Certificates Fabrication Rubbing Surface} [_{Paint Coating System} ] Submit quality control procedures established in accordance with PCI MNL-116 by the precast manufacturer. 1.4 PRECAST FLOATS The work includes the provision of precast, non-prestressed concrete floating pier modules herein referred to as precast floats, and all other items relating to the precast floating pier system. Precast floats shall be the product of a manufacturer specializing in the production of precast concrete floats with a minimum of 10 years experience in the manufacture of precast concrete floating piers. 1.5 QUALITY CONTROL 1.5.1 Precast Concrete Float Design ACI 318/318R, ACI 318M and the PCI MNL-120. Design precast floats (including connections) for the design load conditions and spans indicated, and for additional loads imposed by the work of other trades. Design precast floats for handling without cracking in accordance with the PCI MNL-120. 1.5.1.1 Pier Loading Float and anchorage systems shall be designed for the following load conditions as a minimum. Load cases shall be combined based upon their probability of simultaneous occurrence, and in accordance with applicable codes and standards. Wind and current exposure areas shall be based on average vessel profile and draft, respectively. To account for sheltering effects, 15 percent of the full load shall be applied to all vessels sheltered by the vessels exposed to full load. Calculations shall be performed for wind and current loads both parallel and perpendicular to the pier. NOTE: Designer should consult with a manufacturer of precast concrete floats to determine maximum allowable loadings for a given float size. The use of values exceeding the recommended default maximums should be confirmed with a reputable manufacturer prior to inclusion. Environmental loadings (wind, wave, current & tide surge) will be site specific. Default values for berthing and mooring loads are recommended maximum values, based on limitations of the precast modules. Berthing load is vessel and pier configuration specific. Mooring load is maximum, based on anchorage strength of (default) cleat size (confirm with manufacturer). The designer should input berthing and mooring loads based on the actual vessels berthed. a. Dead load, including all work of other trades (utilities, ect.) b. Live load: [___][3.83] kPa[80 PSF] c. Wind pressure: As indicated on drawings Acting on the projected area of the pier and moored vessels, assuming full occupancy. For vessel area, assume an average height of [___]mfeet above the waterline. d. Minimum current pressure: [___] kPa[PSF][FPS velocity] Acting on the projected area of the pier and moored vessels, assuming normal occupancy. e. Berthing load: [___][136] N/m[100] PLF horizontal f. Mooring load: [___][1.78] kN[400] lb. Line pull acting in any direction at a 45 degree angle from the horizontal. g. Vertical wave load: As determined from a [___][0.9] m[3] ft. wave height h. Lateral wave load: As determined from a [___][0.9] m[3] ft. wave height i. Lateral pile loads at maximum surge level: For surge level indicated on drawings 1.5.1.2 Performance a. Precast float modules shall be sized so that a single module (excluding walers) is used to attain the indicated pier width. The use of more than one module connected side by side to attain pier width is unacceptable. b. Freeboard under dead load only shall not be less than [___]610mm24 in. nor exceed [___] 762mm30 in. . Precast floats shall be designed to float level under dead load only. Maximum out of level tolerance for transverse and longitudinal slope is [___]25mm per 3m1 in. per 10 ft. . Freeboard under dead and live load shall not be less than [___]203mm8 in. . c. Special precast floats must be designed to support the additional concentrated loads as imposed by gangways, transformers, or other equipment. Modules with special loadings shall have the same freeboard as standard modules without special loading, so that there will be no residual stresses or tilting when modules are interconnected. d. Flotation units shall be located within the structure so as to be capable of supporting a [___]136 kg300 lb. moving point load in any area on a module without causing excessive rolling or tilting of the pier. The pier shall be capable of supporting a [___]181 kg400 lb. point load at 305mm1 Ft. from the offshore end of the pier and loose no more than 101mm4 in. of freeboard; and supporting a [___]136 kg300 lb. point load applied to the corner of the offshore end of the pier and loose no more than 51mm2 in. of freeboard differential per 914mm3 Ft. of pier width between the offshore corners. [e. Precast floats shall have PVC sleeves and pull boxes embedded as required for electrical and communications systems. Pull boxes shall have a nominal 25mm1 in. concrete bottom with a light brushed, slip resistant finish. All bolts and inserts for pull box lids shall be 316 stainless steel. Pull box lids shall be flush with the deck surface and rated for the pier deck loading. Sleeves shall remain above water surface under dead load conditions and shall be designed to facilitate installation, removal, and servicing of utilities. Pull boxes and access openings shall be sized and located as indicated on the drawings. ] 1.5.2 _{Gangway Design} Provide gangways of prefabricated aluminum for floating pier access, including connections at the bulkhead and bearing on the floating pier. Gangway shall be designed in accordance with "Specifications for Aluminum Structures", AA, latest edition, using allowable stresses for bridges. 1.5.2.1 Gangway Loading Gangways shall be subject to the same load conditions identified in the paragraph titled "Pier Loading", except for berthing, mooring, current, wave, and pile loading conditions. Additionally, the gangway bulkhead end connections shall be designed to withstand a lateral force equal to 20 percent of the total dead load and 50 percent of the live load acting simultaneously with the dead and live loads. Handrails shall be designed for the following independent load cases: 1) a continuous horizontal load of 27.1 N/m20 PLF applied along the full length of the top rail, and 2) a horizontal point load of 113.4 kg250 lbs acting at any point along the top rail. 1.5.2.2 Performance a. Gangways shall have a minimum clear walkway width of [___]1.07m3.5 ft., and an overall outside width not to exceed [___]1.37m4.5 ft.. Length of gangways shall be as indicated on the drawings. Gangways shall have continuous handrails that are a minimum of 1.07m3.5 ft. above the walking surface, but not to exceed 1.14m3.75 ft. . b. Walking surface shall be skid resistant. c. Gangway pier end connections shall allow unrestricted vertical movement through tidal variation. Gangway bearing on floating piers shall be fitted with UHMW polyurethane rollers of adequate bearing area. Gangways shall be fitted with hinged apron plates to assure a safe uniform transition between gangway and deck surfaces. Apron plates will be designed so as to not damage or mar the floating pier surface. d. Maximum midspan deflection under live load shall not exceed L/240. e. Contact between aluminum and dissimilar metals or concrete shall be avoided, except for the use of compatible stainless steel pins. Where potential for galvanic corrosion exists, the aluminum shall be isolated from direct contact with other metals or concrete by use of suitable non-conducting insulators or bushings. 1.5.3 PCI Quality Certifications NOTE: For normal routine projects, use the first paragraph. For complex or large precast/prestressed projects, use the second paragraph. Note that use of the second paragraph may limit competition. Verify the availability of certified PCI precasters in the bidding area. PCI MNL-116. At the precast manufacturer's option, in lieu of core samples, ACI 318/318R and ACI 318M, full scale load tests may be performed. Perform on randomly selected precast floats, as directed by the Contracting Officer. [1.5.3.1 Product Quality Control PCI MNL-116 for PCI enrolled plants. Where precast floats are manufactured by specialists in plants not currently enrolled in the PCI "Quality Control Program," provide a product quality control system in accordance with PCI MNL-116 and perform concrete and aggregate quality control testing using an approved, independent commercial testing laboratory. Submit test results to the Contracting Officer. ]1.6 DELIVERY AND STORAGE Lift and support precast floats at the lifting and supporting points indicated on the shop drawings. Store precast floats off the ground. Separate stacked precast floats by battens across the full width of each bearing point. Protect from weather, marring, damage, and overload. 1.7 FACTORY INSPECTION At the option of the Contracting Officer, precast floats shall be inspected by the QC Representative prior to being transported to the job site. The Contractor shall give notice 14 days prior to the time the units will be available for plant inspection. Neither the exercise nor waiver of inspection at the plant will affect the Government's right to enforce contractual provisions after units are transported or erected. 1.8 QUALITY ASSURANCE 1.8.1 Drawing Information Submit drawings indicating complete information for the fabrication, handling, and erection of the precast floats and gangways. Drawings shall not be reproductions of contract drawings. Design _{drawings of precast floats} and _gangways (including connections) shall be prepared and sealed by a registered professional engineer, and submitted for approval prior to fabrication. The drawings shall indicate, as a minimum, the following information: a. Floating pier system layout b. Marking of floats for assembly c. Connections between floats, and connections between floats and other construction d. Location and anchorage of mooring fittings e. Waler size and splice pattern f. Guide pile size, length, location and connection to pier g. Reinforcing details h. Material properties of all materials used i. Lifting and assembly inserts and embedded items j. Dimensions and surface finishes of each float k. Erection sequence and handling requirements l. All loads used in design (such as live, dead, wind, current, berthing, handling, and erection) m. Bracing/shoring required n. Gangways [o. Utility routing and connections for work of other trades ] 1.8.2 _{Design Calculations} Submit calculations reflecting design conforming to requirements of paragraph entitled "Precast Concrete Float Design" and "Gangway Design". Design calculations of precast floats and gangways (including connections) shall be prepared and sealed by a registered professional engineer, and submitted for approval prior to fabrication. In addition to member sizing calculations, submit calculations for the pier system which include: a. Anchorage attachment points to insure reactions shall be appropriately and rationally distributed throughout the system b. Overall system loads under full occupancy, with consideration for shielding factors, and deflection of the system and its effects on anchor loading c. Anchorage system capacity for individual and overall load considerations d. Guide pile size, length, cross section, and minimum embedment 1.8.3 _{Concrete Mix Design} Thirty days minimum prior to concrete placement, submit a mix design for each strength and type of concrete. Include a complete list of materials including type; brand; source and amount of cement, pozzolan, and admixtures; and applicable reference specifications. [1.8.4 _{Paint Coating System} Submit IEEE C57.12.29 coating system performance requirements test on "test specimens" of the same material used in fabrication of the receptacle stations. ]PART 2 PRODUCTS 2.1 _{CONTRACTOR-FURNISHED MIX DESIGN} NOTE: Normal precast design is based on concrete having a compressive strength of 35 MPa 5000 psi at 28 days. Some precast manufacturers like to speed up production by using Type III (high early strength) concrete. NOTE: Delete air entraining requirements when the project is located in a nonfreezing climate. ACI 211.2, using weight method. The minimum compressive strength of concrete at 28 days shall be [___][35] MPa [5000] psi with a unit weight of 1800 kg/m3115 pcf dry .Mix shall contain a corrosion inhibitor[ and air-entraining admixtures at the mixer to produce between 5 to 7 percent air by volume]. The use of foaming agents is prohibited. 2.2 PRECAST FLOAT MATERIALS 2.2.1 Cement NOTE: For normal precasting (not requiring sulfate resistance), use the first bracketed item. If sulfate resistance is required, use the second bracketed item. ASTM C 150, Type [I][II]; or ASTM C 595 Type IP(MS) or IS(MS) blended cement, except as modified herein. The blended cement shall consist of a mixture of ASTM C 150 cement and one of the following materials: ASTM C 618 pozzolan or fly ash, or ASTM C 989 ground iron blast furnace slag. The pozzolan/fly ash content shall not be less than 20 percent nor exceed 40 percent by total mass of cementitious material. The content of ground granulated blast-furnace slag shall not exceed 50 percent of the mass of cement. The minimum amount of portland cement is 50 percent of the total mass of cementitious material. For exposed concrete, use one manufacturer for each type of cement, ground slag, fly ash, and pozzolan. 2.2.1.1 Fly Ash and Pozzolan ASTM C 618, Type N, F, or C, except that the maximum allowable loss on ignition shall be 6 percent for Type N and F. 2.2.1.2 Ground Iron Blast-Furnace Slag ASTM C 989, Grade 100 or 120. 2.2.2 Water Water shall be fresh, clean, and potable. 2.2.3 Aggregates 2.2.3.1 Aggregates Selection NOTE: Select gradation(s) based on job requirements and constraints. The maximum aggregate size shall not exceed three-quarters the minimum cover over reinforcing. Aggregate grading sizes with their general grading ranges are as follows: Size 57 (25 mmone inch to No. 4 sieve), Size 67 (20 mm3/ 4 inch to No. 4 sieve), and Size 7 (12 mm1/2 inch to No. 4 sieve). ASTM C 330, Size 8 (3/8 inch), except as modified herein. Obtain aggregates for exposed concrete surfaces from one source. Aggregates shall not contain any substance which may be deleteriously reactive with the alkalies in the cement. 2.2.4 Grout 2.2.4.1 Nonshrink Grout ASTM C 1107/C 1107M. 2.2.4.2 Cementitious Grout NOTE: Delete air entraining requirements when the project is located in a nonfreezing climate. Shall be a mixture of portland cement, sand, and water. Proportion one part cement to approximately 2.5 parts sand, with the amount of water based on placement method.[ Provide air entrainment for grout exposed to the weather.] 2.2.5 Admixtures [2.2.5.1 Air-Entraining NOTE: Delete air entraining requirements when the project is located in a nonfreezing climate. ASTM C 260. ]2.2.5.2 Accelerating ASTM C 494/C 494M, Type C or E. 2.2.5.3 Water Reducing ASTM C 494/C 494M, Type A, E, or F. 2.2.5.4 Corrosion Inhibitor Calcium nitrite, ASTM G 109. Add at the rate of 22.25 l per cubic meter4.5 gallons per cubic yard. 2.2.6 Reinforcement All reinforcement shall be hot-dipped galvanized, ASTM A 123/A 123M or ASTM A 153/A 153M. 2.2.6.1 Reinforcing Bars NOTE: Specify ASTM A 706/A 706M reinforcing where welding or bending of reinforcement bars is important. ASTM A 615/A 615M[ASTM A 706/A 706M], Grade 420 [40] [60]. 2.2.6.2 Welded Wire Fabric ASTM A 185/A 185M or ASTM A 497/A 497M. Provide flat sheets of welded wire fabric, rolled fabric is not acceptable. Maximum fabric grid is 50mm x 50mm (2 in. x 2 in.). 2.2.7 Metal Accessories Provide ASTM A 123/A 123M or ASTM A 153/A 153M, hot-dipped galvanized. 2.2.7.1 _Inserts ASTM A 47/A 47M, Grade 22010 32510 or 35018, or ASTM A 27/A 27M Grade 415-205 U-60-30. 2.2.7.2 Structural Steel ASTM A 36/A 36M. 2.2.7.3 Bolts ASTM A 307 and ASTM A 36/A 36M. Waler rods shall be continuous laterally through the pier, with a minimum diameter of 19 mm3/4 inch. All continuous waler rods shall be placed within PVC sleeves cast into the precast float modules. 2.2.7.4 Nuts ASTM A 563MASTM A 563. 2.2.7.5 Washers ASTM F 844 washers for ASTM A 307 bolts. 2.2.7.6 Cleats Provide [___]457 mm18 in. boat cleats spaced at approximately [___]6100 mm20 ft. . 2.2.8 Foam Core Closed cell, expanded polystyrene (EPS), ASTM C 578. Foam core laminations shall be glued with a low solvent glue. Core shall not be made from more than four laminated sections. Horizontal laminations in the upper 254mm 10 in. are not permitted. Core shall be strapped to prevent de-lamination during transportation and handling. Core shall not contain more than 10 percent reground EPS foam material. Reground foam pieces shall not exceed 10mm3/8 in. diameter. Unit Weight: 70.1 - 155.7 kg/m30.9 - 2.0 PCF Water absorption (ASTM C 272): 3 percent (by volume) Dimensional tolerance: +/- 3mm1/8 in. 2.3 _FABRICATION PCI MNL-116 unless specified otherwise. 2.3.1 Precast Floats Precast floats shall be cast monolithically, cold joints of any type are not acceptable. Modules shall have a minimum deck and wall thickness of 51mm2 in. . Precast float decks shall be constructed to drain freely and there shall be no floodable enclosed spaces. 2.3.2 Forms Brace forms to prevent deformation. Forms shall produce a smooth, dense surface. Chamfer exposed edges of floats 13 mm1/2 inch, unless otherwise indicated. Form tolerance shall not exceed 3mm1/8 in. dimensions indicated on shop drawings. When measured diagonally, floats more than 13mm1/2 in. out of square shall be rejected. 2.3.3 Reinforcement Placement ACI 318/318R and ACI 318M for placement and splicing. Reinforcement may be preassembled before placement in forms. 2.3.4 Concrete 2.3.4.1 Concrete Mixing ASTM C 94/C 94M. Mixing operations shall produce batch-to-batch uniformity of strength, consistency, and appearance. 2.3.4.2 Concrete Placing ACI 304R, ACI 305R for hot weather concreting , ACI 306.1for cold weather concreting, and ACI 309R, unless otherwise specified. Concrete shall be vibrated internally and/or externally to assure a smooth, dense finish. 2.3.4.3 Concrete Curing Commence curing immediately following the initial set and completion of surface finishing. Provide curing procedures to keep the temperature of the concrete between 10 and 90 degrees C 50 and 190 degrees F. When accelerated curing is used, apply heat at controlled rate and uniformly along the casting beds. Monitor temperatures at various points in a product line in different casts. Cure for a minimum of seven days prior to transporting, launching and assembly. 2.3.5 Surface Finish Precast floats containing hairline cracks which are visible and are less than 0.5 mm 0.02 inches in width, may be accepted, except that cracks larger than 0.1 mm 0.005 inches in width for surfaces exposed to the weather shall be repaired. Precast floats which contain cracks greater than 0.5 mm 0.02 inches in width shall be approved by the Contracting Officer, prior to being repaired. Any precast float that is structurally impaired or contains honeycombed section deep enough to expose reinforcing shall be rejected. 2.3.5.1 Unformed Surfaces Provide a steel troweled and broomed finish for pier deck surface. Slip resistant broomed deck finish shall be transverse to pier orientation. All deck edges shall have a 10mm3/8 in. tooled radius with a minimum 38mm 1 1/2 in. wide, smooth, hard steel finished face. 2.3.5.2 Formed Surfaces NOTE: PCI MNL-116 different grades of formed surface finishes: Commercial Grade: Concrete produced in forms that produce a rough finish. Fins are removed and large surface blemishes filled. Sharp edges that will be visible in the finished structure are ground down. Standard Grade: Same finish as commercial grade, except the forms do not produce a texture on the concrete. Surface can be painted, but will have surface voids. Finish Grade B: Same as standard grade, except all surface blemishes should be filled or finished to provide a smooth surface or uniform appearance if painted. Finish Grade A: Same as Finish Grade B, except that the components of the completed structure, where exposed, shall be reasonably color matched. This finish is difficult to obtain. PCI MNL-116 (Appendix A - Commentary), Chapter 3, for grades of surface finishes. Provide a standard grade surface finish for both exposed and unexposed areas. 2.3.6 Float Identification All precast floats are to be clearly identified on one side and one end, between the bottom of the waler and the waterline. Identification shall include name of manufacturer, date of manufacture, specific float type, and job number. 2.4 TIMBER AND WOOD PRODUCTS All walers shall be fabricated from parallel strand lumber (PSL) engineered structural beams. PSL structural beams shall be in accordance with ASTM D 5456 All other structural lumber shall be No. 1 Southern Yellow Pine. 2.4.1 Preservative Treatment Treat wood to be used in contact with salt water or salt water splash in accordance with AWPA C2 (Material Subject to Marine Borer Exposure) with waterborne preservative AWPA P5, (ACA - Ammoniacal Copper Arsenate, ACZA - Ammoniacal Copper Zinc Arsenate, CCA - Chromated Copper Arsenate) to 0.6 pcf retention. For wood continuously immersed, treat in accordance with AWPA C1 and AWPA C18 as applicable, to 2.5 pcf retention. For glue laminated engineered structural beams treat in accordance with AWPA C28 and AWPA C33 as applicable 2.5 _{RUBBING SURFACE} - ULTRA-HIGH MOLECULAR WEIGHT POLYETHYLENE (UHMWPE) Materials including additives shall be traceable by original lot number. Materials used shall be FDA approved or otherwise harmless to marine life. Fabricated form shall be from virgin resin. 2.5.1 Resin ASTM D 4020. Virgin resin shall be homopolymer of ethylene and have an intrinsic viscosity (IV) between 22.0 and 28.0 dl/g. No reprocessed resin shall be used. Resin shall be oil and moisture free (0.2 percent weight maximum). 2.5.2 Composition and Fabricated Form Resin shall comprise a minimum 95.0 percent by weight concentration in the formulation. The finished form shall maintain ultraviolet stability for a minimum of 25 years and be free of saltwater or petroleum product leachable materials. No unfused areas or light patches greater than 300 micrometers No. 50 sieve shall be in the final fabricated form. Form shall be 38mm1 1/2 in. thick, depth equal to design depth of waler, and length as required but not less than 3m10 ft. . Exterior edges shall be rounded to 19mm3/4 in. radius. Color shall be black. The fabricated form shall have the following properties:       Density (ASTM D 792)                       0.92-0.94 g/cc       Tensile Strength (ASTM D 638)           Ultimate, minimum                      31.7 MPa           Ultimate Elongation, minimum           250 percent       Impact Strength (ASTM D 256)           Test Method A, Izod                    Non-break for all five                                                  determinations in sample       Hardness (ASTM D 2240), minimum            Shore D 65       Coefficient of Friction (ASTM D 1894)           Kinetic, maximum                       0.13           Static, maximum                        0.20       Water Absorption (ASTM D 570)              Nil       Abrasion Index (relative to steel = 100),           maximum                                10       Density (ASTM D 792)                       57.5-58.7 lb/cu.ft       Tensile Strength (ASTM D 638)           Ultimate, minimum                      4600 psi           Ultimate Elongation, minimum           250 percent       Impact Strength (ASTM D 256)           Test Method A, Izod                    Non-break for all five                                                  determinations in sample       Hardness (ASTM D 2240), minimum            Shore D 65       Coefficient of Friction (ASTM D 1894)           Kinetic, maximum                       0.13           Static, maximum                        0.20       Water Absorption (ASTM D 570)              Nil       Abrasion Index (relative to steel = 100),           maximum                                10 2.6 GUIDE PILES Guide piles shall be prestressed concrete piles; fabricated and installed in accordance with section 31 62 13.20 PRECAST/PRESTRESSED CONCRETE PILES. Pile size, length, cross section and embedment shall be determined by pier manufacturer's design.[ Recommended pile butt elevation is[ ][ 5.0] ft. [ 1.5] m above [extreme] high water.] Pile quantity and location shall be as indicated on the drawings. Relocation of pile layout and additional piles required by the manufacturer's design to resist the indicated design loads, shall be subject to approval by the government. 2.6.1 _{Guide Pile Caps} Provide heavy UV-resistant, low density polyethylene piling caps with an estimated life in excess of 10 years. Caps shall be cone or pyramid shaped and attached to the piling top with stainless fasteners. 2.7 GANGWAYS 2.7.1 Aluminum Aluminum alloy shall be 6061-T6. Extruded in accordance with the applicable requirements of SAE AMS-QQ-A-200/8 . 2.7.2 Stainless Steel Type 316 L. 2.7.3 Castings F-214 Cast aluminum. Castings shall be true to pattern, structurally sound and free from blow holes or other defects. 2.7.4 Insulators MIL-I-24768/14. Bushings or separation sheets shall be a minimum of 1.5mm1/16 in. thickness. 2.7.5 Rollers FS A-A-55619B, UHMW polyurethane, with UV inhibitors added. Color shall be black. [2.8 _{Receptacle Stations} Receptacle stations shall include enclosure, mechanical interlocks, and related wiring and devices as indicated. 2.8.1 Enclosure Enclosure shall be NEMA ICS 6, type 3R, fabricated of 12 gauge stainless steel. Paint ASTM D 1535 light gray No. 61. Paint coating system shall comply with IEEE C57.12.29. 2.8.2 Mechanical Interlocks UL 231, UL 1686, UL 98. Mechanical interlock devices shall incorporate a fused disconnect safety switch and IEC receptacle in a non-metallic, watertight, enclosure. The interlock mechanism shall prevent making and breaking of power under load. Enclosure shall be rated NEMA 4X and also rated IP67 in accordance with EN 60529. Include matching plug for each mechanical interlock provided. Plugs and receptacles shall be classified to EN 60309-1 and EN 60309-2. 2.8.3 Circuit Breakers UL 489. Individual molded case circuit breakers with voltage and continuous current ratings, number of poles, overload trip setting, and short circuit current interrupting rating as indicated. 2.8.4 Ground-Fault Circuit Interrupter Receptacles NOTE: For LANTNAVFACENGCOM projects, use GFI terminology in lieu of GFCI. NAVFACENGCOM has established these GFCI/GFI safety standards at a higher level of protection than NFPA 70's minimum requirements as a result of a GAO report and DOD concern about health and safety. UL 943, duplex type for mounting in standard outlet box. Device shall be capable of detecting current leak of 6 milliamperes or greater and tripping per requirements of UL 943 for Class A GFI devices. Provide screw-type, side-wired wiring terminals or pre-wired (pigtail) leads. Provide in nonmetallic box with gasketed, weatherproof, nonmetallic cover plate and gasketed cap over each receptacle opening. Provide caps with a spring-hinged flap. Receptacle shall be UL listed for use in "wet locations with plug in use." ]PART 3 EXECUTION 3.1 SURFACE REPAIR Prior to erection, and again after installation, precast floats shall be checked for damage, such as cracking, spalling, and honeycombing. As directed by the Contracting Officer, precast floats that do not meet the surface finish requirements specified in Part 2 in paragraph entitled "Surface Finish" shall be repaired, or removed and replaced with new precast floats. 3.2 LAUNCH AND ASSEMBLY Precast floats shall be launched after the concrete has attained the specified compressive strength, unless otherwise approved by the precast manufacturer. Assemble in accordance with the approved shop drawings. PCI MNL-116 and PCI MNL-120 (Chapter 8), for tolerances. Brace precast floats, unless design calculations submitted with the shop drawings indicate bracing is not required. Follow the manufacturer's recommendations for maximum construction loads. 3.3 ANCHORAGE Provide anchorage for fastening work in place. Conceal fasteners where practicable. Make threaded connections up tight and nick threads to prevent loosening. 3.4 WELDING AWS D1.4/D1.4M for welding connections and reinforcing splices. Protect the concrete and other reinforcing from heat during welding. Weld continuously along the entire area of contact. Grind smooth visible welds in the finished installation. Welding of epoxy-coated reinforcing is not allowed. 3.5 OPENINGS Holes or cuts requiring reinforcing to be cut, which are not indicated on the approved shop drawing, shall only be made with the approval of the Contracting Officer and the precast manufacturer. Drill holes less than 300 mm 12 inches in diameter with a diamond tipped core drill. 3.6 GALVANIZING REPAIR Repair damage to galvanized coatings using ASTM A 780 zinc rich paint for galvanized surfaces damaged by handling, transporting, cutting, welding, bolting, or acid washing. Do not heat surfaces to which repair paint has been applied. 3.7 GROUTING Clean and fill indicated areas, solidly with nonshrink grout or cementitious grout. Provide reinforcing where indicated. Remove excess grout before hardening. 3.8 SEALANTS Provide as indicated and as specified in Section 07 92 00 JOINT SEALANTS.