1、*USACE / NAVFAC / AFCESA / NASA UFGS-05 59 13 (August 2009)-Preparing Activity: USACEUNIFIED FACILITIES GUIDE SPECIFICATIONSReferences are in agreement with UMRL dated July 2009*SECTION TABLE OF CONTENTSDIVISION 05 - METALSSECTION 05 59 13FABRICATION OF HYDRAULIC STEEL STRUCTURES08/09PART 1 GENERAL1
2、.1 REFERENCES1.2 SYSTEM DESCRIPTION1.2.1 Weld Tracking Log Template1.2.2 Weld Tracking Log1.2.3 Welding Procedure Specifications (WPS)1.2.4 Fracture Critical Members (FCM)1.3 SUBMITTALS1.4 QUALITY ASSURANCE1.4.1 Qualification of Welders and Welding Operators1.4.2 Inspector Qualifications1.4.3 Qualif
3、ication of Structural Steel Fabricator1.4.4 Testing by the Government1.4.5 Shop Drawings1.5 DELIVERY, STORAGE, AND HANDLINGPART 2 PRODUCTS2.1 FABRICATION2.1.1 Structural Fabrication2.1.2 Assembly2.1.3 Materials Disposition Record2.1.4 Welded Connections2.1.5 Bolted Connections2.1.6 Miscellaneous Pro
4、visions2.1.7 Shop Assembly2.1.8 Seals2.2 CERTIFIED TEST REPORTS2.2.1 General2.2.2 Nondestructive Testing2.2.3 Inspection of Structural Steel Welding2.2.4 Welds to be Subject to Nondestructive Examination2.2.5 Test Coupons2.2.6 Supplemental Examination2.2.7 Structural Steel Welding Repairs2.2.8 Contr
5、ol DimensionsSECTION 05 59 13 Page 1Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-PART 3 EXECUTION3.1 INSTALLATION3.1.1 Cleaning3.1.2 Alignment and Setting3.2 PROTECTION OF FINISHED WORK3.3 PAINTING- End of Section Table of Contents -SECTION 05 59
6、13 Page 2Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-*USACE / NAVFAC / AFCESA / NASA UFGS-05 59 13 (August 2009)-Preparing Activity: USACEUNIFIED FACILITIES GUIDE SPECIFICATIONSReferences are in agreement with UMRL dated July 2009*SECTION 05 59 1
7、3FABRICATION OF HYDRAULIC STEEL STRUCTURES08/09*NOTE: This guide specification covers the requirements for general workmanship applicable to the fabrication, assembly and testing of fracture critical Hydraulic Steel StructuresEdit this guide specification for project specific requirements by adding,
8、 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 di
9、rected 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*NOTE: This specification i
10、s intended for the fabrication of NEW Hydraulic Steel Structures. Fracture critical hydraulic steel structures (HSS) are critical life safety structures that require added quality control. Fracture critical HSS or components of HSS are those portions whose failure would lead to collapse of the struc
11、ture and potential life loss.The results of the Hydraulic Steel Structures inspection program, undertaken by USACE, has shown that fracture critical fabrication without added oversite has led to a lack of understanding of the techniques required to ensure life safety.SECTION 05 59 13 Page 3Provided
12、by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-This guide specification is intended to ensure fracture critical structures are properly manufactured according to updated welding criteria and ensures that quality control is exercised throughout the fabricatio
13、n process in accordance with ER 1110-2-8157. This specification should be used for the design of fracture critical HSS structures and HSS strutures subjected to dynamic loads. Bulkheads/stoplogs or other HSS structures, not fabricated with fracture critical compoents or subject to static load only,
14、may be fabricated to this specification when an added level of quality control is required. Use of this specification for the repair of existing structures is not recommended and would require numerous modifications to ensure compatibility of existing steel with fracture critical requirements.As of
15、May 2009 all references have been updated to the current edition. The version of the reference being selected is critical considering the need for certain supplements. Changing the version of the ASTM reference such as ASTM A709 will affect the supplement required for toughness testing. For example,
16、 the supplement requirements in the older editions of A709 was S83 and S84. The current edition of A709-08 does not have supplement S83 or S84, S83 applied toughness requirements for non-fracture critical elements, or S84 applied toughness requirements for fracture critical elements. These requireme
17、nts are defined in ASTM A6 Supplement S5 (Charpy Testing) and Section 10 of ASTM A709. Do not change reference years specified without verifying requirements. SPECSINTACT may require the use of an older version depending on the reference database your version of SPECSINTACT is checking against. Be c
18、areful when checking your references.Take great care in adding references to additional steels (ASTM A36, A572, A992 etc.) as these steels do not provide toughness requirements for fracture critical structures and are NOT addressed as acceptable base metals in AWS D1.5. The following items are likel
19、y manufactured from steels that do not comply with AWS D1.5 and must be specifically addressed with a weld procedure generated for qualification such as:1. Rub/Guide Blocks2. Chain3. Pipe or Tubing for Guardrail etc.4. Ancillary items such as anode attachments etc.In all instances where alternate ma
20、terials, other than A709 steel are used, specific weld procedures must be generated to address the mixing of base metals in a given joint configuration. If the engineer chooses to add alternate basemetals to the SECTION 05 59 13 Page 4Provided by IHSNot for ResaleNo reproduction or networking permit
21、ted without license from IHS-,-,-list of approved basemetals then he/she must ensure that these metals are only permitted for individual components where these materials are required and must additionally ensure that pre-qualification records and qualified weld procedures for mixing basemetals are s
22、pecifically required in the submittal section of this guide specification.Note that AASHTO HB-17, Standard Specifications for Highway Bridges, needs to be added to the list of references if slip critical connections and testing are required. See the slip critical testing requirements as defined in t
23、he note provided in the paragraph Bolted Connections. In addition, add reference to ASTM A490 REVA if A490 bolts are specified under that same paragraph. The references to A490 and HB-17 have been removed from this guide specification in order to ensure that the specification compiles properly.*1.1
24、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 Wizards Check Reference f
25、eature when you add a RID outside of the Sections Reference Article to automatically place the reference in the Reference Article. Also use the Reference Wizards Check Reference feature to update the issue dates.References not used in the text will automatically be deleted from this section of the p
26、roject 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 SOCIETY FOR NONDESTRUCTIVE TEST
27、ING (ASNT)ASNT RP SNT-TC-1A (2006) Recommended PracticeAMERICAN WELDING SOCIETY (AWS)AWS D1.5M/D1.5 (2008; Errata 2009) Bridge Welding CodeAWS QC1 (2007) AWS Certification of Welding InspectorsSECTION 05 59 13 Page 5Provided by IHSNot for ResaleNo reproduction or networking permitted without license
28、 from IHS-,-,-ASTM INTERNATIONAL (ASTM)ASTM A 325 (2009) Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile StrengthASTM A 563 (2007a) Standard Specification for Carbon and Alloy Steel NutsASTM A 709/A 709M (2009) Standard Specification for Structural Steel
29、 for BridgesASTM E 165 (2002) Standard Test Method for Liquid Penetrant ExaminationASTM E 709 (2008) Standard Guide for Magnetic Particle ExaminationASTM F 436 (2009) Hardened Steel WashersU.S. ARMY CORPS OF ENGINEERS (USACE)EM 385-1-1 (2008) Safety and Health Requirements Manual1.2 SYSTEM DESCRIPTI
30、ON*NOTE: Insert a list of structures that will be fabricated according to this specification. Note that other Division 5 specifications (Miscellaneous metals etc.) would enable structures to be fabricated according to AWS D1.1 and would permit the use of basemetal without toughness requirements etc.
31、 If more than one Division 5 specification is included in the specification package, then any item not listed below will be fabricated to a separate specification.AWS D1.5 section 1.1.3 specifies that all references to “Engineer“ approval in D1.5 refer to the State Bridge Engineer. The paragraph bel
32、ow addresses this to ensure that the proper authority/responsibility is given to the Engineer of record.*Provide a detailed Work Plan for fabrication, including descriptions of shop facilities, equipment, number of personnel, and related information prior to the Pre-fabrication Conference, and proce
33、dures for safe conduct of the work, careful removal and disposition of materials, protection of property that is to remain undisturbed, and coordination with other work in progress. Include in the procedures a detailed description of the methods and equipment to be used for each operation, and the s
34、equence of operations in accordance with EM 385-1-1. The fabrication of the following listed structures under this contract shall be performed according to this section of the specifications:1. Spillway Tainter GatesSECTION 05 59 13 Page 6Provided by IHSNot for ResaleNo reproduction or networking pe
35、rmitted without license from IHS-,-,-2. Fishway Intake Bulkheads3. Main Unit Head Gatesa. Material with welds will not be accepted unless the welding is specified or indicated on the drawings or otherwise approved. Welding shall not be started until welding procedures, inspectors, nondestructive tes
36、ting personnel, welders, welding operators, and tackers have been qualified and approved. Each Contractor performing welding shall maintain records of the test results obtained in welding procedure, and welder, welding operator, and tacker performance qualifications.b. As it is used in these specifi
37、cations, “The Engineer“ refers to the District or AE engineer of record. The AWS D1.5M/D1.5 definition of “The Engineer“ as specified in AWS D1.5M/D1.5 section 1.1.3 shall refer to the District or AE engineer of record in lieu of the state bridge engineer as specified in section 1.1.3 of AWS D1.5M/D
38、1.5.c. Schedule a Prefabrication Conference as soon as possible after Notice to Proceed and prior to any fabrication. The Prefabrication Conference shall include, at a minimum, the Prime Contractor, Fabricator, the Fabricators primary QC representative, the COR, the GQAR, and the Engineer of record
39、for the structure or structures being fabricated. The Prefabrication Conference shall occur either at the Fabrication Facilities or a similar location as deemed appropriate.1.2.1 Weld Tracking Log TemplateSubmit for approval a weld tracking log template, a minimum of 30 days prior to commencement of
40、 fabrication, to identify all necessary components to be addressed in the tracking of all welds for the structures in question. A weld-tracking log will be developed and maintained as described in the following paragraphs.1.2.2 Weld Tracking LogProvide a log capable of individually identifying and t
41、racking every weld on the project. Member identification shall follow the numbering scheme shown on the shop drawings. The log shall include the member to be welded, member type (FCM and Non-FCM), type of weld including temporary and tack welds, welding position, applicable WPS reference, AWS joint
42、preparation designation, name or stamping designation of welder, welding operator or tacker, date and time of completion of welding and/or tacking, name and date of CWI visual inspection, NDT testing performed, including the type of inspection, date(s) of inspection, inspector name, and the acceptan
43、ce criteria used, description of defects found and reason for non-compliance, corrective action taken, or whether the weld is acceptable. Weld identification on the shop drawing shall match weld tracking log identification. A completed log shall be bound together for each structure and two copies sh
44、all be submitted to the Contracting Officer immediately upon completion of the fabrication of each structure. Draft copies of NDT testing shall be furnished to the Contracting Officer upon request and shall be available on the shop floor during any inspection.1.2.3 Welding Procedure Specifications (
45、WPS)*NOTE: AWS D1.5 1.3.6 defines that Ancillary products can be welded without WPS. Ancillary SECTION 05 59 13 Page 7Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-products are defined as products not subjected to tensile stress when subjected to live load. This requires the Contractor to know what components of the structure are in tension. In addition, Chapter 12 defines attachments less than 100 mm (4 inches) as not fracture critical. Each engineer should
