PROJECT MANUAL FOR Greenbrier Dam Repairs Principal Spillway Slide Gate Valve Replacement GREENBRIER STATE PARK 21843 NATIONAL PIKE BOONSBORO, MARYLAND 21713 WASHINGTON COUNTY BID SET FOR THE DEPARTMENT OF GENERAL SERVICES DGS PROJECT NO. P-052-180-002 / 001B9400150 FEBRUARY 2019 STATE OF MARYLAND DEPARTMENT OF GENERAL SERVICES ELLINGTON E. CHURCHILL JR. SECRETARY 301 WEST PRESTON STREET, ROOM 1405 BALTIMORE, MARYLAND 21201
BOARD OF PUBLIC WORKS LARRY HOGAN, GOVERNOR PETER FRANCHOT, COMPTROLLER NANCY K. KOPP, TREASURER
DEPARTMENT OF NATURAL RESOURCES MARK J. BELTON, SECRETARY 580 TAYLOR AVENUE ANNAPOLIS, MARYLAND 21401
Architect / Engineers Prime Consultant – Civil & Structural
12420 MILESTONE CENTER DRIVE, SUITE 150 GERMANTOWN, MARYLAND 20876 PHONE: 301.820.3000 FAX: 301.820.3009
MINORITY BUSINESS ENTERPRISES ARE ENCOURAGED TO RESPOND TO THIS SOLICITATION
Greenbrier Dam Repairs Principal Spillway Slide Gate Valve Replacement DGS Project No. P-052-180-002 \ 001B9400150 February 2019
GREENBRIER DAM REPAIRS PRINCIPAL SPILLWAY SLIDE GATE VALVE REPLACEMENT GREENBRIER STATE PARK 21843 NATIONAL PIKE, BOONSBORO, MARYLAND 21713 DGS Project No. P-052-180-002 / 001B9400150
TABLE OF CONTENTS
DIVISION 0 – PROCUREMENT AND CONTRACTING REQUIREMENTS
• Notice to Bidders – Solicitation Fact Sheet (eMaryland Marketplace attachment) • Instructions to Bidders for Construction Projects (March 2007) (eMaryland Marketplace attachment) • General Conditions for Construction Contracts (July 2018) (eMaryland Marketplace attachment) • Bid Proposal Affidavit (eMaryland Marketplace attachment) • Contractors Questionnaire • Bid Bond, if applicable (eMaryland Marketplace attachment) • Minority Business Enterprise Utilization Procedures (November 2017) (eMaryland Marketplace attachment) • MBE Attachment D-1A Forms (eMaryland Marketplace attachment) • List of Prevailing Wage Rates (eMaryland Marketplace attachment) • Addenda, if any (eMaryland Marketplace attachment) • List of Drawings • Pre-Bid Conference/Site Visit – Refer to: State Finance and Procurement Article §14302(a) (7)(v) and COMAR 21.11.03.09.C.(2)(e).
DIVISION 01 – GENERAL REQUIREMENTS Page Nos Section 011100 Summary of Work 011100-1 - 011100-10 Section 017000 Execution and Closeout Requirements 017000-1 - 017000-2
DIVISION 02 – EXISTING CONDITIONS (NOT USED) DIVISION 03 – CONCRETE (NOT USED) DIVISION 04 – MASONRY (NOT USED) DIVISION 05 – METALS (NOT USED) DIVISION 06 – WOOD, PLASTICS AND COMPOSITES (NOT USED) DIVISION 07 – THERMAL & MOISTURE PROTECTION (NOT USED)
TABLE OF CONTENTS 1
Greenbrier Dam Repairs Principal Spillway Slide Gate Valve Replacement DGS Project No. P-052-180-002 \ 001B9400150 February 2019
DIVISION 08 – OPENINGS (NOT USED) DIVISION 09 - FINISHES (NOT USED) DIVISION 10 – SPECIALTIES (NOT USED) DIVISION 11 – EQUIPMENT (NOT USED) DIVISION 12 – FURNISHINGS (NOT USED) DIVISION 13 – SPECIAL CONSTRUCTION (NOT USED) DIVISION 14 – CONVEYING EQUIPMENT (NOT USED) DIVISION 21 – FIRE SUPPRESSION (NOT USED) DIVISION 22 – PLUMBING (NOT USED) DIVISION 23 – HEATING VENTILATING AND AIR CONDITIONING (NOT USED) DIVISION 25 – INTEGRATED AUTOMATION (NOT USED) DIVISION 26 – ELECTRICAL (NOT USED) DIVISION 27 – COMMUNICATIONS (NOT USED) DIVISION 28 – ELECTRONIC SAFETY AND SECURITY (NOT USED) DIVISION 31 – EARTHWORK (NOT USED) DIVISION 32 – EXTERIOR IMPROVEMENTS (NOT USED)
DIVISION 33 – UTILITIES (NOT USED)
DIVISION 34 – TRANSPORTATION (NOT USED)
DIVISION 35 – WATERWAY AND MARINE CONSTRUCTION (NOT USED)
DIVISION 40 – PROCESS INTERCONNECTIONS Page Nos
Section 400559.23 Stainless Steel Slide Gates 400559-1 - 400559-8
DIVISION 41 – MATERIAL PROCESSING AND HANDLING EQUIPMENT (NOT USED) DIVISION 42 – PROCESS HEATING, COOLING AND DRYING EQUIPMENT (NOT USED) DIVISION 43 – PROCESS GAS AND LIQUID HANDLING, PURIFICATION, AND STORAGE EQUIPMENT (NOT USED) DIVISION 44 – POLLUTION AND WASTE CONTROL EQUIPMENT (NOT USED) DIVISION 45 – INDUSTRY-SPECIFIC MANUFACTURING EQUIPMENT (NOT USED)
TABLE OF CONTENTS 2
Greenbrier Dam Repairs Principal Spillway Slide Gate Valve Replacement DGS Project No. P-052-180-002 \ 001B9400150 February 2019
DIVISION 46 – WATER AND WASTEWATER EQUIPMENT (NOT USED) DIVISION 48 – ELECTRICAL POWER GENERATION (NOT USED)
TABLE OF CONTENTS 3
Greenbrier Dam Repairs Principal Spillway Slide Gate Valve Replacement DGS Project No. P-052-180-002 \ 001B9400150 February 2019
LIST OF DRAWINGS
DRAWINGS:
The work shall conform to the drawings titled “Greenbrier Dam Repairs Principal Spillway Slide Gate Valve Replacement” which form a part of these specifications and are dated February 7, 2019.
01 TITLE SHEET 02 PLAN VIEW 03 SECTION ELEVATION & DOWNSTREAM SECTION
* HISTORICAL AS-BUILT DRAWINGS (eMaryland Marketplace attachment)
Greenbrier Dam Repairs Principal Spillway Slide Gate Valve Replacement DGS Project No. P-052-180-002 \ 001B9400150 February 2019
SECTION 011100 – SUMMARY OF WORK
PART 1 - GENERAL
1.1 SUMMARY
A. The Project shall be identified as: Greenbrier Dam Repairs Principal Spillway Slide Gate Valve Replacement Project No. P-052-180-002 \ 001B9400150
1. The project location is: Greenbrier State Park, 21843 National Pike, Boonsboro, Maryland 21713.
B. Mr. Chris Elnicki, A.I.A. will serve as the DGS Project Manager. His contact information is as follows: Maryland Department of General Services State Office Building 301 West Preston Street, Suite 1405 Baltimore, MD 21201
C. Ms. Linda Steinmetz will serve as the DNR Project Manager. Her contact information is as follows: Maryland Department of Natural Resources 580 Taylor Ave., D-3 Annapolis, MD 21401
D. Mr. John Roche, P.E. serve as the Maryland Dam Safety Official. His contact information is as follows: MDE Dam Safety Division State Office Building 1800 Washinton Blvd Baltimore, MD 21230
E. Ms. Mary Ironside will serve as the DNR Park Manager. Her contact information is as follows: Maryland Department of Natural Resources 21843 National Pike Boonsboro, MD 21713
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F. Mr. G. Michael McIntyre, P.E. will serve as Engineer-In-Charge for the engineering consultant. His contact information is as follows: AECOM 12420 Milestone Center Drive, Suite 150 Germantown, Maryland 20874
G. This project consists of the Contractor providing all labor, equipment, materials, supplies, insurance, etc., necessary to replace the existing 18" drain valve for the lake located at Greenbrier State Park, Boonsboro, Washington County, Maryland.
H. The Work includes, but is not limited to, the following:
1. Furnish and Install New Gate Valve: a. Remove existing trash rack, as necessary, to gain access into valve tower. b. Disconnect, remove and dispose of existing valve stem. c. Remove and dispose of the existing 18" wedge style gate valve. d. Remove and dispose of existing stem guides. e. Install new slide gate to existing 18” pipe flange. f. Install new stem guides. g. Install new stem. h. Check valve and stem for proper operation. i. Reinstall trash rack as necessary to return site back to a pre-construction status. j. Remove and properly dispose of all debris.
2. Support and Provide Access to AECOM for Engineer’s Inspection: a. Provide AECOM’s Engineer with confined space access to valve tower in accordance with OSHA regulations. Provide necessary equipment for access into interior of the valve tower. Engineer will furnish fall protection harness. b. Provide standby time in work schedule for AECOM’s Engineer to safely complete visual inspection of the valve tower and remotely operated vehicle inspection (ROV) of 18” intake pipe and 36” principal spillway pipe.
I. Work Performed by Others
1. Dewatering a. Dewater 18” lake drain pipe by opening existing gate valve. A metal plate shall be installed at the upstream end of the 18” lake drain pipe by divers (MSI) contracted by others. Reportedly, the metal plate leaked approximately 5 gpm when it was last used in 2013. b. Water Flow to the gate valve will be restored by divers (MSI) contracted by others.
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1.2 SUBMITTALS
A. The Contractor shall submit one copy of a work schedule and a work plan which includes a health and safety plan.
B. The Contractor shall submit all manufacturer 's manuals, warranty, shop drawings, as built drawings, etc., concerning the project. All information shall be submitted electronically to the Engineer.
C. Quality Assurance
1. The Engineer shall review submittals only for general conformance with the Contract Documents. Such review by the Engineer shall not relieve the Contractor or any subcontractor of responsibility for full compliance with Contract requirements; for correctness of dimensions; for proper designing of details; for proper fabrication and construction techniques; for proper coordination with other trades; and for providing all devices required for safe and satisfactory construction and operation.
2. Submittals reviewed by the Engineer and returned to the Contractor will be marked with one of the following designations: a. No Exceptions Taken b. Furnish As Noted c. Revise and Resubmit
3. The Contractor shall not proceed with procurement, manufacture or fabrication of items for review until such submittals have been designated by the Engineer as "No Exceptions Taken" or "Furnish As Noted," unless specifically authorized to do so by the Engineer in writing.
4. Timing of submittals shall allow for review time by the Engineer, which shall not exceed three (3) work days.
5. All submittals shall be transmitted with pre-printed letter of transmittal form of Contractor's choosing, dated and signed, with the job title and Section(s) of the Specification requiring the submittal clearly indicated. The forms shall be sequentially numbered. Resubmittals shall have the original number together with an alphabetic suffix (A, B, ... ) indicating the number of resubmittals, where appropriate.
6. The Contractor shall certify by signing the submittal that review, verification of products required, field dimensions and coordination of information is in accordance with the Work as specified in the Contract Documents.
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7. Identify specific variations from the Contract Documents and Product or system limitations which conflict or may be detrimental to successful performance of the completed Work.
D. Product Data
1. Collect required data into one submittal for each unit of Work or system; and mark each copy to show which choices and options are applicable to the Work. Include manufacturer's standard printed recommendations, notation of field measurements which have been checked, and special coordination requirements.
2. Maintain one set of Product Data (for each submittal) at project site, available for reference by Engineer and others.
3. Mark each copy to identify applicable products, models, options, and other data. Supplement manufacturers' standard data to provide all information unique to this Project.
E. Shop Drawings
1. Prepare Project-specific information, drawn accurately to scale. Do not base Shop Drawings on reproductions of the Contract Documents or standard printed data.
2. Fully illustrate requirements in the Contract Documents. Include the following information, as applicable:
a. Identification of products. b. Schedules. c. Compliance with specified standards. d. Notation of coordination requirements. e. Notation of dimensions established by field measurement. f. Relationship and attachment to adjoining construction clearly indicated. g. Seal and signature of professional engineer if specified.
3. Submit an electronic copy of Shop Drawings to the Engineer.
F. Manufacturers' Instructions
1. When specified in individual specification Sections, submit manufacturers' printed instructions for delivery, storage, assembly, installation, start-up, adjusting and finishing in quantities specified herein.
G. Manufacturers' Certificates
1. Submit manufacturers' certificates to Engineer.
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2. Indicate that a material or product conforms to or exceeds specified requirements. Submit supporting reference data, affidavits, and certifications as appropriate.
3. Certificates may be recent or previous test results on material or product, but must be acceptable to Engineer. If these are outdated and/or not acceptable to Engineer, the Contractor shall submit to the Engineer the new certificates and test results on materials or product.
1.3 REQUESTS FOR INFORMATION
A. A RFI is a request from the Owner, Engineer, or Contractor seeking information from each other during construction. Immediately on discovery of the need for additional information or interpretation of the Contract Documents, Contractor shall prepare and submit an RFI.
B. The content of the RFI shall include a detailed, legible description of item needing information or interpretation and the following:
1. Project name. 2. Project number. 3. Date. 4. Name of Contractor. 5. Name of Engineer. 6. RFI number, numbered sequentially. 7. RFI subject. 8. Specification Section number and title and related paragraphs, as appropriate. 9. Drawing number and detail references, as appropriate. 10. Field dimensions and conditions, as appropriate. 11. Contractor's suggested resolution. If Contractor's solution(s) impacts the Contract Time or the Contract Sum, Contractor shall state impact in the RFI. 12. Contractor's signature. 13. Attachments: Include sketches, descriptions, measurements, photos, Product Data, Shop Drawings, coordination drawings, and other information necessary to fully describe items needing interpretation.
C. The Engineer will review each RFI, determine action required, and respond. Allow three (3) working days for Engineer's response for each RFI.
1.4 CONTRACT
A. The work will be constructed under a single contract with a single Prime Contractor. The contract will be a fixed price type contract.
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1.5 QUALIFICATIONS OF THE CONTRACTOR
A. The Contractor shall be licensed in the State of Maryland as a General Contractor to perform work associated with this project.
B. The Contractor shall have a minimum of three (3) years of experience performing construction work of a similar nature.
C. Divers (MSI) will be contracted by others.
D. The Contractor and his/her employees must be trained and certified in accordance with confined space operations for that phase of the work.
1.6 WORK SEQUENCE AND COMPLETION
A. The Work shall be conducted in one phase. This project has been classified as an emergency. Work shall begin as soon as "Notice to Proceed" has been issued. The work on this project shall be complete and ready for use within 56 calendar days or earlier of the Notice to Proceed.
1.7 CONTRACTOR SCHEDULE AND WORKPLAN
A. The Contractor shall prepare and submit to the Engineer for approval, a work schedule and work plan before work commences. The work plan shall include work approach, equipment to be used for each item of construction, methods, and management. It shall also include a health and safety plan that conforms to all applicable regulations.
B. The sequence of the work shall be performed in accordance with the approved work plan and approved construction schedule. It shall follow the Sequence of Construction provided on the Contract Drawings.
C. The Contractor’s schedule and work plan shall include an allowance of time (8-hours) for AECOM to complete its inspections of the valve tower, 18” intake pipe and 36” principal spillway pipe.
1.8 CODES, LAWS AND PERMIT REQUIREMENTS
A. The Work Plan shall comply with all project permit requirements, and all other applicable federal, state, and local laws, orders, regulations, permits, and good engineering and construction practices. It shall be approved by the Engineer at least 7 days before beginning field activities.
1.9 ACCESS TO SITE
A. The principal spillway riser structure shall be accessed from the crest of the dam. The existing access road from the auxiliary spillway parking lot to the crest of the dam shall be utilized to get to the crest of the dam.
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B. Equipment left on site during construction shall be temporarily barricaded with the use of barricades, cones and caution tape.
1.10 SITE VISITS AND MEETINGS
A. It is suggested the Contractor visit the job site and familiarize himself/herself with the conditions under which the work will be performed. No allowance will be made for errors on the Contractor's part for failure to take into consideration any conditions or circumstances existing at the site which might affect the specified work.
1. As-built Drawings associated with the lake, dam, valve tower, etc., are available on the eMaryland Marketplace.
2. Please contact the Park Manager by calling 301-791-4656 prior to any site visit.
B. Within seven (7) days after Notice to Proceed and prior to starting the Work except mobilization, the Contractor, shall meet with the Owner and the Engineer for a Preinstallation Meeting. The Preinstallation Meeting will be scheduled by the Engineer. The purpose of this meeting is to review submittal procedures, project schedule, and payment and procurement of materials. The principal features of work will also be reviewed and any questions regarding the Contract and work site will be addressed. All work shall be coordinated with the DGS Project Manager, DNR Project Manager, Maryland Dam Safety Official, Park Manager and Engineer at the Preinstallation Meeting. The entity responsible for conducting the meeting will record and distribute the meeting minutes to each party present and to parties requiring information.
1.11 WORK HOURS RESTRICTION
A. The Contractor’s daily work schedule shall adhere to the operation schedule of Greenbrier State Park. The park is open daily from dusk to dawn. Work will not be permitted outside of these hours.
PART 2 – PRODUCTS
2.1 GENERAL MATERIALS AND SUPPLIES
A. All materials shall be as specified or approved equal by the Engineer. In the event the Contractor would like to substitute materials other than those that have been specified, the Contractor shall submit to the Engineer all pertinent data to determine the or-equal status. This material shall be submitted to the Engineer a minimum of ten (10) days prior to the bid opening. The DGS Project Manager shall notify the Contractor within five (5) days as to the or-equal status.
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B. Once the project has been awarded and prior to fabrication, the Contractor shall submit to the Engineer for approval shop drawings, design calculations, and other submittal information outlined in the contract specifications for the new stainless steel slide gate valve.
C. All materials shall be new and where applicable shall be delivered to the job site with labels intact and legible.
D. The Contractor shall be responsible for the coordination, off-loading and proper storage of all materials and supplies up until the time of final inspection.
E. Materials shall be stored in a safe area out of the way of traffic. Any on-site storage shall be approved by the Park Manager prior to the storage of any materials on site. All materials shall be stored up off the ground surface and should be protected from the weather with a waterproof covering. Any special storage instruction required by the material manufacturer shall be performed by the Contractor as if specified herein.
F. Any materials or supplies which have not been specifically mentioned, but are necessary for the complete, safe and satisfactory completion of the project, shall be provided by the Contractor as if specified herein.
2.2 SPECIFIC MATERIALS AND SUPPLIES
A. Gate Valve: shall be an 18- by 18-inch manually-operated, stainless steel slide gate and frame, designed for 50 feet of unseating head, as shown on the Drawings.
B. Mounting: Frame suitable for mounting on an 18-inch pipe flange. Provide an insulated gasket set between the existing pipe flange and the stainless steel slide gate to prevent galvanic corrosion between dissimilar materials.
C. Acceptable Manufacturers: Golden Harvest Inc., Whipps Inc., or approved equal.
D. Refer to Specification 400559.23 for more specific details.
PART 3 – EXECUTION
3.1 GENERAL METHOD OF WORK
A. All work shall be as shown on the drawings and as called for in these written specifications.
B. The Contractor shall coordinate all work with the various trades and material suppliers in order to complete the project expeditiously and within the time limits of the contract. The sequence of events shall be as shown on the Contract Drawings.
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C. All work shall be performed in the best and most professional manner possible by workers skilled in their respective trades.
D. All work shall be performed to minimize disruption to park operations. It is understood that the Contractor shall maintain accessibility throughout the project.
E. The Contractor shall provide and install adequate barricades, signs, etc., necessary to insure public safety as approved by the Park Manager.
F. The Contractor shall adhere to OSHA-MOSHA regulations throughout the project to insure the safety of his/her employees, state employees, and the public.
G. The Contractor shall maintain the work site(s) in a safe, neat, and orderly manner throughout the entire project. The Contractor shall take steps to prevent the accumulation of debris at the job site(s).
H. Throughout the entire project, the Contractor shall be responsible to properly manage water flow into the valve tower and discharge pipe.
I. Any work that has not been specifically mentioned, but is reasonably implied and is necessary for the safe and satisfactory completion of the project, shall be performed by the Contractor as if specified herein.
3.2 DEWATER EXISTING GATE VALVE
A. Divers (contracted by others) will install a plate in front of the "bell end" inlet pipe. With assistance from Park Staff, open gate valve and allow plate to seal "bell end" of inlet pipe. In the event a successful seal is not obtained, the gate valve will be closed and the divers will reposition plate as required and re-attempt the seal process.
B. Check to insure water flow has been reduced to allow for valve replacement.
C. Once the plate has been successfully installed, gate valve shall remain partially opened to insure positive water pressure (from lake side) remains against the plate.
3.3 GATE VALVE REPLACEMENT
A. The Contractor shall be responsible to remove existing trash rack as required to insure adequate access into the valve tower. Existing materials shall be removed and saved for re installation once all work has been completed.
B. Provide and install safety and ventilation equipment for confined space activities as required under OSHA Regulations. Only personnel trained and certified in confined space activities shall be allowed to occupy confined space areas or support confined
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space activities. Ventilation equipment may not be necessary in the valve tower if natural air flow is determined to be sufficient.
C. The existing valve stem shall be disconnected from the existing gate valve as required. The stem and guide assemblies shall be removed from the valve tower and properly disposed of by the Contractor.
D. The existing gate valve shall be carefully disconnected from the flange of the 18" ID inlet pipe. Once the valve has been disconnected it shall be removed from the valve tower and properly disposed of by the Contractor.
E. Existing flange and inlet pipe located in the valve tower shall be inspected and cleaned prior to installation of the new gate valve.
F. The Contractor shall install the new slide gate to the existing flange. New flange bolts and gaskets (as recommended by the valve manufacturer) shall be used in the mounting of the new gate valve.
G. The contractor shall install the new valve stem, stem guides, pedestal and other appurtant features in accordance with manufacturer's recommendations and original design.
H. Test slide gate and stem for proper operation and adjust as required. Check to insure a leak free installation. Make adjustments as required.
I. The Contractor shall remove and dispose of any debris located at the base of the valve tower.
3.4 RESTORE WATER FLOW TO GATE VALVE
A. Water Flow to the gate valve will be restored by divers (MSI) contracted by others.
3.5 SITE RESTORATION
A. All excess materials and debris shall be removed by the Contractor and disposed of properly off of State property.
B. Any disturbances to State lands shall be properly repaired by the Contractor to a pre- construction condition at no additional cost to the State.
END OF SECTION 011100
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SECTION 017000 – EXECUTION AND CLOSEOUT REQUIREMENTS
PART 1 - GENERAL
1.1 SUMMARY
A. This section includes general administrative and procedural requirements governing execution and closeout of the Work.
1.2 SUBMITTALS
A. Record Drawings: Submit one set(s) of marked-up record prints electronically to the Engineer.
B. Record Specifications: Submit one copy of Project's Specifications, including addenda and contract modifications electronically to the Engineer.
1.3 CONSTRUCTION WASTE MANAGEMENT AND DISPOSAL
A. Maintain Project site free of waste materials and debris. Clean Project site and work areas daily, including common areas. Enforce requirements strictly. Dispose of materials lawfully.
1.4 PROTECTING INSTALLED CONSTRUCTION
A. Provide final protection and maintain conditions that ensure installed Work is without damage or deterioration at time of completion of the Work.
1.5 DEMONSTRATION AND TRAINING
A. Prior to the final inspection the Contractor shall demonstrate opening and closing the new gate valve so that the Owner is adequately trained to do so upon completion of the Work.
1.6 FINAL INSPECTION
A. Submit a written request for final inspection for acceptance. On receipt of request, Engineer will either proceed with inspection or notify Contractor of unfulfilled requirements.
1.7 WARRANTY AND GUARANTEE
A. The Contractor shall guarantee all work for a period of two (2) years from the date of acceptance. Any defects found within the warranty period shall be repaired or replaced by the Contractor at no additional cost to the State.
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PART 2 – PRODUCTS
2.1 RECORD DRAWINGS
A. Record Prints: Maintain one set of marked-up paper copies of the Contract Drawings and Shop Drawings at the project site for review by the Engineer. Mark record prints to show the actual installation where installation varies from that shown originally. Require individual or entity who obtained record data, whether individual or entity is Installer, subcontractor, or similar entity, to provide information for preparation of corresponding marked-up record prints. Types of items requiring marking include, but are not limited to: dimensional changes, revisions to details, details not shown on the original Contract Drawings and record information on the Work that is shown only schematically.
2.2 RECORD SPECIFICATIONS
A. Preparation: Mark Specifications to indicate the actual product installation where installation varies from that indicated in Specifications, addenda, and contract modifications. Submit record Specifications as marked up copy of Specifications.
PART 3 - EXECUTION (NOT USED)
END OF SECTION 017000
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SECTION 400559.23 STAINLESS STEEL SLIDE GATES
PART 1 - GENERAL
1.1 DESCRIPTION
A. Removing and disposing of the existing 18-inch gate valve, gate stems and guides, and associated equipment prior to installation of new slide gate.
B. Furnishing and installing one 18- by 18-inch manually operated stainless steel slide gate, gate stem and guides, and pedestal at the location shown on the Drawings.
1.2 REFERENCES
A. American National Standards Institute (ANSI)
B. American Society of Testing and Materials (ASTM)
1. ASTM A 36 Standard Specification for Carbon Structural Steel 2. ASTM A 276 Standard Specification for Stainless Steel Bars and Shapes 3. ASTM D 2000 Standard Classification System for Rubber Products in Automotive Applications 4. ASTM B 584 Standard Specification for Copper Alloy Sand Castings for General Applications 5. ASTM D 4020 Standard Specification for Ultra-High- Molecular-Weight Polyethylene Molding and ands Extrusion Materials 6. ASTM F 593 Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs. 7. ASTM F 594 Standard Specification for Stainless Steel Nuts
C. American Water Works Association (AWWA) 1. AWWA C561 Fabricated Stainless Steel Slide Gate
D. American Welding Society (AWS) 1. AWS D1.6 Structural Welding Code –Stainless Steel
1.3 SUBMITTALS
A. Submit in accordance with Section 011100 Summary of Work.
B. General: Provide a technical submittal demonstrating that all equipment provided conforms completely to the requirements of this Section.
C. Shop Drawings and Data:
STAINLESS STEEL SLIDE GATE 400559.23-1 Greenbrier Dam Repairs Principal Spillway Slide Gate Valve Replacement DGS Project No. P-052-180-002 \ 001B9400150 February 2019
1. Data and Drawings for review and approval prior to fabrication, showing details and materials of the stainless steel slide gate, manual lift, and all data required to locate and install the slide gate and accessories. 2. Cross section drawings labeling all interior parts, including bearings, seals, and other mechanical parts. 3. Anchoring and mounting details. 4. Weights of equipment assemblies and components, to include stem and slide weight. 5. Catalog Data for Dielectric Gasket Sets. 6. Manufacturer's catalog information, descriptive literature, Specifications, and identification of materials of construction including the material thickness of all structural components of the frame and slide. 7. Calculations for the slide gate and service condition demonstrating that the slide gate, gate stems, and appurtenances are designed for this application and in compliance with this specification. Include the following: a. Maximum bending stress and deflection of the slide under the maximum design head. b. Gate opening and closing thrust forces. c. Manual lift and stem sizing calculations.
D. Quality Control Submittals:
1. Special shipping, storage and protection, and handling instructions. 2. Manufacturer's written/printed installation instructions.
E. Operation and Maintenance Manual:
1. Submit as required by the Engineer. Include the following: a. Previously approved submittal shop drawings and product data. b. Significant design criteria. c. Complete, detailed operating instructions for each piece of equipment. d. Information and instructions for lubrication and adjustments. e. Maintenance instructions with illustrations as necessary. f. Recommended schedule of maintenance. g. Lubrication schedule and table of alternate lubricants. h. List of special tools and equipment required for maintenance. i. Recommended spare parts list.
F. Manufacturer’s Warranty.
1.4 DESIGN REQUIREMENTS
A. Design and fabricate gate and frame in accordance with AWWA C561, and as shown on the Drawings.
STAINLESS STEEL SLIDE GATE 400559.23-2 Greenbrier Dam Repairs Principal Spillway Slide Gate Valve Replacement DGS Project No. P-052-180-002 \ 001B9400150 February 2019
B. If there is a conflict between AWWA requirements and this specification, this specification shall govern.
1.5 QUALITY ASSURANCE
A. Manufacturer’s Qualifications: Furnish stainless steel slide gate from a manufacturer having at least 5 years’ experience in the design and fabrication of items of equipment of similar size and pressure.
B. Manufacturer's shop welds, welding procedures, and welders: Qualified and certified in accordance with the requirements of ANSI/AWS D1.6.
1.6 HANDLING, DELIVERY, AND STORAGE
A. Handling and Storage instructions shall accompany the slide gate delivered to the site.
PART 2 - PRODUCTS
2.1 GENERAL
A. 18- by 18-inch manually-operated, stainless steel slide gate, frame, and appurtenances designed for 50 feet of unseating head and installation on the inlet conduit flange as shown on the Drawings.
B. Acceptable Manufacturers: Golden Harvest Inc., Whipps Inc., or approved equal.
2.2 MATERIALS
A. Slide, Frame Assembly, Cover Bars, Gate Stems, Stem Couplings, Flush Bottom Retainer Bar, Seal Retainers, Stem Guide Brackets: Stainless Steel, ASTM A 240 or ASTM A 276, Type 304 or 316 (304L or 316L for all welded components).
B. Lift Pedestal: Stainless Steel, Type 304L or 316L, ASTM A240.
C. Pedestal Support Plate (If Required): Carbon Steel ASTM A39.
D. Flush Bottom Rubber Seals: Neoprene, ASTM D 2000.
E. Lift Nuts and Stem Couplings: Bronze ASTM B 584.
F. Seat/Seals and Facing: Ultra High Molecular Weight Polyethylene (UHMW), ASTM D 4020.
G. Stem Guides: Bronze unless otherwise approved.
H. Assembly Hardware and Fasteners: Stainless Steel, Type 316, ASTM F 593 and F 594.
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I. Anchor Studs: Stainless Steel, Type 316, ASTM A276.
J. Dielectric Gasket Set: Provide an insulated gasket set between the existing pipe flange and the stainless steel slide gate to prevent galvanic corrosion between dissimilar materials.
2.3 FRAME
A. Suitable for flush-bottom style slide gate mounted on an 18-inch ANSI/AWWA, Class 125 pipe flange.
B. Rigid, welded unit composed of guide rails and cross bars with a clear opening, as specified and reinforcement designed to resist all operating loads.
C. Designed to positively retain the polymer (UHMWPE) guide/seal strips.
D. Assembled with non-loosening (prevailing torque) fasteners.
E. Replaceable guide/seal assembly with leaf mounted UHMWPE.
2.4 GUIDES
A. Fabricated from formed plates, standard structural or extruded shapes to meet AWWA C561 safety factors. Minimum thickness of ¼ inch.
B. Designed and fabricated to withstand the total thrust of the gate slide due to the design head.
C. Fabricated in a length that will fully support the height of the slide when the gate is fully open.
2.5 SLIDE
A. Fabricated from stainless steel plates reinforced with structural shapes welded to the plate, to meet AWWA C561 safety factors. Minimum thicknesses: 3/8 inch for the slide plate, and ¼ inch for the reinforcing structural members.
B. Deflection: 1/16 inch or less under maximum head.
C. Flush-bottom design for effective sealing against a sill plate or bottom of frame.
D. Stem connections threaded and bolted (or keyed). Thrust nuts supported in welded nut pockets. The clevis or nut pocket of the gate capable of withstanding at least twice the rated thrust of the manual actuator.
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E. The disc\gate leaf shall be suitable for throttling flow in varying openings from fully closed to fully open.
2.6 GATE SEALS
A. The gate sealing arrangement for the side and top seals may consist of a combination of UHMWPE guides and neoprene J-seals, or self-adjusting UHMWPE guide/seal combination.
B. Neoprene J-seals: Attached with stainless steel retainer bars held in place with stainless steel fasteners. Field replaceable without removing the gate frame from the concrete wall or wall thimble.
C. The top and side seals shall remain in full contact with the slide for effective sealing at any gate position.
D. The bottom seal shall be a neoprene seal attached to either the bottom of the gate slide or the flush bottom retainer bar.
2.7 GATE STEMS
A. Gate stems shall be stainless steel, as specified, designed for tensile strength and column loading for the manual operators specified.
B. Gate stems and stem guides shall be designed to provide a length/radius of gyration (l/r) not greater than 200. The stem guide brackets shall be fully adjustable in both horizontal directions to attain proper stem alignment and shall be suitable for mounting on stainless steel anchor bolts attached to concrete walls.
C. Existing elevations are not precisely known. Provide gate stems with an overall length of 12 inches greater than determined from the elevations shown, and an additional 24 inches of threads at the top for the actuator, to accommodate potential variations.
D. Stem couplings will be required to connect the stem sections.
2.8 MANUAL LIFT
A. Support the manually operated lift device on a pedestal mounted as shown on the Drawings. Design lift for a rising-stem gate, with the hand wheel rotating in the clockwise direction to open, and the hand wheel marked to show the opening direction.
B. Locate hand wheel or centerline of the operating crank approximately 3 feet above the grating on the operating deck as shown on the Drawings.
C. Design and fabricate the pedestal and manual operator to operate the slide gate with no more than 40 pounds pull on the hand wheel or crank and to withstand 80 pounds pull
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on the hand wheel or crank, assuming normal stresses. Provide a torque plate or other means to prevent the stem from twisting and suitable stop nuts to limit gate travel.
D. If the existing steel support beam shown on the Drawings is too narrow to fully support the pedestal, provide a square plate of suitable thickness and dimensions that can be welded to the top of the support beam fabricated with tapped holes for attaching the pedestal.
E. The support beam, and square plate shall be painted to match the existing coating, or the entire support structure and plate shall be painted as described in Section 2.8 G below.
F. Furnish a clear plastic stem cover, with graduations to indicate gate openings from 0 to 100 percent, in 2 percent increments.
G. Coat the operator housing as applicable in accordance with the lift manufacturer’s standard coating.
2.9 FABRICATION
A. Fully assemble fabricated gate in the shop to ensure that the components fit together properly, with proper clearances and alignment.
2.10 SHOP TESTING AND INSPECTION
A. Notification: Notify the Owner or the Owner’s representative in writing a minimum of 14 calendar days in advance of beginning shop tests.
B. Operating Shop Tests: Open and close the gate slide at least two times in the shop to demonstrate that the leaf moves freely, and there is no binding or unusual noise.
C. The Owner or the Owner’s representative may make visits to the gate manufacturer’s facilities to review progress of the work. Conduct shop testing in the presence of the Engineer, unless waived.
2.11 SHIPPING
A. Ship slide gate fully assembled.
B. Crate and wrap and otherwise protect the slide gates, gate stems, pedestal and lift, and accessories from damage during shipment. Repair or replace any damaged parts, including coatings, to the satisfaction of, and at no cost to the Owner.
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PART 3 - EXECUTION
3.1 REMOVAL OF EXISTING SLIDE GATE
A. Prior to installing the new stainless steel slide gate, remove the existing gate valve, including gate stems; stem guides, and manual operator.
3.2 SLIDE GATE INSTALLATION
A. Install the slide gate, gate frames, manual lift, gate stems, and accessories as shown on the Drawings and in accordance with the gate manufacturer’s approved shop drawings and written installation instructions.
B. Attach the slide gate with stainless steel bolts. The required holes on the existing 18- inch pipe flange may have to be enlarged slightly to accept the insulated dielectric gasket set sleeves.
C. If the steel support beam is too narrow to fully support the pedestal and manual lift, attach and weld a square plate of suitable dimensions to the beam.
D. Attach the pedestal to the support pate with suitable fasteners.
E. After welding the support plate, coat the support beam and pedestal support plate with two 5-8 mil coats of high-solids epoxy for a total dry film thickness of 10-16 mils. Prepare surfaces to receive coating in accordance with manufacturer’s instructions.
F. Furnish necessary sealants, insulated gasket set, fasteners, and other hardware for a complete installation.
G. Prior to installation of the slide gate, clean the face of the 18-inch pipe flange with solvents and/or power brushing to provide a clean surface. Install the slide gate on the downstream face of the pipe flange with a dielectric gasket.
H. Install the slide gate stems using the adjustable stem guides and brackets provided, to provide plumb alignment with no offsets to impede movement of the gate stems. Attach the stem guide brackets to the concrete wall of the intake structure with stainless steel epoxy anchors, using a double-nuts allowing adjustment for proper vertical alignment.
I. The gate stem for the new slide gate may be located in a slightly different position through the steel support at the top of the intake tower than the existing gate, as the stem centerline may move upstream or downstream a small distance. Re-drill or enlarge the existing stem holes in the steel support for the gate stem and pedestal as necessary to accommodate the new slide gate stems and operator.
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J. Install lift pedestal with stainless steel bolts, and then the manual lifts attached to the pedestal.
K. Do not disassemble factory fabricated gate components.
3.3 QUALITY ASSURANCE
A. Manufacturer Inspection 1. The Contractor shall include in his bid for the slide gate, a site visit and inspection of the completed gate installation by the gate manufacturer’s factory-trained personnel, including travel to the site. The visit shall be coordinated by the installation Contractor. 2. The factory-trained personnel shall: a. Check the complete installation. b. Make necessary adjustments on the slide gate, and manual lifts. c. Conduct field testing. d. Provide a certificate of proper installation indicating the slide gate is installed and functioning properly.
B. Notify the Engineer 48 hours in advance of inspections.
C. After installation of the slide gate is complete, operate gate through two complete cycles with the gate dewatered in the presence of the Engineer and Manufacturer’s Field Service Representative. Observe the operation for any unusual noise or vibration and note any excessive hand wheel or crank force required for gate operation. Adjust as necessary for smooth operation.
D. When reservoir head is available, operate slide gate through two complete cycles. Observe the operation of the gate for any unusual noise or vibration, as well as excessive operating force. The Contractor and the Engineer shall be present during the testing. Perform leakage tests in accordance with AWWA C561, with the maximum available reservoir head. The leakage shall not exceed the specified maximum allowable in AWWA C561.
E. Repair gate with excessive leakage at no cost to the Owner.
END OF SECTION 400559.23
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