PROJECT: SAUG 1. DESIGN DATA Clear Width, Wo 3.00 m Clear Height, Ho 2.50 m nHead= 5.42. (Efflux. El. 42.92 m~Sill El. 37.50 m) 2. UNIT HYDROSTATIC LOAD + s E E je f a ele s| #2 i (BigBL ) y= (2225497) 4.1) = 5.068 %y Ware ( -PsBh) y= (43245816 (1.10) = 5.5748 Mm 10.6428 7 /m X3m 31,9275 TonsARRANGEMENT OF HORIZONTAL BEAMS & THEIR ASSIGNED LOAD 2.92 "Yw? B32 he 3.72 Pas font a2 ht” feet 5.00 “fy? gi ols —ban'n? 5 5.548 Yu 5.816 Jae | SL 2500 mm Wy = 2(2x2.9243.72) Wa = Mp(2x3.7249.92)+ 96(2x3.72+4.32) Ws = ng(2x4.3243.72)+ 9g (2x4.3245) We = 05 2x5+4.32)+ 93 (2x5+5.544) Ws= 04 (2x5.54445)+ 93 (5.544+5.816) 1.27466 Ym 2.2296 2.20853 10.642788 "/m,PROPERTY OF SECTION FROM STEEL HANDBOOK Beam 1 : MC 10x3 4 21.9Ibsift or MC 254 x88.9 x32.65 kg/m 1, = 4,099.88 em 2% =322.825 om* Depth = 254 mm Flange Width = 87.6mm Flange Thickness = 12.7 mm Wed Thickness = 8.255 m 4 Beams 2 to 5 ‘W = 8 (254 x 203) x 33 Ibs/ft (49.11 kg/m) I, = 7080 cm! (170 in’) 574 em’ (36 in*) Depth = 247.1 mm Flange Width = 202.2 mm Flange Thickness = 11.05 mm Web Thickness = 7.37mm BENDING STRESS OF HORIZONTAL BEAM Max. Bending Stress is at Beam No.2 O,= M = 354880 = 618 “Sm = 618 kg/cm’ < Allowable Bending Stress = 1268kg/em” Banding Stress at Beam No. 1 0, = M = 176889 Zz mar 47.86 kg/em™ SHEARING STRESS OF HORIZONTAL BEAMS Beam No.2 Shearing Force = 3,836 kg - Area of Web = 0.737 (24.71 ~ 2x1.105) = 16.58 cm? Shearing Stress = E = 3836 Ay 1688 = 231.36 kg/em? < Allowable Shearing Stress = 760 kg/m?BENDING MOMENT AND SHEARING FORCE, oe We assume main horizontal beams are simply supported by the «in, wheels a Where B: Sealing Width L: Center-to-center distance between wheels Bending Moment M M= = QL-B)= i (2x3.35-3) = 13875 w Max. Moment at Beam 2 My= 138753255733 = 3.5483 T-m =354,830 kg-cm Shearing Force F Fo MB = ws 2 2 =1ow Shearing Force at Beam 2 F = 1.5x2.55733 =3.836 Tons or 3,836 kg 299/59 Shearing Force at Beam 1 F=15x 1.27466 = 1,912 Tons or 1,912 kg.Beam No.1 Shearing Force = 1,912 kg Area of Web = 0.8255(25.4 ~ 2x 1.27) = 18.87 cm? Shearing Stress = F = 1912 = 101.3 kg/cm? A, 1887 DEFLECTION S)= WB )- LB + B) “8B 2 8 Ss 3 _ Sasiso0 , (300)" = sata 1635-7 + gd = 790.7% © Deflection at Beam No.2 = 770.7 x 25523 S)= 770.7 x 7 = 0.2784 cm Allowable Deflection S. S,= 2 = 38 800800 = 0.419 em Deflection at Beam No.1 S)=770.7 x 124 = 0.24 em —SKIN PLATE . Calculation of skin plate stress shall be based on Timosheko’s Formula. Bending moment the rectangular plate which is loaded uniformly, in case of four edges fixed, is as follows; 8 boy P Where: a= Length of short side (em) we 5S ] b= Length of long side (cm) Px t p= Water pressure on center (kg/em” t= Effective thickness of skin plate minus corrosion allowance Coefficient from following table % iO [ti [i2[i3 [i [is [ie [17 [18 [197207 +] +309 | 32.5 | 33.5 | 34.0 | 34.2 | 34.3 | 34.3 | 345 | 343 | 34.3 | 343 [343 | B (309 [35.5 [38.5 | 41.3 | 43.4 | 45.5 | 47.2 | 48.2 | 49.0 | 49.5 | 49.7 | 50.0 Skin plate Assuming Distances of Vertical Stiffer = 500 mm Panel 1-2 p= 0.332 kg/cm? ba 7 7 b= Male y=343 pH 472 Ox hy x 47.2 (50) x 2382 = 506 kee? ony yal 250)? x 9382, = 2 to % 47-250)" ay ~ 696 Ke/em Panel 2-3 p = 0.402 kg/em* M12 y=335 B=385 ox 33.5 (50) x = 599 kgem™ oy 1 2 940 2 bo *38:5(50)° x 50 = 688 kelent Panel 3-4 p = 0.466 kge/em™ b = 500 a 500 y= B=309 0.466 (0.757 Ox =0y = fae (30. 9)(50) X as)? = 640 kg/em? Panel 4-5 bl ia5 1=3375- fp =39.9- a i fig (33-7540) x = 506 kg/cm? ~ tose = yx 0272 = 2 190 39.9 (40)? x 25272 ~ 598 kglem’ Allowabie Bending Stress o = 1268 kg/em?ARRANGEMENT OF WHEELSARRANGEMENT OF HORIZONTAL BEAMS Ba1B aay e854 BeBe wai sy Bo Ld on 4 a . tf Le typem —— Rar GAZ ky, Ret 1902-6 beg ane Boag 7] sie var oT ZALTTIA__., MLL | wane -s2548 ° LE Uff JLLLLLLLLL i 49890 ~utbas Wy ~o2408 WP” 15 2.456 ~aiouae A Be > er eS EMA OC+) = S844 (19) + BSBA GO) + BBOU(I20) ¥ 14 1B (ZOO) - BETS SO) E Re OP Re = 1002-218 ko EMg OC+) = 58540 50) + SB4uC 190) + SSBC 190) - BESH( 10) - 1412. (40) * Ra(lo) Rar Gaulle Ky Myro Me ~ = 3010 (20)=-44240 A Montini Shear ~ S¥48 Me = ~499404 Bede OC) = - 02908 FAM muns Momend ~ 210428 Mp = ~ oraoy +204.2(50) = -atuag Me = ~ 496-444 (-3254.%(50)) = ~ 210404 My = 21iae + 5t¥8(19) = ~i52a5¢ Mags -15245%4 (1412(20)) = 0SECTION XIX STEEL GATE AND LIFTING MECHANISM SCOPE The contrast works calls for the fabrication, supply, delivery and installation supervision of steel gates, lifting mechanism, embedded parts including all accessories and field painting all in accordance with these specification and the drawings: STANDARDS AND SPECIFICATIONS ‘All materials and equipment to be incorporated in the works shall conform to the latest applicable standards and specifications as specified in the Contract Documents or to approved equivalent applicable standards and specifications established and adopted in the country of manufacture of the materials and equipment. Reference to standard and specifications or to materials shall be considered as followed by the words “or equivalent”. Contractor may propose equivalent standards, specifications and materials which shall conform to that specified. If Contractors propose equivalent standards and specifications or equivalent materials, Contractor shall state the exact nature of the change, and shall submit complete standards and specifications of the materials for the approval of NIA. Such submittal shall ne along with the bid and failure to do so, or purchase of any proposed equivalent materials prior to approval of NIA, will be at the Contractor’s risk. Abbreviations of the tittles of official bodies which issues standards or specifications whenever referred to in these specifications are as follows: ASTM - American Society for Testing Materials AISC = American Institute of Steel Construction AISI - American Iron and Stee! Institute ANSI - American National Standards Institute AISE = Association of Iron and Steel Engineers AWS = American Welding Society ais - Japanese Industrial Standards ssPpc - Steel Structures Painting CouncilAGMA SAE - ASME - MATERIALS A. General ican Gear Manufacturers Association Society of Automotive Engineers American Society of Mechanical Engineers All materials shall be new and shall be the best available for the purpose for which they will be used, considering strength, ductility, durability for the intended service and best engineering practice. Materials to be used for the various components of gates and hoists shall conform to the following specifications: Components Fixed wheel gates, frames, Girders, sill beam, rail Beams, guide frames, seal clamps and other miscellaneous fabricated parts Gate Wheels & Guide Rollers Whee! pins Seal seats and clamp plates for rubber seals Gear Housing Oil Seals Materials Structure Steel Wrought Stee! Corrosion Resistant Steel Corrosion Resistant Steel International Specifications ASTM A36 Specifications for Structural Stee! ASTM A-S04/A-148 specifica- tion for Wrought Carbon Steel ASTM A-276 Specification for Hot-Rolled and cold finished Corrosion resisting steel bars Type 316 ASTM A-2410 Specification for Chromium-Nickel. Stainless Steel Plate, Sheet and Strip Steel Gates and Lifting ‘Mechanism equivalent to those Manufactured by SKF Industries Spring loaded and made of synthetic compound enclosed in a metal retainer, “Synthetic Seal” or equivalentAlemite type 1610-3 or Equivalent Rubber Seal ‘The rubber seal shall be molded from natural or synthetic rubber containing not less than one percent by weight of capper inhibitor or shall have the following physical properties: Property Limit ASTM Test a) Shore A Durometer Hardness 65+ or -5 D-675 b) Minimum Elongation 450percent D-412 ) Ultimate Tensile Strength (min) 14.5 N/sq.mm D-412 4) Water Absorption Less than 10% by weight D-471 (70°C-7 days) ¢) Tensile Strength after accelerated 80 of more percent of D572 rated aging test of 48 hours in strength before aging oxygen at 70°C and 2.1 N/sq.mm. pressure £) Compression Set (Max.) 30 percent D-395 B, Tests of Materials i, All materials, supplies, parts, assemblies used for the work to be done under these Specifications shall be tested according to modem approved methods for the particular type and class of work. Certified copies in triplicate of the tests made and results thereof shall be made available to the Engineer as soon as possible. The data shall be in such a forms as to provide means of assessing compliance with the applicable relevant specifications for the material tested. The Contractor shall state in his tender the place of manufacture, testing, inspection of the various components of the work included in the contract. ii, Where required, at their discretion, the Engineer may nominate an Inspector to the tests or trials on their behalf. Sufficient notice must be given by the Contractor to the Inspector to enable him to reach the site of tests/trials where the pay and expenses of the Inspector shall be included in the quoted price. All authorized representatives of the Engineer shall have free access to the work premises of the contract at all reasonable times and shall be provided by the Contractor full facilities and safety to inspect the process of manufactureii, iv. and the materials used, The Engineer will reject any materials/work that in their opinion does not conform to the specifications and will order the same to be removed and replaced or altered at the expense of the Contractor to conform to the specifications. If materials are not referred to in the applicable Standard Specifications but are required to have certain physical and/or chemical properties, such properties shall be checked by two chemical samples for each 5 tons of materials and fractions thereof in each lot. For lots less than 250 kilograms. Contractor’s warrants will be acceptable in lieu of actual tests provided heat treatment of the fabricated parts using such materials is not required. A lots shall consist of all materials of the same physical size and conditions submitted at one time in which the materials is fom the same melt or heat and on which any subsequent heat treatment has been performed at the same conditions. Not more than two heat treatment to attain the desired physical properties shall be permitted. ‘Notwithstanding the above tests, examination and inspections, the Contractor shall be responsible for the acceptability of the finished work. C. Manufacturing/Fabrication Program i, ii, ‘The fabricator/manufacturer shall prepare and submit to the engineer a manufacturing/fabrication program in Bar Graph Form showing the activities and its sequencing in sufficient details such that the contract works can be properly monitored from commencement to accompletion. The fabricator/manufacturer shall submit said program within thirty (30) calendar days after the date of receipt of Notice of Award from NIA. ‘The fabricator/manufacturer shall show the target dates for commencing and completing the principal activities as required for in the contract works including but not limited to the following: a. procurement of materials and the ». fabrication and manufacture c. painting 4. delivery dates D. Pre-fabrication Inspection Works ‘The fabricator/manufacturer shall be required to submit to the Engineer the mill and/or manufacturer’s certificate for the steel materials, welding electrodes, paints, etc. intended for use in the works. Materials to be used in the fabrication shall be adequately sampled and tested to check its ‘compliance with the specification/standard requirements.iii, No fabrication work and/or use of materials in such work shall commence unless materials for said works are duly inspected, tested, and certified by the Engineer or his authorized representatives as to conformity with the specification/standard requirements. iv, The Engineer shall assign a technical inspector who shall prepare and submit inspection and acceptance report on materials for use in the fabrication works. E. Inspection Works During Actual Fabrication 1, The Engineer should assign knowledgeable and experienced technical inspectors to conduct inspection, 2. The technical inspector shall be entitled at all reasonable time free access to the ‘manufacturer's /fabricator’s plant to conduct inspection during fabrication, to a certain that all the works shall comply in all aspect with the standards and requirements set forth in the contract documents, 3. The technical inspectors shall monitor progress and conduct the fabrication works and prepare and submit progress report on said works at regular intervals, F. Final Inspection Works 1, Sluice and Intake Gates i, The technical inspector shall conduct final inspection based on the approved fabrication drawings and inspections, ii, The gates should be properly marked with the corresponding identification as per approved schedule of dimension such as size of gate, lateral, stationing for proper identification by the end user. 2. Sluice Gate and Intake Gates ‘The technical inspector should sce to it that all component parts should be properly pre- assembled at the fabricator’s/manufacturer’s shop to ascertain the proper fitness of all adjoining parts and should be properly punch mark before disassembling for guidance and reference during field installation 3. The NIA shall issue certificate of pre-delivery inspection and acceptance of complete fabrication works as a basis for the final inspection and acceptance by the field office of deliveries made at the site.WORKMANSHIP A. General All works shall be performed in accordance with the best modem practice of the manufacturer of high grade machinery. All parts shall have accurate machined mounting and being surfaced that they can be assembled without filling, chipping, or remachining. All parts shall conform accurately to the design dimension and shall be free from any defect in workmanship or material that will impair their services. All attaching bolt holes shall be accurately drilled to the layout indicated on the approved drawings. The steel gates shall be completely shop assembled to insure the proper fit and adjustment. B, Welding i) General Whenever welding is specified or permit machine welding shall be used. , the electric arc welding process, manual or Contractor shall provide adequate amount of materials for each type of welding and shall specify the materials on all relevant drawings. Contractor shall also provide detailed drawings showing joints preparation required for each type of welding to be carried out on the site. ii) Preparation The parts to be joined by electric welding shall be cut precisely to the correct size by machine methods suitable for the type of weld to he used and to allow the proper penetration and good fusion of the weld with the base metal. The cut surfaces shall not have visible defects such as scabs, superficial defects caused by shearing or torch cutting operations or any other damaging effect. The surfaces of a 40mm wide strip on each side of the plate adjacent to the edge and the edge to be welded shall be free from rust, oil, grease and other foreign matter. ii) Lamination Any plate in which lamination has been discovered after cutting shall be rejected unless the laminated portion of plate is local and can be cut out and replaced by the welding of a sound plate in the cut out area with the approval of NIA. Repaired surfaces shall be ground smooth to assure neat appearance.iy) Welding Methods and Welder’s Qualifications The welding method that will be employed by the contractor shall be submitted to the engineer for approval. Welds shall be balanced as far as possible to minimize distortion. Welding shall conform to AWS D1.1, Parts Procedures (Welding of Stressed Structural Components) not only with regard to workmanship but also with regard to qualifications of welders. Welders should be certified in the trade and such certification shall be submitted to the Engineer. -y) Electrodes Contractors shall indicate on all detailed drawings the type and size of electrode he proposed for use for shop and/or field welding. In general, welding electrodes for structural steel shall conform to Table 1.17.2 of the AISC ‘Specification for the Design, Fabrication and Erection of Structural Steel for Buildings. Contractor shall provide the net quantity plus ten percent (10%) of each type of electrode required to complete each field welded joint. C. Non-Destructive Testing i) General [All tests shall be conducted with the approval of NIA and the cost of test shall be borne by the Contractor. Radiographic, Ultrasonic, magnetic particles or liguid dye penetrant tests shall be conducted on components as specified below. Where ultrasonic or magnetic particles tests indicate the possibility of a flaw, the suspected part shall be tested by radiography. Alll flaws shall be removed by thermal or mechanical gauging processed and replaced by welding. The replacement weld and contiguous parts of the original weld, if any, shall then be tested radiographically. All radiographs shall become the property of NIA. ‘The acceptability of the parts inspected by magnetic particles and liquid dye penetrate test and the acceptability of use of these methods will be subject to agreement between Contractor and NIA.ii) Welds Radiographic examination shall be applied to the whole length of butt welds in plate furnishing stressed members. Ultrasonic examination shall be applied to all other stressed groove welds. Radiographic and Ultrasonic examination shall be in accordance with AWS D1.1, Section 6. iii) Casting Casting shall be off fine grain quality and the surfaces which do not undergo machining particularly those of steel or iron in contact with water, shall be dressed smooth in the foundry with all joints blended into adjacent surfaces and shall be free from foundry irregularities, such as projections, ridges, hollows, honeycombing, pock marks, below holes and cracks or chip marks, so that they will not require surface smoothing operations prior to painting. All defects shall be fully explored and casting shall b repaired, plugged or welded to the satisfaction of the Engineer. ix) Carbon Steel Plates and Shapes Carbon Steel Plates, shapes, bars, etc. for welded construction shall conform to materials specifications ASTM A-36, Steel shapes shall be in accordance with ASTM specifications, Plates from which webs, flanges and other stressed members are cut shall be ultrasonically tested for laminations according to ASTM A-578 at the place of manufacture, v) Forgings Forgings shall conform to ASTM A-668 Class D and shall be free from defects affecting their strength and durability, including seams, pipes, flaws, cracks, scales, fins, porosity, hard spots, excessive non-metallic inclusion and segregations, ‘The largest fillets compatible with the design shall be incorporated wherever a change in section occurs. ‘Tool marks or teating of the metal by the finishing tools will not be acceptable on the surface of fillets. Such marks if it occurs, shall be removed by grinding or polishing. All finished surfaces of forging shall be smooth and free from tool marks.All forging in excess of 150 mm diameter shall be subjected to examination internally for the detection of flaws and to heat treatment for the relief of residual stresses. D. Fastening i) All screws, bolts, studs and nuts shall be of International Standard (Metric) from the threads. Bolt heads and nuts shall be hexagonal. Hexagonal recesses shall be provided in the head of countersunk head bolts and machine screws. The bolt length shall be such as ensure that at east two full threads are projecting after the nut has been tightened. ii) Nuts and bolts for pressure containing parts shall be of best quality bright steel machined on the shank and bearing faces of head and nut. iii) Where there is risk of corrosion, bolts shall be finished flush with the top of the mut after tightening, except in cases where the connected components are required to be frequently remove for replacement or adjustment when the bolts and nuts shall be of corrosion resisting steel or bronze. All nuts shall be provided with washer, parallel or taper as appropriate. Mechanical locking devices of an approved from shall be provided where there is a possibility of nuts becoming loose due to vibration. Spring type washer will not be permitted where there maybe damaged any protective coating. Special locking compound maybe used as an alternative to mechanical devices subject to NIA approval. E, Structural Works Unless otherwise, specified, design and fabrication of structural parts shall conform to the applicable provision of the AISC “Specifications for the Design, Fabrication and Erection of Structural Steel in Building” of the AISC “Code Standard Practice for Steel Building and Bridges”. F. Machine All tolerances, allowances and gauges for metal shall conform to the ASA Standard B42, Tolerances, Allowances and Gauges for Metal fits, for the class of fits as required, Finished contact or bearing surfaces shall be true and exact to secure full contact. All holes or field assembly with bolt shall be accurately located and drilled for shop assembly. Journal surfaces shall be polished and all surfaces shall be finished with sufficient smoothness and accuracy to insure proper operation when assembled. All drilled holes for bolts shall be accurately located and drilled from template.PROTECTION OD MACHINED SURFACES Machine finished surfaces shall be thoroughly cleaned of foreign matter. Finished surfaces of large parts and other surfaces shall be protected with wooden pads or other suitable means, Unassembled pins and bolts shall be oiled and wrapped with moisture resistant paper or protected by other approved means. EABRICATION a, General All members shall be free from twist, bonds or other deformation, and all surfaces that will be in contact shall be thoroughly cleaned before assembling. All parts shall be cut accurately to the dimer shown on the drawings. All edge shall show sound metal, free from laminations, surface cracks and other injurious defects. Bumping of heating will be allowed. Parts shall be adjusted to fit, and shall be firmly bolted or otherwise held securely together so that surfaces are in closer contact before welding is commenced. Close adherence to the dimensions and tolerance called for in the drawings is required. b, Straightening Rolled materials shall be straight and true before being laid out or worked. Necessary straightening shall be accomplished by methods that will not injure the metal. Sharp kinks or bents will be considered causes for rejection, ¢. Bending “Where bending or forming of plates or shapes is required, the plates or shapes shall be bent to the proper curvature by cold forming. Heating shall not be employed except with specified approved by the Engineer, and special precautions, therefore shall be taken to avoid overheating. Prior to rolling or bending the plates, the edges shall be pressed properly to the correct curvature, as determined by templates to produce continuity from the edges. Corrections of curvature by hammering will not be permitted. 4. Shearing, Chipping and Flame-Cutting Al plates or shapes shall be cut accurately o shape and size, with the edges to be joined by welding formed properly to suit the selected type of welding and to allow throughout penetration of the weld metal. Sheared edges shall be machined to a depth of not less than one-quarter of the thickness of the materials to remove surfaces cracks caused by the shearing operation. Flame-cut edges shall beuniformed and smooth and shall be free from loose scale and slag accumulations before being welded. Whenever possible, flame-cutting shall be guided by mechanical means. No materials shall be cut by electric are. Chipping shall be done neatly and accurately and exposed edges shall be smooth. ¢. Preparation for Field Welding Al necessary chipping, grinding, leveling and other preparation for joints or splice to be made by field welding shall he done in the shop. f. Punching In punch works, holes in materials having a thickness of less than three-quarter of an inch may be punched to full size, Holes in materials having a thickness equal to or greater than three-quarter of an inch shall be drilled to full size. All holes shall be cleaned-cut without torn or ragged edges. g. Drilling, Reaming, Countersinking and Tapping Unless otherwise called for on the drawings and except where reaming or tapping is required or where tight bolts are to be used, full sized drill and/or reamed holes shall be not less than 1.59 millimeter not more than 2.38 millimeter larger than the nominal drilled and/or reamed perpendicular to the face of the member and if necessary, shall be drilled to a template. Countersinking, were required, shall be true and square with the holes. Outside burns shall be removed. Tapped holes shall be drilled to the proper diameter for the tap used and shall be tapped carefully so that the threads will be continuous, smoothly cut and free from imperfection. h, Tolerance Contact faces of gates and guides shall not depart more than 1 millimeter from a plane surface. Bottom contact edges shall not depart more than I millimeter from a plane surface, Bottom contacts edges shall not depart more than 2 millimeters from the designated planes. Fits, tolerance and finish when not specified, shall conform with the best modem shop practices in the manufacture of finished products of similar nature. i, Lubrication Before assemble all bearing surfaces, joumnals, grease and oil grooves shall be carefully cleaned and lubricated with an approved oil or grease. After assembly each lubricating system shall be filled with an approved lubricant.GENERAL DESCRIPTION OF THE INSTALLATION AND OPERATING ARRANGEMENT. A, Sluice Gates Sluice gates as shown on the Drawings are to be installed to desilt the sluiceway. The gates shall be of fixed wheel type. Each gate shall consist of an upstream skin plate supported by vertical and horizontal stiffeners spaced at required intervals which in turn shall be supported by end vertical girders. Wheels are to be mounted on the end vertical girders and provided with necessary bronze bushings. The total horizontal load on the gates shall be transmitted through the wheels on to the wheel track plates fixed on the piers with necessary embedments. Rubber seals on sides and bottom shall not be provided on the upstream side of the gate to render the gate leak proof. B, Intake Gates i) Intake gates shown on the drawing are to be installed to regulate the flow of water through the intake. The gates shall be of sliding type. Fach gate shall consist of a downstream skin plate supported by vertical stiffeners spaced at required intervals and horizontal girders which in tum shall be supported b end vertical girders. The total horizontal load n the gate shall be transmitted to the vertical frame fixed on the piers with necessary embedments. The details of construction are shown in the NIA bid drawings. ii) The gates are to operate at water level corresponding to normal and high flood level condition and the operation is hydraulically unbalanced. )) The gates are to be operated through manually operated pedestal lift with rising stem of adequate capacity STRUCTURAL DESIGN CRITERIA FOR GATES A. General The design shall ensure that: 1) The gate shall be reasonably watertight; ‘be capable of being raised or lowered by the hoist at the speed specified; 3) Since all the gates are for regulation, they shall be held in partially open position within the range of travel to pass the required discharge without undue vibratiB, Wheels and Whee! Tracks 1) The gate wheel shall be suitable to withstand the stressed developed due to the loads they carry; 2) The wheels and wheel tracks shall be machined true and shall operate smoothly without vibration and without undue drift; 3) The hardness of the wheel track shall be 50 points Brinell Hardness Number (BHN) higher than the BIIN o the wheel thread. C. Wheel Bearing 1) The wheel bearing shall be bronze bushing with grooves for lubrication. D. Wheel Pin 1) The wheels shall be mounted on fixed pins and the pin shall be harder than the bushing. Wheel pin shall be of stainless steel and the contact surfaces shall be finished smoothly; 2) The wheel pins shall be of cantilever type with support from the cantilever box of the end vertical girder. The rigidity of the cantilever box should be ensured. E, Seals and Accessories 1) Seals shall be fixed by means of stainless steel seal clamps and galvanized steel bolts to ensure positive water pressure between the seal and the gate and to bear tightly on the seal seat to prevent leakage, Edges of the seal clamp adjacent to seal bulb shall be rounded; 2) Side rubber seats shall be angle shape type — bottom seal maybe of wedge type; 3) The initial interference of side rubber seat seal shall be 3mm pre-compression. The projection of bottom wedge seat shall be 6mm. suitable chamber shall be provided at the bottom of skin plate/clamp plate to accommodate the bottom wedge seal in compressed position. F. Guides and Sill Frames 1) The guide and seal frames shall be composed of steel plates and steel sections to build up as to suit the gate structure. They shall be securely fixed in concrete by means of anchor members to ensure that all hydraulic loads exerted on the gate will be safely carried and transmitted to the concrete works;2) The guide frames shall be true ad shall be sufficient for the lifting height of the gate; 3) The side seal seat shall be stainless stee! with a minimum width of 75mm. The seal seat shall be fixed on the seal seat base by welding. The fixing of the seal seat on its base shall ensure rigidity and water tightness. The seal seat shall be finished smooth and the edges shall be rounded/chamfered to prevent damage to the seal; 4) All the seals seat base including the sillbeam shall be embedded in concrete: 5) Sill beam flange width shall not be less than 100mm and the length shall cover the entire waterway, The seal seat (stainless steel plate) welded to the top flange shall be at least 25mm wider than the top flange width of sill beam. It shall be flushed with surrounding concrete. Each end of sill beam shall have provision for the connection of each side vertical frame to facilitate their location. G. Embedded Parts i) All structural parts of the guides, seal seats, wheel tracks shall be constructed straight and be free from twist and warping. The end of sections of side guides shall be machined so that when assembled, the finished surfaces of adjoining sections shall be flushed and ends shall butt firmly to form watertight joints. The faces of all seal seats shall be in a true common plane and this plane shall be parallel to the plane tangent to wheel-track face. The end of track sections shall also be machined smooth and square so that when tracks are assembled to the track base, the ends of adjoining section shall butt firmly. HOIST A. Hoist for Sluice Gate 1. General a) The Contractor shall provide manually operated rope drum hoist of adequate capacity complete in every respect along with hoist supporting units and all accessories that would be required for the satisfactory operation of the sluice gates. ) Each hoist mechanism shall consist of provision with gear reducers, wire ropes, rope drums, shafting, bearing, sprockets for diesel engine drive and all other mechanical accessories for the satisfactory operation of hoist.©) The hoisting equipment shall be designed to raise, lower and hold the gate in any position between fully opened and fully closed positions. Hoisting equipment shall be enclosed in dust proof housing with suitable lugs and eye bolts for handling. LIFTING MECHANISM INSTALLATION, TESTS AND ADJUS: TS The installation of the lifting mechanism and anchorage shalll be in accordance with the details as shown on the Drawings. The Contractor shall send qualified and experienced Installation Supervisor who will supervise the installation of the lifting mechanism. Lifting mechanism shall be installed completely with gear reductions, couplings, shafting, shafting bearings, drums, wire ropes, anchor bolts and all other materials for complete assembly. Lifting mechanism shall be assembled and accurately placed in correct alignment by the use of shims and wedges between the sole plates or base plates and conerete, Dry packing shall be done after the dry-pack has set. After the lifting mechanism have been completely installed, adjusted and made ready for operation, the Contractor shall conduct test runs for the gates and lifting mechanism. All units shall be tested for normal operating speed to ensure that all necessary clearances and tolerance have been provided and that no binding occurs in any moving part. The cost of performing all the required test shall be bome by the Contractor. Alll tests shall be performed in the presence of the Engineer or his authorized representative. All data shall be certified correct and tted to the Engineer. All defects found during the test as a result of the installation work shall be corrected according to the satisfaction of the Engineer. EMBEDDED PARTS Special attentions shall be given to the method by which embedded parts are aligned during erection and secure against movement during the placing of the second stage concrete, The proposed method which is indicated on the drawings utilize adjusting anchors welded at one end to anchor plates embedded in first stage concrete and fastened by means of two adjusting nuts at the other end to the embedded parts.ANTI-CORROSION MEASURES AND PA A. General i, The steel gate shall be designed to minimize as much as possible the effects of localized corrosion. Drain holes shall be provided in all locations where the entrapment of water can occur. ii, All steel surfaces except stainless steel surfaces shall be coated and/or painted with a protective film specified under Section C below. ii, Crevicesover which the protective film can bridge shall be retouched or repaired prior to coating. iv, Boxes in members shall be provided with access holes or shall be treated internally with an effective coating material. y. All coating or paint materials to be used shall be original sealed container bearing the ‘manufacturer's label revealing complete identification of content and shall be subject to inspection by the Engineer prior to coating and/or painting. The NIA shall have the right to reject any paint material supplied under these specifications which is found to be defective. B. Surface Preparation and Shop Pai ing Upon complete of fabrication and machining works but prior to application of coating materials, the Contractor shall notify the Engineer in writing that the surface preparation for painting is in progress, Coating application shall commence only after the Engineer or his duly authorized representative have inspected the subsequently approved the surface preparation in accordance with these specifications. ‘The Engineering or his designated inspector shall undertake from time to time, inspecting of the painting works while itis in progress. The Engineer reserves the right to reject outright any deviation to ‘material specifications and procedure noted during inspection. spection, the Contractor shall be held responsible for the acceptability of the finished work. All oil, grease, soil and other contaminants shall be removed from steel and cast iron surfaces by the use of clean solvent, emulsion, cleaning compound or other methods which involves cleaning action. Following the solvent, the surfaces shall be cleaned of all defective or damage areas of existing paint and of all loose rust, loose mill scale and other foreign substance in accordance with the requirements for surface preparation as specified hereunder.i) Immersed Steel Except where otherwise specified, all steel surfaces and all parts of structures that have surfaces which are exposed and/or permanently immersed in water, shall be blast cleaned by commercial blast cleaning (SSPC-SP6) then painted with 2 coats of coal tar epoxy paint conforming to U.S. Military Specifications MIL-P23236 (Ships) Type I, Class 2 to produce a total dry film thickness of 400 microns (16 mils.), ii) Steel Exposed to Atmosphere (Lifting Mechanism and Accessories including Enclosure) Except where otherwise specified all steel and cast iron surface of lifting mechanism and accessories including its enclosure which are exposed to atmosphere shall be blast cleaned by commercial blast cleaning (SSPC-SP6) then applied with | coat of Alkyd Red Lead Primer. After proper drying time is attained apply 2 coats of Alkyd Enamel finish to attain a total dry film thickness of 175 microns (7 mils). iii) Embedded Stool Work Where not otherwise specified, all steel surfaces which will be embedded or against which concrete will be placed shall be cleaned by power tool cleaning (SSPC-SP3) then painted with 1 coat of cement latex milk consisting of 10 parts of Portland Cement (by weight), 5 parts of water and 1 part modifier latex emulsion. iv) Repair of Paint Film ‘The contractor shall retouch or repair areas of steel gates which maybe damaged during transit from shop to the site of delivery. All paints shall be applied in conformity with SSPC-PAI shop, Field and Maintenance Painting by skilled personnel fully experienced in this type of work. C. Machine Surfaces All finished surfaces of ferrous metals that will be exposed during shipment or while waiting installation shall be cleaned in accordance with a coating of heavy, gasoline rust preventive compound. D. Stainless Stee! Surfaces No painting is required for finished or unfinished stainless steel parts.PREPARING FOR TRANSPORTATION ii, iii, iv. wi Shipment of fabricated works to the Project Office should be made only upon issuance of pre- delivery inspection and acceptance report to the fabricator/manufacturer by the Engineer. The project Engineer reserves the right to conduct its own final inspection upon arrival at the project site/office before issuance of final acceptance report and any findings made thereat should be noted in the final inspection report for appropriate action by the NIA Central Office. All parts shall be prepared for transportation so that slings for handling maybe attached readily wherever the parts are to be moved. When it is unsafe to attach slings to the boxes/crates, boxes parts shall be packed with sling attached to the part and the sling shall project through the box or crate so that attachment can be made easily. {All exposed finished surfaces shall be adequately protected against abrasion and injury during transportation and all long and slender pieces shall be safety supported and blocked. Rubber seal shall be dismantled after shop assembly and shall be transported separately. They shall be so packed and protected that their size, shape and physical properties are not affected during transportation. The gates shall be prepared for transportation as to involve the mi assembly. yum amount of field A. Packing ii, iii, ‘The bid shall include and provide for securely protecting and packing the equipment so as to avoid the damage during transport. All packing shall allow for easy removal and checking at site. Special precaution shall be taken to prevent rusting of the parts. Gas seals or other methods if proposed to be used shall have the approval of NIA. Each carton or package shall contain a packing memorandum mentioning the name of the Contractor, the number and date of the Contract and the name of the office placing the order. The equipment shall be insured for loss or damage during transit to the field, the cost being bore by the Contractor. Notwithstanding anything stated above, the Contractor shall be entirely responsible for loss, damage or depreciation to the equipment and materials. B. Marking Each part of gates, hoist and embedded parts which need to be transported from the field site as separate piece shall be marked to show the unit of which it is a part and match marked to show its relative position in the unit to facilitate assembly in the field. Unit marks and match marks shall be made with heavy steel stamps and paints. Each piece, sub-assembly or package to be transported separately shall be labeled or tagged with transportation designation consisting of the Specification number and the mark number of such piece or the number of parts grouped in such assemblies or package.ACCEPTANCE OF WORKS After the steel gates have been installed in the field, it will be operated and tested by the Engineer and when so operated and tested it shall meet all the requirements of the specifications. The gates shall be raised and lowered several times for the full length of the travel. The primary requisite for acceptance shall be that each gate operates smooth and shall be watertight. A. Test i) The Contractor shall cary out such tests on the gates and hoist equipment as maybe required by the Engineer. Contractor shall be responsible for all modifications and adjustments required for the works as a result of such tests, ii) The test shall include: 4) operational tests in the dry ») operational tests with fully hydrostatic load ©) leakage test iii) Test maybe repeated, if necessary, until they successfully carried out to the satisfaction of the Engineer. iv) The tests will be carried out at the convenience of the Engineer the cost thereof shall be bore by the Contractor. B. Operational Test in the Dry Operational tests in the dry shall be carried out after completion of erection when all the power supply have been connected and adjusted. The tests shall include at least two complete traverses from the maximum raised position to the full seating position. Manual operation will also be similarly tested. All adjustment, clearances, brakes, motors and controls, ete. shall be checked for proper operation. C. Operational Test under Hydrostatic Head i) These tests shall simulate the actual operating conditions as closely as possible. )) At least one complete traverse will be made on the sluice and intake gates from the full closed position to the normal raised position as follows:a) With the gate initially in the fully closed position raise it to the normal open position until stopped by the limit switch; b) Lower the gate to the fully closed position; ©) Ascertain proper operational against aver-travel; @) Record and report fan speed, motor torque and current while raising and fan speed during, closing; D. Leakage Tests Leakage test shall be carried out with the gate lowered on the sill. Before the observation for leakage, the gate shall be raised and lowered hy about one meter, several times to dislodge any debris that might have lodged on the side seals. The leaking shall then be measured. Excessive leakage shall be rectified until it is reduced to 15 (fifteen) liters/minute/meter length of the seal. MANUAL The fabricator/manufacturer shall prepare and furnish to the Engineer and the contractor's installation staff, the installation procedure, operation and maintenance manuals for all of the works as provide for in the Contractors Documents. METHOD OF MEASUREMENT Measurement for furnishing and installation of gates and stoplog will be made on the number of assemblies of the different classes and sizes acceptably installed and tested, BASIC OF PAYMENT ‘The cost for the supply and delivery of various steel gates will be paid at the contract unit price per assembly or the lump sum price whichever is states in the Bill of Quantities, which shall include all equipment and materials prescribed in this section and directed by the Engineer. The cost for the installation provided under this time will be paid at the contract unit price which shall constitute full compensation for furnishing all labor, materials, tools, equipments, supplies and all incidentals and subsidiary works necessary for the successful completion of the works. Payment for the work provided under this item will be made separately for the supply and delivery and installation of various gates and lifting mechanism as follows:‘A. Supply and Delivery For the supply and delivery of various gates and lifting mechanism, 70 percent (70%) of he respective unit price in the bill of Quantities shall be paid upon delivery to the project site in accordance with this technical specification acceptable to the Engineer. All equipment/materials delivered at the site, shall be kept by the Contractor and will be responsible for any loss or damage of the equipment/materials until they are installed. Any loss or damage to the equipment/materials shall be replaced by the Contractors at his own expense. ‘Twenty Percent (20%) shall be paid upon installation of the equipment and materials and ready for operation. ‘The remaining ten percent (10%) of each unit price shall be paid upon final acceptance by the Engineer of the contract works. B, Installation Ninety percent (90%) of the respective unit price of each installation works which shall include labor, consumable materials, subsidiary works and other incidentals required for the successful completion of the works shall be paid upon complete installation of the respective equipment/materials all in accordance with the drawings and accepted by the Engineer. The remaining ten percent (10%) o! the Engineer of the contract works. allation cost shall be paid upon final acceptance by