25316-000-3PS-SS01-00010, Rev. 000 - Technical Specification for Design and Purchase of Structural...

~., Specification 25316-000-3PS-SS01-0001 0

TECHNICAL SPECIFICATION

FOR

DESIGN AND PURCHASE

OF

STRUCTURAL AND MISCELLANEOUS STEEL

FOR

MECHANICAL EQUIPMENT

Bechtel ConfidentialBechtel Power Corporation, 2006. Contains confidential and/or proprietaryinformation to Bechtel and its affiliated companies which shall not be used, disclosed,or reproduced in any format by any non-Hechtel party without Bechtel's prior writtenpermission. All rights reserved ..

BECHTEL POWER CORPORATIONFREDERICK MARYLANDJ

NO. DATE REVISIONS BY CfiK'D PSQS APPROVAL-" -

0 !lizI lab Issued for Use LJRB> O'-~ v~r ~e

Specification 25316-000-3PS-SS01-0001 0

TABLE OF CONTENTS

1.0 GENERAL

1.1 SCOPE1.2 WORK INCLUDED1.3 RELATED WORK NOT INCLUDED1.4 REFERENCE CODES AND STANDARDS1.5 QUALITY STANDARDS1.6 SUBMITTALS

2.0 PRODUCTS

2.1 GENERAL2.2 STRUCTURAL STEEL SHAPES AND PLATES2.3 STRUCTURAL PIPES2.4 STRUCTURAL TUBING (SQUARE OR RECTANGULAR)2.5 HIGH STRENGTH BOLTS2.6 OTHER BOLTS2.7 NUTS FOR HIGH STRENGTH BOLTS2.8 NUTS FOR OTHER BOLTS2.9 WASHERS2.10 DIRECT TENSION INDICATORS2.11 FLOOR CHECKERED PLATES2.12 FLOOR GRATING AND STAIR TREADS2.13 GRATING FASTENERS2.14 TOE PLATES AND KICK-PLATES2.15 LADDERS2.16 HANDRAILS AND GUARDRAILS2.17 CRANE RAILS2.18 WELD ELECTRODES2.1 9 SHEAR CONNECTORS2.20 OTHER ITEMS2.21 ALTERNATE MATERIALS AND SHAPES

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TABLE OF CONTENTS (CONTINUED)

3.0 EXECUTION

3.1 DESIGN AND ENGINEERING3.2 SHOP DRAWING PREPARATIONS3.3 BOLTED CONNECTIONS3.4 WELDING3.5 SHOP FABRICATION3.6 SHOP COATING3.7 GALVANIZING3.8 SHOP INSPECTIONS AND TESTING3.9 MARKING, HANDLING, AND STORAGE3.10 DEFECTIVE MATERIALS AND WORK

APPENDIX A - DOCUMENT SUBMITTAL REQUIREMENTS

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Specification 25316-000-3PS--SS01-0001 0

TECHNICAL SPECIFICATIONFOR

DESIGN AND PURCHASEOF

STRUCTURAL AND MISCELLANEOUS STEELFOR

MECHANICAL EQUIPMENT

1.0 GENERAL

1.1 SCOPE

1.1.1 The work covered by this specification consists of furnishing all design,engineering, detailing, equipment, materials and labor to perform all operations requiredto furnish, fabricate, assemble, coat, inspect, and deliver structural and miscellaneoussteel for mechanical equipment.

1.1.2 Perform all work in compliance with this specification and the applicable industrycodes and standards, safety requirements, and government regulations.

1.2 WORK INCLUDED

1.2.1 Design, detail, furnish, fabricate, assemble, coat, inspect, and deliver structuralsteel.

1.2.2 Design, detail, furnish, fabricate, assemble, coat, inspect, and delivermiscellaneous steel, including grating, floor checkered plate, stairs and stair framing,toe plates, kickplates, ladders, safety cages, safety devices, personnel gates,guardrails, handrails and posts, edge forms, crane rails, and other miscellaneous items.

1.2.3 Design, detail, and furnish shop welded connections and field bolted connections,including furnishing shop welding materials and field bolting fasteners.

1.2.4 Perform shop welding inspection and non-destruction examinations (NDE) ofshop welds.

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1.2.5 Inspect shop bolted connections.

1.2.6 Provide surface preparations and shop coating after fabrication of structural andmiscellaneous steel.

1.2.7 Furnish all shop galvanizing facilities, tools and materials. Clean and galvanizestructural and miscellaneous steel after fabrication.

1.2.8 Furnish grating fasteners and headed studs.

1.3 RELATED WORK NOT INCLUDED

1.3.1 Unload structural and miscel~aneous steel at the site.

1.3.2 Grout column base plates.

1.3.3 Erect structural steel.

1.3.4 Install miscellaneous steel.

1.3.5 Furnish and install embeds, anchor bolts, siding, and roof decking.

1.3.6 Perform field touchup painting.

1.4 REFERENCE CODES AND STANDARDS

1.4.1 Unless noted otherwise, the editions of the codes and standards referred to in thisspecification are those in effect at the time of contract award.

1.4.2 American Institute of Steel Construction (AISe)Code of Standard Practice for Steel Buildings and Bridges

Specification for Structural Steel Buildings

Specification for Structural Joints Using ASTM A325 or A490 Bolts

Manual of Steel Construction (ASO or LRFD)

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1.4.3 American Society for Testing and Materials (ASTM)

A6 Standard Specification for General Requirements for Rolled Steel Plates,Shapes, Sheet Piling, and Bars for Structural Use

A36 Standard Specification for Structural Steel

A53 Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-CoatedWelded and Seamless

A106 Standard Specification for Seamless Carbon Steel Pipe for High-Temperature Service

A108 Standard Specification for Steel Bars, Carbon, Cold Finished, StandardQuality

A123 Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron andSteel Products

A153 Standard Specification for Zinc Coating (Hot-Dip) on Iron and SteelHardware

A194 Standard Specification for Carbon and Alloy Steel Nuts for Bolts for HighPressure and High Temperature Service

A307 Standard Specification for Carbon Steel Bolts and Studs,Tensile Strength

A325 Standard Specification for Structural Bolts, Steel, Heat Treated I 120/105 ksiMinimum Tensile Strength

A384 Standard Practice for Safeguarding Against Warpage and Distortion DuringHot-Dip Galvanizing of Steel Assemblies

A446 Standard Specification for Sheet Steel, Zinc-Coated (Galvanized) by theHot Dip Process, Structural (Physical Quality)

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A490 Standard Specification for Heat-Treated, Steel Structural Bolts, 150 ksi(1035 MPa) Tensile Strength

A500 Standard Specification for Cold-Formed Welded and Seamless CarbonSteel Structural Tubing in Rounds and Shapes

A501 Standard Specification for Hot-Formed Welded and Seamless CarbonSteel Structural Tubing

A525 Standard Specification for General Requirements for Steel Sheet, ZincCoated (Galvanized) by the Hot-Dip Process

A563 Standard Specification for Carbon and Alloy Steel Nuts

A569 Specification for Steel, Carbon (0.15 Maximum. Percent) Hot-Rolled Sheetand Strip, Commercial Quality

A572 High-Strength Low-Alloy Columbium-Vanadium Steels of Structural Quality

A618 Standard Specification for Hot-Formed, Welded and Seamless HighStrength. Low-Alloy Structural Tubing

A659 Specification for Steel, Carbon (0.16 Minimum to 0.25 Maximum Percent),Hot-Rolled Sheet and Strip, Commercial Quality

A759 Standard Specification for Carbon Steel Crane Rails

A786 Standard Specification for Rolled Steel Floor Plates

A913 Standard Specification for High Strength, Low Alloy Steel Shapes ofStructural Quality Produced by Quenching and Self-Tempering Process

A992 Specification for Steel for Structural Shapes for Use in Building Framing

A1011 Standard Specification for Steel, Sheet and Strip, Hot-Rolled, Carbon,Structural, High-Strength Low-Alloy and High Strength Low-Alloy withimproved Formability

B695 Specification for Coatings of Zinc Mechanically Deposited on Iron and Steel

F436 Specification for Hardened Steel Washers

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F959 Specification for Compressive-Washer-Type Direct Tension Indicators foruse with Structural Fastener

F1852 Specification for "Twist-Off' Type Tension Control StructuralBoltlNutlWasher Assemblies, Steel, Heat Treated, 120/105 ksi MinimumTensile Strength

1.4.4 American Welding Society (AWS)D1.1 Structural Welding Code

1.4.5 Building Code Requirements

International Building Code 2003

Applicable local bUilding codes and as required by the Contract Documents.

1.4.6 Occupational Safety and Health Administration (OSHA)Health and Safety Regulations for Construction, 29CFR, Parts 1910 & 1926

1.5 QUALITY STANDARDS

1.5.1 Seller and Sub-vendors, as applicable, shall have a Quality Management Systemthat controls the manufacturing, fabrication, testing, and inspection of their products.

1.5.2 Buyer reserves the right to evaluate the Seller and Sub-vendor QualityManagement System Documentation and to decide if the systems meet therequirements of this project. Buyer or its representatives also reserve the right to carryout appraisals and Quality Audits of the Seller and Sub-vendor Quality ManagementSystems, at any time during the period of the contract, to verify compliance with andmaintenance of the quality system and contract requirements.

1.5.3 The design, materials, products and workmanship covered in this specificationare subject to quality surveillance by Buyer or its representative. However, such qualitysurveillance shall not relieve Seller of the responsibilities to furnish design, materials,products and workmanship in accordance with the Contract Documents.

1.5.4 Seller shall identify and document any deviations from the requirements of thisSpecification. A deviation request must be reviewed and dispositioned by the Buyer

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prior to performing the related activity. Use the Supplier Deviation Disposition Request(SDDR) Form, for a deviation request.

1.6 SUBMITTALS

1.6.1 Conform to Appendix A, Document Submittal Requirements, and thisspecification.

1.6.2 Submit an electronic list ("Excel" file template, provided by the Buyer/Contractor)of all planned submittals identified by the Document codes of Appendix A. EachDocument code on this form must have an associated Seller/Subcontractor submittal.The Seller/Subcontractor shall identify applicable pre-approved/Code 1 documents bytyping the corresponding Buyer/Contractor document number in the Object Name. TheSeller/Subcontractor is responsible for verifying that preapproved/Code 1 documentsare current and valid.

1.6.3 Electronic Submittal Data - Steel. Provide the following steel componentinformation after the Seller's design and prior to fabrication:

Job Number Piecemark Tag Sequence Priority Size/Profile Quantity Quantity UOM Description Purchase Order Number Vendor Manufacturer Fireproofing Type Shop Detail Drawing Pay item Pay Code Unit of Measurement Pay Code Quantity TOS Elevation Notes

1.6.4 Provide detailed requirements for handling and short and long term storage for all

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materials to be shipped to the Jobsite. Identify jobsite storage criteria based on thefollowing:

Storage Category 1 - Outside StorageStorage Category 2 - Outside Storage, CoveredStorage Category 3 - Outside Storage, Covered with heatStorage Category 4 - Inside StorageStorage Category 5 - Inside Storage, Climate Controlled

1.6.5 Provide an electronic list (Excel file) for all materials being shipped to the jobsiteshowing in complete detail split shipment packaging contents and their shipping dates.As a minimum, the spreadsheet shall indicate:

Supplier's name Part numbers Buyer's equipment or skid numbers Seller's reference drawing number Forecast ship date Actual ship date for each carton or container Erection IIFC Drawing number Quantity Unit of measure

2.0 PRODUCTS

2.1 GENERAL

2.1.1 Use new materials conforming to specifications indicated. Do not use substitutematerials unless written permission is obtained from Buyer prior to fabrication.

2.1.2 Obtain and maintain certified mill test reports for structural steel and high strengthbolts. Make reports available, on request, for review by Buyer at locations where thework is performed.

2.1.3 Submit certified Certificate of Compliance on all structural and miscellaneoussteel materials and products in accordance with Appendix A, Document SubmittalRequirements.

2.2 STRUCTURAL STEEL SHAPES AND PLATES

2.2.1 Conform to ASTM A36; ASTM A572, Grade 50; ASTM A913, Grade 65; or ASTMA992.

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2.2.2 Conform to standard shape profiles in ASTM A6.

2.3 STRUCTURAL PIPES

2.3.1 Conform to ASTM A53, Type E or S, Grade B.

2.4 STRUCTURAL TUBING (SQUARE OR RECTANGULAR)2.4.1 Conform to ASTM A500, Grade B or C, or A501 for square and rectangulartUbing.

2.5 HIGH STRENGTH BOLTS

2.5.1 Conform to ASTM A325 or A490, Type 1.

2.5.2 Provide 7/8 in. diameter (typically) and 1-1/4 in. diameter (where required byheavy loads) high strength bolts conforming to ASTM A325, unless otherwise approvedin writing by Buyer prior to fabrication.

2.5.3 Limit the use of A490 bolts to a single (1-1/4 in.) diameter.2.5.4 Conform to ASTM F1852 for tension control bolts/nut/washer assemblies.

2.6 OTHER BOLTS

2.6.1 Conform to ASTM A307, Grade A.

2.6.2 Provide 5/8 in. diameter bolts for stair tread to stringer connections, purlins,under~carriage stair bracing, ladder standoffs, and other miscellaneous steel framing.

2.7 NUTS FOR HIGH STRENGTH BOLTS

2.7.1 Conform to ASTM A563, Grade DH, heavy hex or ASTM A194, Grade 2H, heavyhex.

2.8 NUTS FOR OTHER BOLTS

2.8.1 Conform to ASTM A563, Grade A, heavy hex.

2.9 WASHERS

2.9.1 Conform to ASTM F436.

2.9.2 Provide thickened washers at locations reqUired per AISC standards.

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2.10 DIRECT TENSION INDICATORS

2.10.1 Conform to ASTM F9S9, Type 325 or 490, as appropriate for the bolts beingfurnished.

2.11 FLOOR CHECKERED PLATES

2.11.1 Conform to ASTM A36 or Buyer-approved alternate.

2.11.2 Provide floor checkered plates with a nominal thickness of 5/16 in (not includingthe depth of the standard two-way pattern), and with a pattern designation inaccordance with ASTM A786, Figure 3.

2.11.3 Conform to the rolling and production tolerances defined in ASTM A786.

2.12 FLOOR GRATING AND STAIR TREADS

2.12.1 Conform to ASTM A569 or A659.

2.12.2 Provide plain welded steel floor grating for indoor use. Outdoor grating shall beserrated.

2.12.3 Submit Manufacturer catalog for floor grating and stair treads, in accordancewith Appendix A. Document Submittal Requirements.

2.13 GRATING FASTENERS

2.13.1 The pre-approved grating fasteners are listed below:

a. "Grating Attachment System" by ITW RamsetiRed Head

b. "G-Clip Fasteners" by Grating Fasteners, Inc.

c. "Saddle Clips," secured to the supporting steel by powder tool-fastened studs orby Teks self-drilling and tapping studs

2.13.2 Other grating fasteners may be used, subject to Buyer prior written approval.2.13.3 Furnish sufficient grating fasteners to allow two fasteners per panel at eachsupport with a minimum of four fasteners per panel.

2.13.4 Submit Manufacturer catalog on grating fasteners in accordance with AppendixA, Document Submittal Requirements.


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2.14 TOE PLATES AND KICKPLATES

2.14.1 Cohform to ASTM A36 or A569, or Buyer-approved equal.

2.15 LADDERS

2.15.1 Conform to ASTM A36 or Buyer-approved equal.

2.16 HANDRAILS AND GUARDRAILS

2.16.1 Conform to ASTM A53 or A106 for pipe material

2.16.2 Provide pipe handrail posts of weldable, mild carbon steel with a minimum yieldstrength of 50 ksi.

2.16.3 Conform to ASTM A36 for angle handrail and guardrail rails.

2.17 CRANE RAILS

2.17.1 Conform to ASTM A759 or Buyer-approved equal.

2.17.2 Rail clips shall be Gantrex 3120/15 or Buyer-approved equal.

2.18 WELD ELECTRODES

2.18.1 Conform to E70 Series as listed in AWS 01.1.

2.19 SHEAR CONNECTORS

2.19.1 Provide Nelson studs, Type S3 (with ferrules) or Buyer-approved equal of ASTMA108, Grade 1010, 1015, or 1020, and either semi- or fully-killed material.

2.20 OTHER ITEMS

2.20.1 Submit compatibility documentation if welding two or more different materials, inaccordance with AWS 01.1, Structural Welding Code, and in accordance with AppendixA, Document Submittal Requirements.

2.20.2 For items not listed above, submit descriptive materials to Buyer prior tofabrication in accordance with Subsection 1.6.3.

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2.21 ALTERNATE MATERIALS AND SHAPES

2.21.1 Structural and miscellaneous steel conforming to other than AISC standards andASTM specifications may be substituted for AISC shape profiles and ASTM materials,subject to prior Buyer written approval and the following conditions:

The substitute material is the closest available in terms of material compositionand yield strength to the ASTM specification, and the sectional properties of thesubstitute shape equal to or exceed the corresponding AISC shape profile.

For material/shape substitutions, submit a Supplier Deviation DispositionRequest (SDDR) with a comparative listing of all substitute shape properties andcorresponding AISC shape properties, and the substitute material properties andthe corresponding ASTM material properties.

3.0 EXECUTION

3.1 DESIGN AND ENGINEERING

3.1.1 Design and detail all structural and miscellaneous steel in accordance with theInternational Building Code 2003, applicable local building codes, AISC Code ofStandard Practices, Specification for Design, Fabrication and Erection of StructuralSteel for Buildings, the AISC Manual of Steel Construction, and requirements of theContract Documents and this Specification.

3.1.2 Perform all design and detailing of structural and miscellaneous steel under thedirect supervision of a Professional Engineer registered in the U.S. All designcalculations and engineering draWings shall be checked, and shall be sealed by aProfessional Engineer registered in the State where the plant facility is located.

3.1.3 Participate and assist, if requested by Buyer, in the review and approval processof Seller engineering documents by the Building Code Officials where required.

3.1.4 Submit design calculations and engineering drawings in accordance withAppendix A, Document Submittal Requirements.

3.2 SHOP DRAWING PREPARATIONS

3.2.1 Prepare under the direct supervision of a Professional Engineer registered in theU. S., shop drawings (including connection design calculations) and erection drawingsfor structural and miscellaneous steel in accordance with the AISC Code of Standard


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Practice, Specification for Design, Fabrication and Erection of Structural Steel forBuildings, and this specification.

3.2.2 Submit shop drawings and erection drawings in accordance with therequirements of Appendix A, Document Submittal Requirements

3.2.3 Use standard commercially available software for connection design, shopdrawings and erection drawings.

3.2.4 Seal by a Professional Engineer registered in the State where the plant facility islocated, all connection design calculations, shop drawings and erection drawings.

3.2.5 Indicate the quantities, locations, top of steel elevations, spacing, sizes, profiles,connections, attachments, fasteners, and piece marks of members on shop drawings.

3.2.6 Provide a bill of material showing member piece marks, shape designations,number of pieces required, length, unit weight, total weight of each member, and totalweight of steel shown on each drawing.

3.2.7 Use bolted field connections. When welded field connections are unavoidable,the locations and selections shall be specifically approved by the Buyer prior tofabrication.

3.2.8 Simple beam shear connections may be shop-bolted or welded at the fabricator'soption. Weld other shop connections, unless prior Buyer written approval is obtained.

3.2.9 Show the piece marks, locations, and details of field connections of members onerection drawings. Include a point-to-point bolt list for all field connections. All point-to-point lists, inclUding those generated by sub-detailers, shall be uniform and shall beindependently checked by the Seller's Steel Supplier Engineer.

3.2.10 Indicate clearly, on the erection drawings, all A325 and A490 field bolts that needonly be "snug tightened".

3.2.11 Indicate clearly on each erection drawing all A325 and A490 field bolts requiredto be fully tensioned.

3.2.12 All tension-controlled bolts, where used, shall be fully tensioned.

3.2.13 Proportion column splices for the design loads in accordance with the AISCSpecification for Design, Fabrication and Erection of Structural Steel for BUildings.

3.2.14 Indicate welded connections using standard AWS welding symbols.

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3.2.15 Submit an index of shop drawings and erection drawings including drawingnumbers, titles, and revisions in accordance with Appendix A, Document SubmittalRequirements. Titles of these drawings shall correspond to the Seller's structural andmiscellaneous steel design drawings.

3.2.16 Provide an erection lifting hole at the tops of all columns and holes above floorlevels for safety lines.

3.2.17 Provide lifting holes in all floor checkered plates. Provide lifting handles on allremovable floor checkered plates.

3.2.18 Cut and suitably band with toe plates in shop all openings and cutouts throughfloor checkered plates.

3.2.19 Shop band grating with toe plates at all opening and cutouts. Shop band gratingat the ends of bearing bars at ladders and stair landings.

3.3 BOLTED CONNECTIONS

3.3.1 Unless otherwise required to resist wind loads, seismic loads or dynamic loads,provide field bolted, bearing-type connections with threads included in the shear planethat conform to 7/8 inch ASTM A325 high strength bolts.

3.3.2 Unless the steel is hot-dipped galvanized, provide field bolted, slip criticalconnections with oversized holes for all bracing connections using 7/8 inch, ASTM A325high strength bolts. If the steel is hot-dipped galvanized, provide bearing typeconnections for all bracing as described in Paragraph 3.3.1.

3.3.3 Fully tension all shop-installed bolts in accordance with AISC requirements.

3.3.4 For projects located in the United States, provide 2 percent more than thenumbers indicated as required on the shop drawings for each size and grade of loosenuts, bolts, and washers for field erection.

3.3.5 For projects located outside the United States, provide 5 percent more than thenumbers indicated as required on the shop drawings for each size and grade of loosenuts, bolts, and washers for field erection.

3.3.6 Unless otherwise indicated in the Contract Documents and this Specification,prOVide mechanically galvanized bolts, nuts, and washers in accordance with applicableASTM standards. Washer thickness and number of washers shall be in accordancewith the AISC Specification for Structural Steel Buildings.

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3.3.6 Do not galvanize ASTM A490 high strength bolts by any method.

3.4 WELDING

3.4.1 Provide shop-welded connections conforming to the AISC Specification forDesign, Fabrication and Erection of Structural Steel for Buildings.

3.4.2 Qualify all welders and welding operators for structural and miscellaneous steelin accordance with AWS requirements. Qualification records for welders and weldingoperators shall be available for Buyer review, when, requested, at the locations wherethe work is performed.

3.4.3 Submit all welding procedures, welder and operator qualification procedures,weld inspection procedures, non-destructive examination (NDE) procedures, and weldmaterial control procedures in accordance with Appendix A, Document SubmittalRequirements.

3.4.4 Perform all welding in accordance with Buyer-approved procedures.

3.4.5 Perform all welding inspection and NDE examinations in accordance with Buyerapproved procedures.

3.4.6 Maintain, for Buyer review, all welding inspection and NDE records at locationswhere work is performed

3.5 SHOP FABRICATION

3.5.1 Fabricate structural and miscellaneous steel in accordance with the AISC Code ofStandard Practice and this specification. ;, '

3.5.2 Substitute sections or modify details only with Buyer written approval of aSupplier Deviation Disposition Request (SDDR) prior to fabrication, after shop drawingsand erection drawings have been reviewed by Buyer.

3.5.3 Prepare column bases, base plates, and splices in accordance with the AISCSpecification for Design, Fabrication and Erection of Structural Steel for Buildings.

3.5.4 Shop assemble platforms, stairways, and handrails in the largest units suitable forshipping and handling. Ladder cages shall be shop-assembled on ladders.

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3.6 SHOP COATING

3.6.1 Shop coat structural and miscellaneous steel in accordance with the provisions ofthe Contract Documents and the requirements of this Specification.

3.6.2 Perform blast cleaning on steel for shop coating only after fabrication iscompleted and just prior to coating application.3.6.3 Protect nonferrous metal, galvanized steel, and surfaces within 2 inches of fieldwelds during surface preparations and coating operations.

3.6.4 Inspect and test each phase of shop coating. Correct defects in accordance withthe coating manufacturer's written instructions and re-inspect prior to proceeding withthe next phase.

3.6.5 Submit all shop priming, painting and touchup procedures include cleaning,application, curing, repairs, and inspection in accordance with Appendix A, DocumentSubmittal Requirements. Also include the proposed inspection record to be used fordocumenting inspections.

3.6.6 Submit coating manufacturers' product data sheets and material applicationinstructions for the coating materials in accordance with the referenced shop coatingspecification and in accordance with Appendix A, Document Submittal Requirements.

3.7 GALVANIZING

3.7.1 Galvanize structural and miscellaneous steel in accordance with the provisions ofthe Contract Documents and the requirements of this Specification.

3.7.2 Hot-dip galvanize all floor grating, floor checkered plates, handrails, guardrails,toe plates, kick-plates, and stair treads, etc. in accordance with ASTM A-123. All bolts,nuts, washers shall be mechanically galvanized, Class 55 minimum.

3.7.3 Mechanically galvanize all bolts (except ASTM A490 bolts), nuts and washers.All threads on bolts and nuts shall be mechanically chased after galvanizing to ensureproper fit. Each bolt, nut and washer shall be assembled and delivered as a unit.

3.7.4 Do not galvanize, by any method, bolts that conform to ASTM A490.

3.7.5 Provide bolts and nuts from the same manufacturer. Submit manufacturer'scertification of the compatibility of the bolting components after galvanizing, regardlessof the galvanizing method specified, in accordance with Appendix A, DocumentSubmittal Requirements.

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3.7.6 Complete all shop welding and inspection of individual pieces prior to galvanizing.

3.7.7 Safeguard against warpage and distortion of assemblies to be hot-dippedgalvanized in accordance with ASTM A384 requirements.

3.7.8 Submit galvanizing procedures in conformance with the applicable standardsdelineated in this specification in accordance with Appendix A, Document SubmittalRequirements. Include cleaning, handling, galvanizing, and inspection procedures; andthe proposed inspection record to be used to document inspections.

3.8 SHOP INSPECTIONS AND TESTING

3.8.1 Provide certified inspectors to inspect material and workmanship in the fabricatingshop.

3.8.2 Submit an Inspection Plan for the work in accordance with Appendix A, DocumentSubmittal Requirements.

3.8.3 Use the acceptance criteria specified in Subsection 6.9 of AWS D1.1 for visualexamination of welding for joints.3.8.4 Perform nondestructive examination (NDE) of welds in accordance with AWSD1.1, Section 6.

3.8.5 Provide access and assist Buyer in performing shop inspections and testing asnecessary to ensure compliance with this specification. Correct or replace any non-conformance items.

3.9 MARKING, HANDLING, AND STORAGE

3.9.1 Establish procedures and maintain controls for material handling and storageduring fabrication and preparation for shipment, to prevent damage and deterioration.

3.9.2 Mark all pieces with metal tags and bar codes indicating the piece and erectiondrawing number, bUilding, area, elevation, and any other information required foridentification. Provide marks visible when material is stacked and legible for a minimumof 1 year of exterior exposure. Tie or die stamp galvanized items.

3.9.3 In preparation for shipment, indiVidually assemble each bolt set, including thebolt, nut, and hardened washer (if required) so that the entire assembly can be shippedas an individual unit. Ship bolt assemblies in boxes or kegs and protect from moistureand oxidation. Clearly mark each container to identify the contents.

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3.9.4 Handle steel in a manner that avoids damage. Use nylon slings during handlingof galvanized steel.

3.10 DEFECTIVE MATERIALS AND WORK

3.10.1 When it is impractical to return defective materials or work to the shop, or whenthe construction schedule does not permit it, Buyer will make arrangements for therepairs in the field and shall be compensated by Seller for the costs incurred.

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DOCUMENT SUBMITTAL REQUIREMENTS APPENDIX

8 SPECIFICATION TITLE SPECIFICATION NO. ADESIGN AND PURCHASE OF STRUCTURAL AND 25316-DOO-3PS-SS01-0D010 REVISION: 0

MISCELLANEOUS STEEL FOR MECHANICAL EQUIPMENT

-.c N'

6 = - n;_ w Xl;:;-... ::l =... ~-- .. 'E.! I- lfw 011-.... z 0III 0 ;~ EI- OZ"tI .. ,Q 0 Zo U ::lZ 1110 .5~u I!! E_ CI) II) II) OZ

Data/Submittal Requirements ::l III II) Remarks~c u CIJ ... II) e "tI II) "tin;o 0 .e~ II) II) III ::lIII 0 II) "'CI) .!:: cE U Q Co c- :; III __ ::l III... 0 ~ii! "tI_::l- .- ... "tI :;2 i::Eu ... eo.o III lila: III zE- D:Q ~ ,Q &!-- .c::l u ...m U) CI)1.01 In accordance with PO Section 3, submit an electronic list "If resubmittal of a

("Excel" file template, provided by the Buyer/Contractor) of all document is notplanned submittals Identified by the Document Codes on this required afterform, Each document Code on this form must have an proposal, all columnsassociated Seller/Subcontractor submittal. after Submit

"Y I 14 N N Document WithThe SelierlSubcontractor shall identify applicable pre- Proposal" should beapproved/Code 1 documents by typing the corresponding left blankBuyer/Contractor document number (99999-) in the ObjectName. The Seller/Subcontractor is responsible for verifying thatpre-approved/Code 1 documents are current and valid,

See separate paae 4 of 4 for project requirementsThe SELLER/SUBCONTRACTOR shall provide electronic copies as specified in the Purchase Order, excluding InstructionManuals. which shall be as specified In the Remarks column.NOTE 1 P = Issued for Permission to Proceed - Buyer/Contractor pemnission to proceed is required prior to use of documents in the

design, fabrication, installation, or other work process.

R = Issued for Review - Buyer/Contractor review of this document does not constitute acceptance or approval of design details,calculations, analyses, test methods, or material developed or selected by the Seller/Subcontractor and does not relieve theSeller/Subcontractor from full compliance with contractual obligations.

1= Issued for Information - Document is not subject to Buyer/Contractor review, unless the submittal conflicts with contractualobligations. If Buyer/Contractor review of Issued for Information submittals reveals any noncompliance with the contractualrequirements, the Buyer/Contractor will notify the Seller/Subcontractor of such noncompliance and the Seller/Subcontractorshall take all actions necessary to ensure full compliance with the contract documents.

NOTE 2 Calendar Days After Contract Awardor

F - Before Fabrication 1- Before Installation W - With Shipment S - Before Shipment P - Before Final Payment D - BeforeDesign T - Testing

Design Basis Submittal of documentation shall be in complete compliance with the contractual requirements and in accordancewith the schedule above. Documentation requiring review must show all information necessary for the Buyers/Contractor'sdesign of foundations and any other Buyer/Contractor interface. Documentation will be reviewed only with regard toarrangement and confomnance with the specifications and related documents. [Documents must show job title, job number.purchase order number, Document Submittal Requirements document code, line. equipment, tag or code number, and themanufacturer's serial number(s)).. A Buyer/Contractor-approved Design Basis Submittal that Is subsequently resubmitted by theSeller/Subcontractor and thus affects or changes the Buyer'slContractor's design shall be subject to the Backcharges Clause inthe Purchase Order / Subcontract.

If the Seller'sISubcontractor's information Is modified from the Design Basis Submittal prior to shipment / turnover, a finalsubmittal must be made reflecting any additional changes.,

NOTE 3 Liquidated Damages (YIN) to be assigned .. Assessed values per item are defined in the Purchase Order / Subcontract. Thisrequirement will not be satisfied until the Seller's/Subcontractor's documentation provides all information required by theBuyer/Contractor..

NOTE 4 CADO files shall be provided for all physical graphical data, These files shall be prOVided translated to the Microstation OGNformat. If translation of CADD files to Microstation is not commercially available, the graphical data file shall be provided inSupplier's native format This Supplier requirement is applicable to both 2D and 3D graphic files ..

Bechtel Confidential Bechtel Corporation 2006, All Rights ReservedDSR Instruction

Sheet 1 of 4


"SPECIFICATION TITLE SPECIFICATION NO. A

DESIGN AND PURCHASE OF STRUCTURAL AND 25316-0DO-3PS-SS01-DOO10 REVISION: 0MISCELLANEOUS STEEL FOR MECHANICAL EQUIPMENT

I J ,

".--

000 'V7t./Cfp Issued for Use (-"~j,,.) I~ ( 1l.6 -t"Jfi.REV. DATE REASON FOR REVISION ORIGINATOR CHECKER APPROVALS

Bechtel Confidential Bechtel Corporation 2006. All Rights Reserved.DSR Instruction

Sheet 2 of 4


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SPECIFICATION TITLE SPECIFICATION NO. A

DESIGN AND PURCHASE OF STRUCTURAL AND253160003PSSS0100010 REVISION: 0MISCELLANEOUS STEEL FOR MECHANICAL. EQUIPMENT

A. MAILING INSTRUCTIONS

The schedule of document submittal requIrements Is to be fulfilled before rendering final invoices. Failure by theSeller/Subcontractor to comply with the document submittal requirements may result in final payment being withheld.Correspondence shall be forwarded as follows:

Bechtel Corporation5275 Westview DriveFrederick, Maryland 21703-8306Attn: Prairie State Energy Campus

PROJECT ADMINISTRATOR

B. DEFINITION OF SELLER/SUBCONTRACTOR DOCUMENT REVIEW STATUS ASSIGNED BY THE BUYER/CONTRACTOR

The guidelines listed below are followed in assigning the document status code to the Seller/Subcontractor documents" Finalsubmittal of Seller/Subcontractor documents will not be required as long as the document status code Is 1C, or 4 and the "ASBUILT' condition of the component agrees with the current document.Status 1, 2, or 4 does not constitute acceptance or approval of design details, calculations, analyses. test methods, or materialsdeveloped or selected by the Seller/Subcontractor and does not relieve the Seller/Subcontractor from full compliance withcontractual obligations"

Status 1: Work may proceed.The document conforms to procurement document requirements" The document requires no changes or additions" MattersremainIng to be resolved do not require document change and will be handled by correspondence. Where it is known that thedesign information on a Seller/Subcontractor document is not complete and re-submittals will be required, e.g., due to "hold"areas, the document is assigned another status code.

Status 1C: Work may proceed.Content is as described for status 1" Editorial comments need only be Incorporated if document is revised for other purposes"

Status 2: Revise and resubmit. Work may proceed subject to resolution of indicated comments.The document is in basic conformance with procurement document requirements. Minor deviations from procurement documentrequirements have been noted or other minor technical or physical changes in the equipment are reqUired. Such changes mayinclude those affecting dimensions, material, colors, etc" Administrative type changes, such as inclusion of eqUipment or tagnumbers and shipping notes, may be combined with technical changes in this status. The Seller/Subcontractor shall resolvecomments and resubmit documents prior to shipment/ turnover of commodity"

Status 3: Rejected. Revise and resubmit.The document: (One or more of the following) Does not conform to the procurement requirements, Is of a design that Is technically unacceptable without significant changes, Does not meet project requirements. Le." orientation of eqUipment, nozzles, conduit connections, etc., Does not conform to project criteria or with proposal documents or data, or Does not meet minimum submittal requirements.

'This submittal rejection does not relieve Seller/Subcontractor of any schedule commitments

Status 4: Review not required"The document is not subject to Buyer/Contractor review, Typical uses for this status are in the review of items that areSeller/Subcontractor standard products, small internal parts of major equipment, or Seiler/Subcontractor-standardized dats

Bechtel Confidential Bechtel Corporation 2006. All Rights ReservedDSR Mailing and Status

Sheet 3 of 4


". SPECIFICATION TITLE SPECIFICATION NO A

DESIGN AND PURCHASE OF STRUCTURAL AND 25316-000-3PSSS010001D REVISION: 0MISCELLANEOUS STEEL FOR MECHANICAL EQUIPMENT

.. 'i" iii_ N z;;o l/) ~- UJ- = =.... :iii- ... 'E S I- ClUJIII 0 -z 0 I'll I- o!l-'CI'U ;~ .CI 0 Z EO OZo I'll E_ =z Gl 8z .5~o .. o Gl Gl-c Data/Submittal Requirements = I'll 'CIiii Remarks(.l l/) .. Gl e 'CI GlI: 0 o 0 ~!!. III Gl I!! =III 0 C c- Gl -0 ._ I:E_ _ 0 1:- '5 I'll ..... = I'll0- 'CI_=.. .- .. l/)~ 'CI 'S z i:iii(.l Gl Ea., I'll a., III .!r~ ~o >. .CI &- .c:c = = (.l ..JaI 0 0

1.01.01 Electronic List of Submittals, Subsection 1.6.2 Y I 14 N N1,02.13 Electronic Submittal Data - Steel, Subsection 1,6,,3 N I F N N To be updated

monthly1,03,01 Electronic Jobsite Storage and Storage Maintenance Information, N I F N N

Subsection 1.6.41.06.01 Spreadsheet Bill of Materials, Subsection 1.6.5 N I S N N

3.04 Detailed Shop Drawings and Erection Drawings with Index,Subsections 3.2.2 and 3.2.15 N R F N N

3.14 Engineering Drawings, Subsection 3.1..4N p F N N

4,,01 Welding and Weld Repair Procedure & Welder QualificationRecords, Subsections 2.20.1 and 3.4.3 N R F N N

4.04 Coating/Painting/Galvanizing Procedures (including FrictionCoefficient Report), Subsections 3.6.5 and 3.7.8 N I F N N

4.06 Certificate of Compatibility, Subsection 3.7.5 N I S N N4.07 Certificate of Compliance, Subsection 2.1.3 N I S N N4.1.3 Inspection Plan, Subsection 3.8.2 N R F N N

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5.02 Calculations and Design Analyses Subsection 3.1.4 N P F N N6,03.01 Manufacturer Catalog - Floor Grating and Stair Treads, Subsection

2.12.3 N I F N N6.03.02 Manufacturer Catalog - Grating Fasteners, Subsection 2.13.4 N I F N N6.03.03 Manufacturer Product Data Sheets and Material Application

Instructions ,- Subsection 3.6.6 N I F N N.-

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Bechtel Confidential Bechtel Corporation 2006. All Rights Reserved,DSR Body

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Appendix A - DSR

25316-000-3PS-SS01-00010, Rev. 000 - Technical Specification for Design and Purchase of Structural...

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