SECTION 15106

ROLLER GATES AND APPURTENANCES

(NTS: Metric dimensions are shown in brackets, delete if project does not require
metric dimensioning. This specification is for roller gate type stop logs.)
PART 1 - GENERAL

1.01 DESCRIPTION:
(NTS: Edit to suit project requirements.)

A. Provide and test roller gates and appurtenances as indicated and specified.

1.02 RELATED WORK:

(NTS: Edit the following to suit project requirements.)

A. Section 03300: Cast-In-Place Concrete

B. Section 14300: Hoisting Equipment

1.03 REFERENCES:

A. American Society for Testing and Materials (ASTM) Publications:

1. A36: Specification for Structural Steel.

2. A276: Specification for Stainless and Heat-Resisting Steel Bars and Shapes.

3. D2000: Classification System for Rubber Products in Automotive

Applications.

B. Society for Protective Coatings (SSPC):

1. SP-10: Surface Preparation Specifications, No. 10 Near White Blast

Cleaning.

C. American Welding Society (AWS) “Structural Welding Code” D1.1, With

Amendments to Date.

1.04 SUBMITTALS:

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 A. Submit the following in accordance with Section 01300 - Submittals:

1. Certified shop and erection drawings.

2. Shop drawing data for accessory items.

3. Templates or certified setting plans, with tolerances, for anchor bolts.

4. Manufacturer's literature as needed to supplement certified data.

5. Operating and maintenance instructions and parts lists.

6. Listing of reference installations as specified with contact names and

telephone numbers.

7. Qualifications of field service engineer.

8. Shop and Field inspections reports.

9. List of recommended spare parts other than those specified.

10. Recommendations for short and long term storage.

11. Special tools.

12. Shop and field testing procedures and equipment to be used.

13. Number of service man days provided and per diem field service rate.

14. Manufacturer's product data and specifications for shop painting.

15. Provide a listing of the materials recommended for each service specified and
indicated. Provide documentation showing compatibility with process fluid
and service specified and indicated.

16. ISO 9000 certification or quality system plan.

17. Recommended storage requirements.

18. Material Certification:

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 a. Provide certification from the equipment manufacturer that the
materials of construction specified are recommended and suitable for
the service conditions specified and indicated. If materials other than
those specified are proposed based on incompatibility with the
service conditions, provide technical data and certification that the
proposed materials are recommended and suitable for the service
conditions specified and indicated including an installation list of a
minimum of five (5) installations in operation for a minimum of five
(5) years. Provide proposed materials at no additional cost to the
Owner.

b. Where materials are not specified, provide technical data and

certification that the proposed materials are recommended and
suitable for the service conditions specified and indicated.

B. A copy of the contract mechanical process and structural drawings, with addenda
that are applicable to the equipment specified in this section, marked to show all
changes necessary for the equipment proposed for this specification section. If no
changes are required, mark all drawings with "No changes required".

1. Failure to include all drawings applicable to the equipment specified in this

section will result in rejection of the entire submittal with no further review.

C. A copy of this specification section with addenda and all referenced specification
sections with addenda, with each paragraph check-marked to indicate specification
compliance or marked to indicate requested deviations and clarifications from the
specified requirements.

1. If deviations and clarifications from the specifications are indicated, therefore

requested by the Contractor, provide a detailed written justification for each
deviation and clarification.

a. Failure to include a copy of the marked-up specification sections and

or the detailed justifications for any requested deviation or
clarification will result in rejection of the entire submittal with no
further review and consideration.

D. Equivalent British/European codes and standards may be used; however, the

equivalency shall be demonstrated and submitted by the Contractor and approved by
the CM/CS.

1.05 QUALITY ASSURANCE:

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 A. Provide in accordance with Section 01400 and as specified.

B. Gates shall be the product of one manufacturer.

C. Gates shall be manufacturer's standard cataloged product and modified to provide

compliance with the drawings, specifications and the service conditions specified
and indicated.

D. Welding: In accordance with American Welding Society Code D1.1. or equivalent.

E. Shop testing as specified.

F. Gate manufacturer shall provide gates, lifting attachment, guides and rails regardless
of manufacturer as a complete integrated package to insure proper coordination,
compatibility and operation of the systems.

G. Provide services of factory-trained service engineer, specifically trained on type of

equipment specified:

1. Service Engineer shall have a minimum of five (5) years of experience on the
type and size of equipment specified.

2. Service Engineer shall be present on site for all items listed below. Man-day
requirements listed are exclusive of travel time, and do not relieve
Contractor of the obligation to place equipment in operation as specified.

(NTS: Insert the number of service days to meet project requirements.)

a. Installation: Supervise location of rails, anchor bolts; setting,
leveling, alignment and field erection.

___ man-days.

b. Functional Testing: Calibrate, check alignment and perform a

functional test with water. Tests to include all items specified.

___ man-days.

c. Field Performance Testing: Field performance test equipment

specified.

___ man-days.

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 d. Vendor Training: Provide classroom and field operation and
maintenance instruction including all materials, slides, videos,
handouts and preparation to lead and teach classroom sessions.

___ man-days.

3. Credit to the Owner, all unused service man-days specified above, at the
manufacturer's published field service rate.

4. Any additional time required of the factory trained service engineer to assist
in placing the equipment in operation, or testing or to correct deficiencies in
installation, equipment or material shall be provided at no additional cost to
the Owner.

H. Manufacturer of roller gates shall have at least five (5) operating installations with
roller gates of the size specified and in the same service as specified operating for
not less than five (5) years.

1.06 DELIVERY, STORAGE AND HANDLING:

A. Provide in accordance with Section 01610 and as specified.

B. Shipping:

1. Ship equipment, material and spare parts complete except where partial
disassembly is required by transportation regulations or for protection of
components.

2. Pack spare parts in containers bearing labels clearly designating contents and
pieces of equipment for which intended.

3. Deliver spare parts at same time as pertaining equipment. Deliver to Owner

after completion of work.

4. Pack elastomeric parts for protection against degradation due to sunlight and
exposure to the elements.

C. Receiving:

1. Inspect and inventory items upon delivery to site.

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 2. Store and safeguard equipment, material and spare parts in accordance with
manufacturer's written instructions.

1.07 SPECIAL REQUIREMENTS:

A. Refer to the applicable sections of Division 1 with regard to providing the following:

1. Foundations, Installations and Grouting

2. Lubricants

3. Special Tools

4. Bolts, Anchor Bolts, and Nuts

5. Sleeves and inserts

6. Protection against electrolysis

7. Nameplates

8. Operating and maintenance instructions and parts lists.

PART 2 - PRODUCTS

2.01 MANUFACTURERS:

A. Rodney Hunt, Co., Orange, MA.

B. Waterman Industries, Exeter, CA.

C. Hydro-Gate, Commerce City, CO.

D. Or acceptable equivalent product.

2.02 SERVICE CONDITIONS:

(NTS: The Roller Gate Schedule is normally and preferred to be included on the
drawings. Project requirements may dictate that the schedule be included in the
specifications, such as prepurchase specification ect. Included at the end of this
specification is a sample Roller Gate Schedule.)
A. Roller gate operating data are indicated in the Roller Gate Schedule.

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2.03 MATERIALS:

A. Gate Disc Skin Plate: A36, Structural Steel

B. Gate Disc Frame Members: A36, Structural Steel

C. Seals: J-Seal - Neoprene D2000 Grade 2BC515 - Neoprene D2000 Grade AA625

D. Retainer Bars & Fasteners for Seals: A276, Type 316 Stainless Steel

E. Fasteners, Studs, Anchors: A276, Type 316 Stainless and Assembly Bolts: Steel

F. Metal Contact Surfaces For Seals, Bottom Sill and J-Side Seal: A276, Type 316
Stainless Steel

G. Roller Assembly:

1. Wheels: AISI 1045 Carbon Steel Forging

2. Bearings: ASTM B22/B271, C86300 Self-Lubricated, Sleeve Type

3. Axles: A564, Type 630 Stainless Steel

4. Hubs: A276, Type 316 Stainless Steel

H. Roller Slots (Prefabricated): A36, Structural Steel

I. Rails: 25 lb. ASCE Type

J. Type 304 stainless steel is not acceptable.

2.04 ROLLER GATES:

A. Gate Discs: Gate disc to consist of a smooth skin plate with horizontal and vertical
structural reinforcing members continuously welded to form a box-like structure.

1. Provide minimum weld size in conformance with AWS D1.1.

2. Provide gate to withstand the maximum unbalanced head as specified and

indicated in the Roller Gate Schedule and provide gates to withstand an
unbalanced head of 25 feet [7.6 meters] without exceeding 15,000 psi

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 [103,475 kPa] tensile and 10,000 psi [68,950 kPa] shear for all steel
materials.

3. Maximum allowable stress for all other materials: 40% of the yield strength
or 25% of the ultimate strength whichever is smaller.

4. Disc deflection: Not to exceed 1/1000 of the nominal gate width.

5. Provide a flat bar welded to the outer periphery of the skinplate and
machined to a true plane to provide a mounting surface for the gate seals.
Seal support surface must be within an 0.03 in. [0.76 mm] overall flatness
tolerance.

6. Line-bore the axle mounting holes in the disc after fabrication to be parallel
to the seal support surface within an 0.005 in. [0.127 mm] parallel tolerance.

7. All steel gate components: Provide a minimum thickness of 5/16 in. [8 mm].

8. Where two or more gate sections are necessary machine the splice between
the sections to a true plane perpendicular to the seal mounting surface and
key and bolt the sections together to form an integral structural unit.

a. Assemble the sections and rollers in the manufacturer's shop and

align. Repair or replace at no additional cost to the Owner.

B. Seals:

1. Provide resilient seals along the top, bottom and both sides of the gate to
prevent leakage.

2. Seal attaching hardware: Type 316 stainless steel and attached in a manner
to permit replacement of the seals.

3. Side and top seals: "J" type and the bottom seal of the flush-bottom type.

4. Form J-seal corners using continuous molded sections.

5. Provide double J-seals for gates subject to seating and unseating heads as
indicated in the Roller Gate Schedule.

6. Joints between the molded corners and top or side seals: Square butt type
located a minimum of 12 in. [300 mm] from the corner.

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 7. Bond the molded corner to the top and side seal and assemble to the gate
disc in the manufacturer's shop.

8. Mitered joints are not acceptable.

C. Roller Assemblies:

1. Space the rollers along the side of the gate disc to support equal portions of
the hydrostatic load.

2. Provide the rollers with turned threads and bored for bearing size.

3. Provide permanently lubricated roller axle bearings rated for continuous

submerged service.

4. Roller loadings: Not to exceed 900 times the roller diameter times the
effective head width of the rail.

5. Provide roller assemblies complete with axles that are removable from the
gate.

6. Align rollers to within an 0.010 in. [0.25 mm] straightness tolerance along
the rollers.

D. Roller Slots, Yoke Sill:

1. Provide all gates with symmetrical guides and slots so that gates can be
installed in the seating position regardless of the direction of flow.

2. Provide prefabricated structural steel roller slots including the location of the
Type 316 stainless steel rubbing surface and the mounting of the rails.

3. Provide standard steel rails as specified or indicated to guide the rollers on

the gate disc as it moves.

a. Shop attach rails inside the roller slots on the upstream and
downstream side of the gate using Type 316 stainless steel fasteners.

4. Locate rails so that compression of the seal will be obtained.

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 5. Extend guides above the sill the height of the channel so that the gate can be
raised completely out of the flow.

6. Type 316 stainless steel seal rubbing surface shall have a maximum
roughness of 125 micro-inch rms.

7. Bottom sill: Structural steel beam with a Type 316 stainless steel seating
surface.

E. Roller Gate Lifting Device:

1. Provide one roller gate lifter for each size gate.

2. Provide lifter to fit into the roller gate frame.

3. Provide lifter with a latching device to engage and disengage roller gates.

4. Materials: Type 316 stainless steel.

2.05 SHOP PAINTING:

A. Primer and Finish Paint: Shop apply to all exterior ferrous surfaces, a high solids
epoxy with the following characteristics:

1. Solids by Volume: Minimum 69% (percent +2)

2. Type: Polyamidoamine, self priming.

3. Dry Film Thickness: 4-8 mils per coat.

4. No. of Coats required: Three

5. V.O.C. Requirement: 2.79 max.

6. Color: As selected by the CM/CS.

B. Surface preparation, mixing and application and safety requirements shall be in

accordance with the paint manufacturer's printed instructions.

C. Ferrous surfaces obviously not to be painted shall be given a shop applied coat of
grease or rust resistant coating.

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 D. Provide additional shop paint coating for touch-up to all surfaces after installation
and testing is completed and equipment accepted.

(NTS: Edit the type and number of spare parts as appropriate.)

2.06 SPARE PARTS:

A. Provide in accordance with Section 01730 and as specified.

B. Provide spare parts that are identical to and interchangeable with parts installed.

C. Provide the following spare parts for set of gates of each size:

1. Two roller assemblies.

2. 10 feet [3 meters] of J-seal.

(NTS: It is preferred that the Roller Gate Schedule be included as part of the
drawings. If the Roller Gate Schedule is included as part of the drawings, delete the
following paragraph. Attached to this master is a sample Roller Gate Schedule.)
2.07 ROLLER GATE SCHEDULE: Attached.

PART 3 - EXECUTION

3.01 INSTALLATION:

A. Install items in accordance with manufacturer's printed instructions and as indicated

and specified.

B. Prior to installation, protect stored gates and appurtenances from damage due to
exposure to sunlight, heat, dirt, debris, freezing and thawing, vandalism, etc.

1. Gates and appurtenances shall be stored in accordance with manufacturer’s

printed instructions.

C. Clean debris, dirt, and gravel, from inside of gates and channels before placing gates
in place.

D. Erect and support gates in respective positions. Clean out debris and foreign
material from gate openings and seats, test operating mechanisms to check

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 functioning, and check nuts and bolts for tightness. Repair, gates and other
equipment which do not operate easily or are otherwise defective at no additional
cost to the Owner. After this has been completed, perform leakage test as specified.

E. Set frames straight and true and test to see that gates move easily and seat without
binding.

3.02 FIELD TESTING:

(NTS: Utilize paragraph A for large projects. At this time Section 01680 has not been
issued as a Masterspec.)
A. Provide in accordance with Section 01680 and as specified.

B. After installation of equipment, and after inspection, operation, testing and

adjustment have been completed by manufacturer's field service engineer, conduct
an operational and a leakage test for each gate in presence of CM/CS to determine
its ability to operate within the limits specified. During tests, observe and record
head and leakage. Promptly correct or replace all defects or defective equipment
revealed by or noted during tests, at no additional cost to the Owner, and repeat
tests until specified results and results acceptable to the CM/CS are obtained.
Contractor to provide all labor, piping, equipment, flowmeters and materials for
conducting tests.

1. Operational Test: Install and remove gates and reinstall for leakage testing to
demonstrate its ability to operate smoothly and without jamming.

2. Leakage Test:

a. At seating head, leakage not to exceed 0.10 GPM per foot (20 ml/sec
per meter) of seating perimeter.

(1) Seating head: As indicated in the Roller Gate Schedule.

C. Make all adjustments to place equipment in specified working order at time of above
tests.

D. Test gates on water. Water for testing furnished by Contractor.

E. Remove and replace equipment at no additional cost to the Owner with equipment
that will meet all requirements specified and indicated if unable to demonstrate to
satisfaction of CM/CS that units will perform the service specified and indicated.

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3.03 FIELD TOUCH-UP PAINTING:

A. After installation and approved testing by the CM/CS, apply touch-up paint to all
scratched, abraided and damaged shop painted surfaces. Coating type and color
shall match shop painting.

3.04 CONTRACT CLOSEOUT:

A. Provide in accordance with Section 01700.

END OF SECTION

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