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NEELUM JHELUMCONSULTANTS

liv between MWH nt NORPLAN NESPAK, ACE & NDCI Tel: (+92) 5822433653
Malik House, Lower Chatter Fax: (÷92) 5822432978
Muzaffarabad e-mail: njc~njprojecLcom

Date: 26 November 2012


Our ref: P0-10154
Your ref: GZBZJ-NJC-3689 Dated 15 Nov 2012

Authorized Project Manager DELIVERY: BY HAND


CGGC-CMEC Consortium
(Office at Site C3), Chatter Kalas,
Muzaffarabad

ATTEN11ON: MR DENG YINOI


NEELUM JHELUM HYDRO-ELECTRIC PROJECT
Cl: CONTRACTORS PROPOSAL TO CHANGE STAINLESS-STEEL WATER-STOP TO PVC
Dear Sir
We acknowledge receipt of your above mentioned letter requesting NJC reconsider our design
requirement for a stainless steel water-stop in favour of using a more flexible PVC water-stop. Your
request to revert to PVC water-stop for the works at Cl is approved.
However, the Contractor is still obliged to bring TIG welding machines to this project as follows.
• The Contractor is required to make use of MIG and TIG welding equipment for welding stainless steel
in many locations. Most of this work will be carried out by the Contractors Consortiums mechanical
team.
• C3 Powerhouse All stainless steel is required to be welded with inert gas methods. This includes

stainless hydraulic oil lines, instrument tubing, stainless embeds, and cooling water lines.
• Both TIG and MIG machines are part of the shop equipment.
• Cl Dam All stainless steel is required to be welded with inert gas methods. This includes stainless

hydraulic oil lines, instrument tubing, and stainless embeds.

This office therefore recommends that these machines be brought to site earlier than anticipated in order
to train your craftsmen to perform this particular welding.
We attach for your perusal and reference a “Jobsite guide” for the installation of a typical stainless steel
water-stop from an American company called “Green streak” this company clearly advises the use of TIG
welding equipment.
We take this opportunity of reminding your design team that water-stop and jointing materials shall be
obtained from an approved manufacturer, who should have available for your use and guidance:-
• A product brochure
• A design guide
• A product specification See attached suggested specification from “Green streak”
-

• An installation guide
• A list of splicing tools and recommended equipment (in this case TIG welding equipment is advised)
• Material Safety Data Sheets
• CAD drawings of recommended splice shapes
• Field quality control instructions and test parameters.
Please note the important fact that your construction team are to meticulously follow the approved
product manufacturers guide for splicing water-stops. Please submit the relevant product specifications
and guides. Therefore the Contractor must furnish splicing tools and train their craft workers,
Filing 130. 580 Distribution’ Addressee
Owner: Neetum Jhelum Consuftants CEO(NJHPC GM&PD
Printed: 26 November 2012 GRE-Cl
Author: OAOC RE-Hi
File
Status: Final Ooc ref P010154 Cl Dam Slainless Steel Waler Stop Revised
NEELUM JHELUMCONSULTANTS

For the welding of stainless steel, your welders wilt need to be certified in TIG welding. NJC’s RE
Hydraulics will be available for the testing and qualification of your nominated welders. In terms of a test
plan we will require your use of PT testing materials etc.
Yours faithfully
For NEELUM JHELUM CONSULTANTS

WILLIAM B. DOBBS, P.E.


Project Manager

Dcc ret P0 1015401 Dam Stainless Sleel Water Slop Revised


GRE a STAINLESS STEEL
WATERSTOP JOBSITE GUIDE

GREENSTREAK STAINLESS STEEL WATERSTOPS are for use in concrete joints


subjected to severe chemical, ozone, or high temperature exposure. Embedded in
concrete, stainless steel waterstops span the joint to form a continuous, watertight
diaphragm that prevents the passage of fluid. The waterstop must be designed and
installed properly to accommodate joint expansion, contraction and other lateral and
transverse movements.

FORMING AND POSITIONING direction, intersections, and transitions by


REQUIREMENTS the use of mitered welds. Poorly
Stainless Steel waterstops are installed prior constructed intersections and splices are
to the initial concrete pour to ensure proper prime locations for leaks. Riveting or bolting
positioning. Split formwork is generally of the waterstop should never be permitted.
required. This allows half of the waterstop to Properly constructed mitered welds should
be positioned inside the first pour with the be performed by a qualified welder using
other half projecting into the second pour. proper TIC welding equipment.
The centerline of the waterstop should be
aligned to coincide with the center of the joint. TIC is extremely well suited to join thin
The split form should firmly hold the waterstop sheets since the heat input in this process is
in position to prevent misalignment of the small and the chance of “burn through” is
waterstop during concrete placement. A tight minimal. TIC welds do not create undercuts
fit is also necessary to prevent excessive or excessive penetration, with lowest
leakage of concrete paste, which could lead to distortion when compared to any other
honeycombing of the concrete. When welding process. For this reason, “stick
installed in joints with expected movement, a welding” or Shielded Metal Arc Welding
2” wide strip of duct tape should be placed (SMAW) are not recommended splicing
over the center “V’ section to prevent methods.
concrete paste from filling the “V” area.
Properly cutting and fitting mitered ends of
Once embedded in the first pour of concrete, the stainless steel waterstop is difficult and
the rigidity of the waterstop offers sufficient best performed under controlled conditions
support to withstand the second placement of in a shop environment. It is therefore
concrete. Attachment to surrounding Greenstreak’s recommendation that factory
formwork or reinforcing steel is not generally fabrications be used for all changes in
req u i red. direction, intersections and transitions,
leaving only straight end-to-end splices for
SPLICING REQUIREMENTS field welding.
Continuity of the waterstop, including the In this way, the owner, engineer, and
flanges and the centerline “V” section, is contractor can be assured of a high quality
critical for optimum performance. Continuity waterstop system.
should be maintained through changes in

3400 Tree Court Industrial Blvd. • St. Louis, MO 63122


Phone 800.325-9504 or 636.225-9400 • Fax 800.551-5145 or 636.225-2049
Greenstreak.com • Email info~greenstreak.com
Below is a general list of items required for Equipment
performing TIG welds in the field. • WP2O - Weldcraft TIG Torch, Air
Cooled with Flow Meter for Argon or
Consumables similar
Tungsten electrode - .040, 2% • Torch Accessories
Thoridated AWS Class EWTH-2 (red o .040 Collet
identifying band). Prepare a pointed- o 45V42 Collet Body Gas Lens
end for DCEN welding (DC-Straight o 53N60 Ceramic Cup Gas Lens
Polarity) with 3/8” orifice
• Wire—316L .030 • Welding Hood with #9 lens
• Backing Flux — Solar B Flux mixed • Light weight gloves with gauntlets
with methanol to paste-like
consistency (brushed on the Workinq Conditions
underside of the weld section to • Minimum ambient temperature 0°F
prevent contamination of the weld as • Shield against winds over 20mph
the Argon gas does) Use LPS Zero Tn Spray cleaner or equivalent
Shielding Gas —Argon 100% to ensure material is free of dirt, grease,
water, etc.

Manual Welding Parameters for 316L Stainless Steel

Welding Thickness Current Voltage Filler Rod Argon Flow Weld Speed Wire Feed
Method (in.) (amps) (volts) (AWS) (ft3Ih) (in.!min) (in.Imin)

TIG 0.030 30/70 DCEN 12-14 ER316L 20-30 2-4 As Required

Figure 1

UNACCEPTABLE SPLICING DEFECTS


Defects would include misalignment of center “V’ section more than 1/32~ inch, tensile strength
less than 80% of the parent section, or visible porosity or ‘burn through” in the weld.
IMPORTANT PRECAUTIONS
Thoroughly consolidate the concrete around the waterstop to prevent voids or honeycombing next
to the waterstop. Pay particular ätention to the underside of horizontally placed waterstops.
Intimate contact of the concrete and waterstop is necessary for full performance of a waterstop.
Voids next to the waterstop can significantly reduce its water stopping ability. Maintain adequate
clearance between reinforcing steel and the waterstop. Typical clearance should be twice the
maximum aggregate size. Inadequate clearance can promote the formation of voids due to
aggregate bridging.

It is important to maintain continuity of the entire waterstop system. Splices must be properly
completed at all changes of direction, transitions, intersections, and butt joints. Any breach in
continuity can be a Doint of leakaae.

3400 Tree Court Industrial Blvd. • St. Louis, MO 63122


Phone 800.325-9504 or 636.225-9400 • Fax 800.551-5145 or 636.225-2049
Greenstreak.com • Email info~greenstreak.com
1-06 CH

GREENSTREAK

SUGGESTED MASTER SPECIFICATION


SECTION 031513 STAINLESS STEEL WATERSTOPS
PART I GENERAL

1.01 SECTION INCLUDES

A. Provision of waterstops embedded in concrete and spanning control, expansion, and/or


construction joints to create a continuous diaphragm to prevent fluid migration.
B. Formed metallic waterstops for use in concrete joints when non-metallic waterstops are
inappropriate, such as severe chemical and high service temperature environments.

1.02 REFERENCES

A. Chemically resistant waterstop performance is not currently governed by state or federal


standard specifications. EPA Title 40 CFR requires the use of chemically resistant waterstop.

1.03 QUALITY ASSURANCE

A. Waterstop manufacturer shall demonstrate five years (minimum) continuous, successful


experience in production of waterstops.
B. Store waterstops in protected area to prevent damage prior to installation.

1.04 SUBMITTALS

A. Submit manufacturers test data for chemical resistance.


B. Submit CAD shop drawings and fabrication drawings indicaing placement of waterstop and
shop fabrications.

PART 2 PRODUCTS

2.01 MATERIALS

A. Provide formed stainless steel grade [316L], gauge [20] waterstop as manufactured by
Greenstreak, profile style number (fill in orofile style number).
B. The stainless steel waterstop shall be suitable for severe chemical and high service temperature
environments when non-metallic waterstops are not acceptable, as determined by specific
testing for the application.
C. Performance Requirements as follows:
Property Test Method Grade 316L
Ultimate Tensile Strength ASTM A 370 75,000 psi (515 Mpa)
Duct Elongation in 2” mi ASTM A 370 40%
Rockwell B Hardness ASTM A 370 95 max.
Yield Strength ASTM A 370 30,000 psi (205 Mpa)

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1-06 CR

2.02 ACCESSORIES

A. Provide factory made waterstop fabrications for all changes of direction, intersections, and
transitions leaving only straight butt joint splices for the field.
B. TIC welding equipment.

PART 3 EXECUTION

3.01 PREPARATION

A. Ensure steel reinforcing bars do not interfere with proper position of waterstop.
B. Clean concrete joints and waterstop of dirt and construction debris prior to second pour of
concrete.

3.02 INSTALLATION

A. Lap metal waterstop at splices and continuously weld exposed edge on containment side. Use
.035 diameter 316 stainless steel alloy filler rod for grade 316L stainless steel.
B. Weld factory supplied intersections and directional changes to straight length sections per
method of 3.02.A.
C. All welds to be made by qualified welder with TIC welding experience.
D. Splices to be free from defects as defined in ‘Field Quality Control” in section 3.03
E. Center waterstop on joint with peak of “V’ section oriented toward containment side.
F. Seal base (open side) of “V’ expansion area in metal waterstop with one layer of two-inch wide
duct tape.
C. At expansion joints, keep “V area unembedded.
H. Place concrete without disturbing waterstop and thoroughly vibrate concrete to maximize
intimate contact between waterstop and concrete.
I. After first pour, clean protruding waterstop leg to ensure hill contact of second pour.

3.03 FIELD QUALITY CONTROL

A. Waterstop splicing defects which are unacceptable include, but are not limited to the following:
1. Tensile strength less than 80 percent of parent section.
2. Misalignment of”V” section and flanges greater than 1/16 inch.
3. Visible porosity or “burn-through’ in the weld.
4. Adhesive bonds, free lap joints, or lap joints with mechanical fasteners.
5. Misalignment of waterstop splices resulting in misalignment of waterstop in excess of
1/2 inch in 10 feet.

END OF SECTION

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