11-820 Installation Procedure

Gate System Installation Procedure
Wedge Air Bladder

Junquillo 11-820
Table of Contents
1.0
2.0
3.0
4.0
5.0
6.0
SCOPE OF THIS DOCUMENT

GATE SYSTEM DEFINITIONS
ABUTMENT PLATE INSTALLATION
MAIN ANCHOR BOLT INSTALLATION
AIR PIPING
FOUNDATION FINISH, EMBEDDED PNEUMATIC PIPING,
CONDENSATE PURGE LINE and INCLINOMETER CONDUIT
7.0 SPILLWAY GATES
8.0 INSTALLATION OF INTER-PANEL SEALS
9.0 ABUTMENT & J-BULB SEAL INSTALLATION
10.0 RESTRAINING STRAPS
11.0 LOCATING AND ANCHORING AIR SUPPLY, ACC and PLC
12.0 ELECTRICAL
13.0 FIELD TESTING
14.0 TORQUES AND TOOLS
15.0 COMMON CONSTRUCTION ERRORS AND TIPS
16.0 CHECK LISTS
16.1 Abutment Plate
16.2 Main Anchor Bolt
16.3 Concrete
Created By
PAC
Approved
Date
Sept 18, 2013
This Document is property of Obermeyer Hydro, Inc.

and is not to be used, disclosed, reproduced or
transmitted by electronic or any other means without
prior written authorization from OHI.
COPYRIGHTED, OBERMEYER HYDRO, INC.,
2005
Revision
Created Install Procedure
No.
1
OBERMEYER HYDRO, INC.

PO BOX 668, FORT COLLINS,
CO 80522 TEL 970-568-9844
FAX 970-568-9845
GATE SYSTEM INSTALLATION PROCEDURE

Junquillo 11-820
Printed: 9/18/2013
1.0 SCOPE OF THIS DOCUMENT

Note: This is a general guide only. Actual field conditions may dictate different
construction methods.
This procedure is to be used by the CONTRACTOR installing the OHI gate system. This
document is divided into several sections:
Definition of spillway gate components.

Civil works: Installation of Abutment Plates, Main & Restraining Strap Anchor
Bolts, Spillway Finish, and Pneumatic Piping.
Spillway Gates: Installation of the Gate Panels, Air Bladders, Hinges, Clamp
Castings, Seals & Restraining Straps and other associated hardware.
Installation of air controls including Air Compressor, Blowers, ACC and PLC
Cabinets.
Site specific construction requirements to follow torque values, and tolerances
set by design drawings and proper construction tools required
OHI field inspection responsibilities
General Notes: Use anti-seize compound on all threads. Use Teflon tape and thread
sealant compound pipe dope on all air fittings. Caulk must be 100% silicone or
aquarium grade. Silicone will not bond to wet surfaces, so keep them clean and dry.
Keep sharp objects and surfaces away from rubber parts.
OBERMEYER Hydro Inc.
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2.0 GATE SYSTEM DEFINITIONS

The spillway gate assembly comprises the components found on the spillway and
includes the air bladders, gate panels, anchor bolts, etc. The air bladders inflate to raise
the gate system and deflate to lower the gate system.
GATE PANEL
The Gate Panel acts as a movable, rigid barrier to the water. The Gate Panels attach
along the upstream edge to the Hinge Flap. Two adjacent Gate Panels are connected
together using the Inter-Panel Seal.
MAIN ANCHOR ASSEMBLY
The gate and bladder system are anchored to the spillway with the Main Anchor
Assembly. The Main Anchor Assembly is a continuous fabricated steel unit that spans
the channels width and has a series of anchor bolts that fasten the assembly to the
spillway. In some cases this may be a series of studs anchored to the spillway,
depending on construction techniques. These are large studs extending upwards from
the assembly, which are used to fasten the Air Bladder, Hinge Flap, Inner-Panel Seal,
and Abutment Seals via clamp castings. The Main Anchor Assembly therefore evenly
transmits the larger hydrostatic forces generated by the Gate Panel downward into the
concrete. It also provides for water stop under the bladder.
AIR BLADDER
The Air Bladders rest on top of the spillway and are held in place by Clamp Castings
that mount to the upstream edge of the spillway. When inflated, the Air Bladder imparts
the upward and upstream force on the Gate Panel that impounds the water. The air
control system is connected to the underside of the Air Bladder by means of a threaded
fitting and flexible hose.
The Hinge Flap
Hinge Flap connects the Gate Panel to the dam surface and acts as a water seal. The
upstream wedge section is compressed along with the Air Bladder wedge sections in
the Clamp Castings. The downstream portion of the Hinge Flap connects to the Gate
Panel using the bottom row of Gate Panel studs with the provided Hinge Flap Retainers,
washers and hex nuts. In the fully raised position, with the Air Bladder inflated, the
Hinge Flap transmits a compressive force from the Clamp Castings to the bottom edge
of the Gate Panel.
NOTE: Inflation of an Air Bladder, even under low pressure, without clamps
securely tightened, can cause permanent damage or rupture of the Air Bladders.
The Air Bladder should never be inflated unless properly installed.
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CLAMP CASTINGS
The Clamp Castings are positioned over the Main Anchor Bolts and retain the Air
Bladder and Hinge Flap in place. The Clamp Castings transmit a force to the bottom
edge of the Gate Panel through the Hinge Flap. This force, and the force imparted to
the Gate Panel by the inflated portion of the Air Bladder, provides the moment required
to support the cantilevered Gate Panel. The Clamp Castings also provide the sealing
mechanism for the Air Bladder.
HINGE FLAP RETAINERS
The Hinge Flap Retainers clamp the Hinge Flap to the upstream edge of the Gate
Panel. With the gate fully raised or fully lowered, the forces tending to pull the Hinge
Flap out from under the Hinge Flap Retainers are low. At intermediate gate positions,
high forces occur, which requires the Hinge Flap Retainers be kept tightly clamped.
RESTRAINING STRAPS
The Restraining Straps are the reinforced rubber strips that attach to the spillway and to
the bottom side of the Gate Panel. The Restraining Strap limits the upstream travel and
height of the Gate Panel during inflation and insures that the Gate Panel does not flip
over upstream when the gate system is fully raised and the water elevation is less than
full pond depth.
RESTRAINING STRAP CLAMPS
The Restraining Strap Clamps fasten the Restraining Strap to the spillway and to the
Gate Panel. The Restraining Strap Anchor Bolts used to fasten the clamp to the
spillway and the hex head bolts used to fasten the clamp to the Gate Panel are typically
of the same diameter and should be kept tight at all times.
NAPPE BREAKERS
The Nappe Breakers divide the water flowing over the top edge of the raised gate
system. This provides an air path to the otherwise closed off space under the raised
Gate Panel created by the water wall. Without the Nappe Breakers, a vacuum could
occur behind the water wall and high gate loads or vibration may occur.
ABUTMENT PLATES
The Abutment Plates may consist of concrete, stainless steel or UHMW polyurethane.
The Abutment Plate component is located at each section end of the gate system. It
provides a smooth vertical surface for the Abutment Seal that is attached at each end of
the Gate system to create a watertight seal.
ABUTMENT SEALS
The Abutment Seals are the reinforced rubber strip that seals the end Gate Panels to
the Abutment Plates.
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ORIENTATION
GATE
RIGHT
Flow
NOTE: Left and

Right are defined
by looking
downstream (into
flow)
LEFT
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3.0 ABUTMENT PLATE INSTALLATION

1. Abutment plate dimensions, materials, and construction for this project are detailed
on project drawings 11-820-240L-F&R and 11-820-240R-F&R.
2. Installation and construction methods are provided on drawings 11-820-112 and 11820-240L-F&R & 240R-F&R. Contractor to form abutment walls. These plates may
be installed during the initial construction of the abutment walls or with the required
block-out for later installation depending on the contractors preferred method.
Stainless Steel Abutment Plates will be positioned and adjusted in the block out
space using Contractor provided hardware so that they are plumb to within 3mm
and are perpendicular to the Main Anchor Bolt centerline. The Abutment Plate to
Abutment Plate distance must be maintained pursuant to the construction drawings
to within 6mm. The Abutment Plate must be installed so that it is coplanar to within
6mm.
3. The plates must be secure and capable of withstanding the hydrostatic forces the
grout placed behind the plates creates. Any shifting of the Abutment Plates during
grouting may require the removal of the plate and reinstallation, at the Contractors
expense.
4. Tolerances for Abutment Plate installation are critical.
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4.0 MAIN ANCHOR BOLT INSTALLATION

NOTE: Under no circumstances will welding of any metal to the anchor bolts be allowed.
Unapproved heating of the bolts could lead to failure of the anchoring system.
1. Formation of the concrete cross section where the Main Anchor Clamp Casting sits
will be made using OHI provided foam forms. Refer to drawings 11-820-207-A5-1
through 11-820-A5-3.
2. Contractor will secure into place the provided OHI foam forms. Contractor will check
that form placement does not interfere with any expansion joints in the concrete
spillway.
3. Refer to drawings 11-820-101,102 for plan view detail layout of Main Anchor Bolt
locations. Refer to drawing 11-820-111 for section view of Main Anchor Bolt detailed
layout.
4. The Pivot Embed (See drawings 11-820-208-1 through 11-820-208-3) and Wedge
Embed (See drawings 11-820-209-1 through 11-820-209-3) are fastened to the OHI
foam form. Refer to drawing 11-820-102 for assembly of embeds to the foam forms.
5. Contractor to ensure the OHI foam form pans are firmly secured using tie rods that
are embedded in concrete as needed. Contractor to finalize method of fastening tie
rods. Contractor can submit anchorage methods to Obermeyer Hydro for ideas and
approval.
6. After pouring of concrete, Contractor to apply extra vibration near the forms to
ensure no air pockets form under the foam forms. Honeycomb formation under the
OHI foam form pans, Pivot & Wedge Embeds, or around the Main Anchors Bolts
shall be avoided.
7. Contractor to ensure Main Anchor Bolts are to be 142mm above finished concrete
surface. Refer to drawing 11-820-111 for section view.
8. After concrete has cured, the Pivot & Wedge Embed studs welded to the embed
angles shall be cutoff and ground flush. All grinding must be done with a new or
non-contaminated grinding media.
9. Restraining Strap Anchor Bolts may be poured in place or core drilled and epoxy set
to adhere bolt to concrete. Drawing 11-820-101 gives plan view detailed location
layout of bolts. Drawing 11-820-111 gives section view of bolts in relation to Main
Anchor Bolts.
10. Restraining Strap Anchors are to be 102mm above finished surface in concrete
block-out. Refer to drawing 11-820-111 for section view.
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5.0 AIR PIPING

1. The piping between the Main Air Supply and Air Control Cabinet (ACC) should
have a working pressure of at least 150 psig. The piping between the Air Bladders
and the Air Control Cabinet will normally contain pressures less than 50 psig.
2. All piping should be blown out with air to remove any scale or debris prior to
connection to the ACC or the Air Bladders.
3. Providing all piping and wiring and the installation of all piping and wiring is the
responsibility of the Contractor. Installation of the compressors, blowers, dryers,
filters, tanks, drain valves, ACC and associated equipment is the responsibility of
the Contractor.
4. Contractor to provide means of removing condensate from air line at low point of
air pipe system or at control side abutment. Refer to drawing 11-820-125 for
recommended details of condensate purge locations.
5. Any exposed portions of the piping shall be securely supported, as outlined in the
local building code or project specification.
6. All air piping shall utilize welded fittings. All welding to be in accordance with AWS
Structural Welding Specifications. All pipe joints to be leak proof.
7. Before installation of gate system, the entire run of pipe and connections shall be
inspected and pressure tested to 50 psig and each joint checked for leaks with the
owners representative present.
8. All electrical conduit shall be up to code and as specified in the plans
9. Piping at expansion joints to be sleeved to allow for movement of concrete.
10. All piping and conduit shall be rigid, except that flexible metal conduit may be used
in short lengths where needed to connect to vibrating equipment.
THE LOWEST POINT OF ALL AIR SUPPLY LINES MUST BE AT THE

CONDENSATE PURGE
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6.0 FOUNDATION FINISH, EMBEDDED PNEUMATIC PIPING,

CONDENSATE PURGE LINE and INCLINOMETER CONDUIT
1. Embedded Air Piping
a) The air supply pipes between the gate and the air control cabinet shall be
tested prior to final embedment in concrete by pressurizing to 50 psi for a
continuous 24 hour period. Pressure readings and ambient air temperature
shall be recorded at six different times during the test.
b) A wet test of the air lines may be performed with a leak detection solution at 50
psi in place of the 24 hour timed test.
c) Any joints or fittings exhibiting leakage during this time shall be repaired or
replaced.
2. The concrete area along the spillway crest to which the clamping assembly is to be
bolted shall be made level and flat with a high quality smooth surface. The areas
that supports the bladders will be made smooth (trowel finish) and shall be free of
sharp or abrasive objects or protrusions, which could damage the air bladder.
3. The pneumatic and conduit piping shall be placed in accordance with the drawings.
A plan view of the conceptual pneumatic & conduit piping layout are shown in
drawing 11-820-101 & 125. Contractor to review drawing to ensure Pneumatic
Piping, Inclinometer, and Condensate Purge Line(s) are correct size.
4. See drawing 11-820-111 for section elevation view of Main Air Supply & Air BlockOut detailed layout.
5. Contractors scope to include piping stub out into the air-connection block-out that
terminates with a female thread. See drawing 11-820-123 for details.
6. Contractor to provide for and construct Condensate Purge Valve(s) at low point(s)
in piping system. See drawing 11-820-125 for recommended section view of
piping layout.
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7.0 SPILLWAY GATES

Bladders, Hinges, and Gate Panels
1. Spillway Prep: Clean spillway of dirt & debris, especially wedge area. Wire brush
anchor bolt threads to remove any concrete splatter. Repair damaged threads with
3-corner file or proper die size.
*** USE COPPER OR NICKEL-BASED ANTI-SEIZE LUBRICANT ON ALL
THREADS ***
2. Locate Gate Panels.
3. Locate Air Bladder and Hinge Flaps.
4. Prior to bolting respective Gate Panels together, apply silicon for each Gate Flange
and around bolt holes. Set aside. See pic. 4.1 and drawing 11-820-120-1.
pic 4.1
5. Install Hinge Flaps onto Gates Panel using Hinge Retainers and stainless steel
fastening hardware. On larger gates it may be necessary to cut the hinge and
install it in multiple sections. (use generous amounts of copper or nickel-based
anti-seize lubricant on all stainless steel threads)
6. On the Gate Panel apply silicon around all the threaded holes and one big bead
along the joint or the round stock and flat as well as up and over where the ribs
come into the round stock (see pic 4.2).
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Silicon
pic 4.2
7. Locate Air Bladders and miscellaneous air plumbing hardware.

a. Attach brass elbow to brass bulkhead fitting located on bottom surface
of Air Bladder.
b. Connect stainless steel barb to end of Contractor supplied air piping.
8. Refer to drawing 11-820-123 to install air assembly (Use Teflon tape and pipe
dope on all screw type pipe fittings).
a. Locate the precut Poly reinforced hose with the stainless spiral insert.
b. Bend the end of the spiral insert so it will not slip over the end of the hose
barb during installation. Measure the length of the spiral insert and make
sure it will span the length between the hose barbs, minus the plastic insert.
c. Insert the clear plastic insert in the hose between the stainless spiral and
the brass barbed fitting on the bladder and clamp the hose to the brass
fitting with provided Mikalor clamp.
9. Position the wedge of Air Bladder on spillway just downstream of Main Anchor
Bolts. The wedge should touch the upstream wall of the wedge embed. Make
sure the Air Bladder fitting fits correctly into Air Block-Out.
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10. Roll the Air Bladder in half from left to right, or lift the wedge of the bladder to
expose Air Bladder connection.
a Loop the hose back around to the stainless fitting and secure with provided
Mikalor clamp
b Fill the Air Block-Out with expandable foam isolation, in geographical
locations where freezing is present.
11. Roll Air Bladder into final position. Make sure the air supply line does not kink.
12. Repeat steps 4 thru 11 for remaining Air Bladder(s).
13. Apply generous amounts of copper or nickel-based anti-seize lubricant on all
stainless steel threads.
14. Place assembled Gate Panel/Hinge Flaps onto Air Bladders. Reference drawing
11-820-110 for section view. Align the upstream edge of Hinge Flap with the Air
Bladder wedges. The upstream profile of the two 30 degree Air Bladder wedges
and the single Hinge Flap 30 degree wedge should follow a circular 90 degree
arc.
15. Locate Main Anchor Clamp Castings. Position Main Anchor Clamp Castings over
the Air Bladder and Hinge Flap wedges so the hinge wedge is tight against the
arch of the clamp. Make sure to use generous amounts of copper or nickel-based
anti-seize lubricant on all stainless steel threads and on bearing surfaces of
stainless steel nuts. Tighten nuts enough to get the next clamp placed
16. Install Abutment Seals. Refer to Section 8.0
17. Do not torque anchor bolts or inflate the system until the Abutment Seals are
installed.
18. Tighten stainless steel hex nuts starting at the Abutment Seals working toward the
middle of each bladder. After all nuts are snug (135-270 N-m), torque to 1400 Nm, working from the ends of the bladders to the middle. Make sure the main
anchors are tightened evenly to keep the clamp even. Make sure to use generous
amounts of copper or nickel-based anti-seize lubricant on all stainless steel
threads and on bearing surfaces of stainless steel nuts.
19. Repeat steps 14 through 18 for remaining Gate Panel(s). Double check the
abutment-to-abutment direction measurement after placing each gate, to ensure
that Gate Panels and Air Bladders are set correctly.
20. Beginning at the Abutment seal and working toward the center of the Air Bladder,
re-torque each of the Main Anchor Bolts to 1400 N-m
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21. Starting at one end re-torque all Main Anchor Bolts to 1400 N-m.
22. Wait 24 hours and again torque all anchor bolts 1400 N-m. (Note: 1400 N-m is
an estimated only, temperature affects on the rubber may require a higher torque
value to seat rubber into casting)
23. Inflate gate system to proper height of 3 M and then lower the gate and re-torque
the bolts.
CAUTION: Be careful when inflating the system at this time. Since the
Restraining Straps are not installed yet, the gates can tip over upstream if raised
to far. See Section 9.0 to install the Restraining Straps.
24. Install Nappe Breakers on downstream top edge of each Gate Panel.
8.0 ABUTMENT SEAL INSTALLATION

NOTE: Cold vulcanize seals at joint areas. Install Abutment Seals before vulcanizing in
order to maximize the time sensitive materials involved in the process. See vulcanization
technique in OHI-SPEC-3004 and drawing 11-820-120-1 for cross sectional views.
1. The Abutment Seals incorporate a 30 degree wedge section at the upstream end
(same as the Hinge Flap). Trim back Hinge Flap so the Abutment Seal wedge
section fits snuggly against the Hinge Flap section. Allowing a 3mm interference
on each side works well. Test fit Abutment Seal, securely positioning the wedge
between the Hinges.
2. Use anti-seize lubricant or marking paint, coat the tops of the studs holding the
Abutment Seal. By hand, push the Abutment Seal against the Abutment Plate so
the flat sealing surface of the seal is flush with the Abutment Plate. This is so the
seal will have tension on the Abutment Plate and make a seal. Holding it in place,
hit the seal with the sledge hammer directly over the first stud, marking the
underside of the seal. This marks the upstream to downstream location.
3. Measure the distance from the first stud to the Abutment Wall. Transpose that
measurement onto the Abutment Seal and mark location (Measurement A).
Measure from bladder side the distance to marked location (Measurement B).
Use this distance (Measurement B1) to locate the studs right to left. A slight
oblong hole (perpendicular to Abutment Wall) is preferred for adjustment. A good
reference point for locating the holes is the location of the first stud past the formed
section for the clamp plate. Remove the seal and either punch or cut the holes in
the seal.
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Bladder Side
Upstream
Printed: 9/18/2013
Location of First Stud
B1
Downstream
Abutment Side
4. Install seal using generous amount of 100% silicone caulk between the seal and
the Gate Panel. Place a bead of silicone caulk along the edge of the Gate Panel
where the Abutment Seal will be bolted to the gate. Place a bead of silicone caulk
on the bladder before placing the Abutment Seal down.
5. Locate Abutment Seal Retainers, washers, and nuts. Install according to drawing
11-820-120-1. Do not forget to apply generous amounts of copper or nickel-based
anti-seize lubricant on all stainless steel threads and on bearing surfaces of
stainless steel nuts.
6. Refer to Section 14 for the required torque values.
Cold vulcanizing may be performed at this time. If it is too

difficult to cold vulcanize the Abutment Seal and Hinges in there
current positions proceed to step 7. This molds everything into
place and makes it easier.
7. Place Clamp Casting over wedges and Main Anchor Bolts and torque Main Anchor
Bolts to 1400 N-m.
8.
Beginning at the ends of the Gate Panels and working toward the middle of the
bladder, re-torque each of the Main Anchor Bolts to 1400 N-m.
9. Test seal by checking for any visual gaps between the seal and the Abutment
Plate with the gates in the fully closed position. Adjust seal as required so that no
visual gap is present.
10. Wait 24 hours, and again torque all anchor bolts 1400 N-m.
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8.0 RESTRAINING STRAPS

1. Locate Restraining Strap Clamps and fasteners that match up with both the
concrete and gate. See drawing 11-820-124 for visual guide.
2. Raise the gate about halfway. Be careful not to over rotate the gate as it can flip
over without the Restraining Straps installed.
3. Attach one end of the molded Restraining Strap to the gate with the clamp, nuts,
and washers. The nylon rod should be positioned just upstream of and contacting
the clamp. Attach the other end of the molded Restraining Strap to the concrete
spillway with the molded in nylon rod positioned upstream of the clamp. Reference
the photo below for installation.
GATE
LONG SIDE OF CLAMP
MOLDED NYLON ROD
UPSTREAM SIDE
NYLON ROD
LONG SIDE OF CLAMP
CONCRETE
UPSTREAM SIDE
4. Tighten the Restraining Strap anchor nuts to avoid slippage of the strap
temporarily.
5. Torque all restraining strap anchors to 350 N-m.
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9.0 LEAK TEST GATE SYSTEM
***ONCE THE GATE IS INSTALLED COMPLETELY THE

SYSTEM MUST BE CHECKED FOR LEAKS. ***
* TESTING
-THE GATES SHOULD BE RAISED TO AN
INTERMEDIATE LEVEL.
- THE ABUTMENT SEALS SHOULD BE MARKED AT THE
ABUTMENT WALLS AND CHECKED AFTER 24 HRS.
-THIS LEVEL WILL BE SUBJECT TO FLUCTUATIONS
BASED ON AMBIENT TEMPERATURE
*TESTING ALTERNATE (PREFERRED)
- FLOOD THE UPSTREAM SIDE OF THE GATE ENOUGH
TO SUBMERGE THE MAIN ANCHOR CLAMPS.
- FLOOD THE DOWNSTREAM SIDE OF THE GATES
JUST ENOUGH TO COVER THE SPILLWAY BY 3-4
INCHES OF WATER.
- INFLATE THE GATE TO 5 PSI FOR APROXIMATELY 12
HOURS
- LOOK FOR VISIBLE SIGNS OF AIR LEAKAGE ALONG
THE BLADDERS AND CLAMPS.
- RE-TORQUE AS NECESSARY
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10.0 LOCATING AND ANCHORING AIR SUPPLY, ACC and PLC

1.
Place Air Control Cabinet (ACC) into its final position.
2.
Using a marker, mark the holes on the wall or floor accordingly. Move the
cabinet away from the marked holes.
3.
Using the concrete drill, bore holes which match the manufacturers
recommended depth and diameter for the stainless steel wedge type anchors.
Install the wedge type anchors.
4.
Place the cabinet in the appropriate position. Tighten anchors until the cabinet
is firmly anchored.
5.
Connect the pipes to appropriate ports per the project drawings.
6.
Repeat the process for the air compressor equipment, blowers, and Program
Logic Controller (PLC).
11.0 ELECTRICAL
1. Contractor to supply and install control wiring between the ACC and PLC per
applicable building codes.
2. All electrical conduit shall be as specified in the drawing.
3. Contractor to supply and install power supply conduit and wiring between the
circuit breaker and compressor & blower motors per project drawings.
4. Contractor to supply and install sensor cabling between external termination
boxes and the PLC cabinet per project drawings.
5. Contractor to procure circuit breaker panel per project drawings and install in
accordance with appropriate building codes.
12.0 FIELD TESTING

1. An OHI field representative should be on site for system start up.
2. The air supply pipes shall be tested prior to covering with concrete, backfilled,
or otherwise concealed. The air piping between the gate and the air control
cabinet shall be tested by pressurizing to 50psi for 24-hours. Pressure
readings and ambient air temperature shall be recorded at six different times
during the test.
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3. A wet test of the air lines may be performed with a leak detection solution at 50
psi in place of the 24 hour timed test.
4. Any joints or fittings exhibiting leakage during this time shall be repaired or
replaced.
5. The air piping between the air control cabinet and high pressure equipment
shall be tested by pressurizing to 150 psi for 24-hours. Pressure readings and
ambient air temperature shall be recorded at six different times during the test.
Any joints or fittings exhibiting leakage during this time shall be repaired or
replaced.
6. After installation of the gate system, before removing the cofferdam the spillway
gates shall be fully raised and lowered three (3) times using a portable air
supply. The gate shall operate smoothly with no binding.
7. Do not inflate air bladder past the operating pressure found in the hydraulic
calculations.
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13.0 TORQUES AND TOOLS

a. Torque Values: The following Torque settings will be used for the project:
Main Anchor Bolt (1-3/4- 5 UNC x 1000mm):
Gate Panel Flange Bolt (M24 x 75mm):
Restraining Strap Anchor (M30 x 460mm):
Restraining Strap Bolt (M30 c 100mm):
Hinge Flap Retainers (M30):
Abutment/J-Bulb Seal Retainers (M16):
Nappe Breaker Bolt (M12 x 40mm):
1400 N-m
270 N-m
350 N-m
270 N-m
270 N-m
100 N-m
50 N-m
b. Required Tools
Controls & Compressor (tools)
Adjustable wrenches
Pipe wrenches
Screw driver
Fine point permanent marker
8 Stainless steel M12 diameter x 150mm length wedge anchors
Concrete drill for M12 diameter wedge anchor
Lifting/moving apparatus
Gate System Installation (tools)
Wrench and socket for Main Anchor Bolts. Air impact wrench in
combination with manual torque wrench is satisfactory. A hydraulic
torque wrench is more convenient if available.
Sockets and ratchet wrenches for seal retainer and hinge flap nuts.
Utility knives for cutting rubber
3lb hammer and (7/8=22mm) rubber punches for Abutment/J-Bulb seals
Anti-seize compound sufficient for all studs, washers, and nuts.
32 tubes of 100% silicone or aquarium grade caulk and 2 caulk guns.
Rags for cleaning up silicone messes.
Abrasive cutoff saw and motorized reciprocating saw (e.g. Sawzall) or
chain saw for trimming Hinge Flaps to length.
Air bladder lifting clamps (designed by OHI).
Hand held angle grinder.
Lifting shackles to fit Gate Panel lifting holes, spreader bar for bladders.
2 Pry bars approximately 1M long.
Electric drills.
Pipe joint compound and Teflon tape for air fittings.
Pipe wrenches for air fittings.
Pliers
Shackles to fit crane hook to L shaped clamp casting lifting bracket.
Thread File.
Thread cutting dies to fit all smaller threads for repair if required.
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Junquillo 11-820
Printed: 9/18/2013
14.0 COMMON CONSTRUCTION ERRORS AND TIPS

c. Common Construction Errors
Remember !!!
Mistakes cause rework and delays Lost Contractor Profit
Mistakes create loss of gate performance Lost Owner Revenue
Abutment Plate to Abutment Plate Spacing Not Correct This is a very common
mistake. If the span width is too great the gate system may not seal properly.
If the span width is too short, the gates may not fit. There could also be permit
issues related to insufficient waterway width.
Anchor Bolt Assemblies Not Secured for Concrete Placement - Anchor bolt
assemblies can move from pressure of concrete causing shifting so they are no
longer perpendicular to abutment wall (which creates interference with how the
gate swings up and down), or to drift left or right (which will cause the clamp
castings and bladders to not fit.
Projection of Anchor Bolts - Anchor bolt projection not enough (making

installation of clamps difficult or impossible) or projection is too much (reducing
embedment length and reducing pull out strength.
Anchor Bolt Spacing Anchors are not spaced properly because hole pattern
not used properly or other reason. This will cause clamp castings to not fit.
Abutment Walls Not Plumb When abutment walls are not cast plumb, the OHI
supplied Abutment Plates (either stainless steel or UHMW plastic) will not be
plumb. This will create a variable width gap between the Abutment Wall and
gate which could lead to gate interference and water leakage.
Abutment Walls Bowed Insufficient form bracing can cause the Abutment
Walls to bow out. If this exceeds 12mm the OHI Abutment Seals will not work
properly. This may lead to the gate system not sealing as it should. Steel form
work is recommended.
Concrete Surface not Level If top of concrete elevation varies by more than
12mm over a span of 1.5M, or more that 50mm over the width of the waterway,
the clamp castings will not seat as designed possibly leading to leak paths
between the Gate Panels (that can not be sealed) or a total gate system crest
height that varies, which reduces overall storage capacity.
Spillway Elevation variations in elevation across the spillway will result in

even larger variations in the top-of-gate elevation. This is because low sections
of the gate are further lowered by greater water pressure. A 50mm variation in
spillway crest elevation result in a 100mm top of gate elevation. Keep the top
of concrete crest LEVEL.
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Junquillo 11-820
Printed: 9/18/2013
d. Tips for a Successful Project

ANCHOR BOLTS
Check that anchor bolt templates match drawing
Double check bolt to bolt spacing on assemblies
Ensure bolt to bolt spacing is correct between anchor bolt assemblies
Double check concrete pour depth with design bolt projection
Double check that all anchor bolts are within 3mm of alignment.
Form a 3 4 5 triangle (to create 90 degrees) and ensure the centerline of
anchor bolts is exactly perpendicular to both abutment walls
CONCRETE LEVEL ON ANCHOR BOLT CENTERLINE
If stainless steel heel and pivot angle embeds are supplied, pre-level and use
as screed line surfaces
If no other embeds are provided (except anchor bolts) pre-survey top of
concrete lines and double check.
ABUTMENT WALLS
Check that abutment wall forms are plumb
Check design of abutment wall formwork. Is lateral support adequate? Are
forms properly braced and tied off?
Are abutment wall perpendicular to anchor bolts.
CONCRETE QUALITY
Concrete should be trowel finish quality under all rubber surfaces
Concrete should be trowel finish quality 600mm in both directions of the anchor
bolt line
All air assembly, instrument junction box and restraining strap block outs should
have a 25mm chamfer cast in place. Chamfer must be ground after pour to a
radius.
EPOXY GROUTING OF ANCHOR BOLTS

Use proper drill template
Ensure all holes are properly washed and dried prior to application of epoxy.
Store epoxy per supplier requirements
Do not exceed manufacturers recommended hole diameter. An excessively
large hole may result in excessive epoxy shrinkage, failure of the epoxy bond to
the concrete, and anchor bolt pullout.
BLOCK OUTS AND PIPING
Cap all air lines prior to concrete pours. Make efforts to keep normal
construction debris and wildlife (fish, rodents, insects, snakes, crustaceans) out
of the airlines.
Double check location of block-outs. Are dimensions called out to the center
line or the edge of the block out? The number of air block outs matches the
number of bladders.
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Junquillo 11-820
Printed: 9/18/2013
15.0 CHECK LISTS
e. Abutment Plate Check List

A.
Abutment face to Abutment face dimension
a)
At base near anchors

b
b)
At tip of gate in up position
c)
At tip of gate in down position.

a
PER DRAWING
(mm)
TOLERANCE +/- 6mm

All three measurements should be within 6mm of above dimension
B.
Abutment Plate Plumb
(difference between top and bottom of each section)
d.1)
Left Abutment at anchors bolt plane
d.2)
Right Abutment at anchors bolt plane
e.1)
Left Abutment at middle of lowered gate
e.2)
Right Abutment at middle of lowered gate
f.1)
Left Abutment at lowered gate tip plane
f.2)
Right Abutment at lowered gate tip plane
TOLERANCE +/- 6mm

Total out of plumb measurement must be within 6mm
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Junquillo 11-820
Printed: 9/18/2013
C.
Abutment Plate Horizontal Flatness (deflection across plate)
g.1)
Left Abutment vertical at anchor bolts
g.2)
Right Abutment vertical at anchor bolts
h.1)
Left Abutment vertical middle
h.2)
Right Abutment vertical middle
i.1)
Left Abutment vertical gate up
i.2)
Right Abutment vertical gate up
Sketch shows section looking at top or side of abutment

plate using a taught string line between the two stand
off points.
Abutment Plate edge view

2 stand off
at edge of
plate
Measured Offset
2 stand off
at edge of
plate
TOLERANCE +/- 6mm

No point on each horizontal line can be more than 6mm out of plane
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Junquillo 11-820
Printed: 9/18/2013
D. Squareness of Anchor Bolt Alignment to Abutment Plate
Actual Angle
Left Abutment
Actual Angle
Right Abutment
j.1)
Angle between Left Abutment and Centerline of anchor bolts
j.2)
Angle between Left Abutment and Centerline of anchor bolts

TOLERANCE +/- 0.1 degree
Calculate Angle A by laying out a 3-4-5 triangle,

then measure what the 4 leg actually is.
5 ft
Angle A = arccos (16 b2) / (6b)
b(? ft)
If b = 4, the anchor bolts are perpendicular to

the abutment wall.
B
A
3 ft
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Junquillo 11-820
Printed: 9/18/2013
f. Main Anchor Bolt Check List

A.
Anchor Bolt Spacing

N1 = distance from face of right
abutment wall to centerline of first
main anchor bolt
N2 = distance from face of left

abutment wall to centerline of first
main anchor bolt
Right Abutment Plate

Left Abutment Plate
k.1)
Distance between Right Abutment Plate Face to Center of nearest anchor bolt
k.2)
Distance between left Abutment Plate Face to Center of nearest anchor bolt
B. Straightness of Anchor Bolt Alignment
Centerline of anchor bolts drawn with taught

string line between two outer most anchor bolts
Distance of center of anchor

bolt most out of alignment
l)
Distance between center line of anchor bolts and bolt most out of alignment
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Junquillo 11-820
Printed: 9/18/2013
g. Concrete Check List

Elevation (top of concrete & anchors) Across the Spillway
m.1)
Difference between highest and lowest elevations across the spillway crest (measured near
the main anchor bolts
(mm)
n.2)
Difference between highest and lowest elevations of main anchors ______________(mm)_
26 of 27

Junquillo 11-820
Printed: 9/18/2013
Positioning of Block outs
Distance between Left

abutment wall and
centerline of first air
assembly block out
Distance between
centerline of first air
block out and center of
second air block out
o.1)
Distance between Left abutment wall and centerline of first air assembly block out
__
o.2)
Distance between CL first left air block out and CL of second air block out
__
p.1)
Distance between Right abutment wall and centerline of first air assembly block out
__
p.2)
Distance between CL first right air block out and CL of second air block out
__
q.1)
Distance between Left abutment was and centerline of first restraining strap block out _____
q.2)
Distance between CL first left restraining strap block out and CL of second restraining strap
block out _______
r.1)
Distance between Right abutment was and centerline of first restraining strap block out ____
r.2)
Distance between CL first right restraining strap block out and CL of second restraining strap
block out _______
27 of 27

11-820 Installation Procedure

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11-820 Installation Procedure

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Gate System Installation Procedure

Wedge Air Bladder

SCOPE OF THIS DOCUMENT

This Document is property of Obermeyer Hydro, Inc.

OBERMEYER HYDRO, INC.

GATE SYSTEM INSTALLATION PROCEDURE

1.0 SCOPE OF THIS DOCUMENT

Definition of spillway gate components.

OBERMEYER Hydro Inc.

GATE SYSTEM INSTALLATION PROCEDURE

2.0 GATE SYSTEM DEFINITIONS

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GATE SYSTEM INSTALLATION PROCEDURE

OBERMEYER Hydro Inc.

GATE SYSTEM INSTALLATION PROCEDURE

NOTE: Left and

OBERMEYER Hydro Inc.

GATE SYSTEM INSTALLATION PROCEDURE

3.0 ABUTMENT PLATE INSTALLATION

OBERMEYER Hydro Inc.

GATE SYSTEM INSTALLATION PROCEDURE

4.0 MAIN ANCHOR BOLT INSTALLATION

OBERMEYER Hydro Inc.

GATE SYSTEM INSTALLATION PROCEDURE

5.0 AIR PIPING

THE LOWEST POINT OF ALL AIR SUPPLY LINES MUST BE AT THE

OBERMEYER Hydro Inc.

GATE SYSTEM INSTALLATION PROCEDURE

6.0 FOUNDATION FINISH, EMBEDDED PNEUMATIC PIPING,

OBERMEYER Hydro Inc.

GATE SYSTEM INSTALLATION PROCEDURE

7.0 SPILLWAY GATES

OBERMEYER Hydro Inc.

GATE SYSTEM INSTALLATION PROCEDURE

7. Locate Air Bladders and miscellaneous air plumbing hardware.

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GATE SYSTEM INSTALLATION PROCEDURE

OBERMEYER Hydro Inc.

GATE SYSTEM INSTALLATION PROCEDURE

8.0 ABUTMENT SEAL INSTALLATION

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GATE SYSTEM INSTALLATION PROCEDURE

Location of First Stud

Cold vulcanizing may be performed at this time. If it is too

OBERMEYER Hydro Inc.

GATE SYSTEM INSTALLATION PROCEDURE

8.0 RESTRAINING STRAPS

MOLDED NYLON ROD

LONG SIDE OF CLAMP

OBERMEYER Hydro Inc.

GATE SYSTEM INSTALLATION PROCEDURE

9.0 LEAK TEST GATE SYSTEM

***ONCE THE GATE IS INSTALLED COMPLETELY THE

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GATE SYSTEM INSTALLATION PROCEDURE

10.0 LOCATING AND ANCHORING AIR SUPPLY, ACC and PLC

Place Air Control Cabinet (ACC) into its final position.

Connect the pipes to appropriate ports per the project drawings.

12.0 FIELD TESTING

OBERMEYER Hydro Inc.

GATE SYSTEM INSTALLATION PROCEDURE

OBERMEYER Hydro Inc.

GATE SYSTEM INSTALLATION PROCEDURE

13.0 TORQUES AND TOOLS