1-Wire_Rope_IDIQ_Contract_Spec(1-26-23).docx

FABRICATION OF CARBON STEEL WIRE ROPES

CG Specification: P-613-2035 26 January 2023 Rev 1 / Change No 1

REVISION No. 1 CHANGE No. _1_

SPECIFICATION

FABRICATION OF CARBON STEEL

WIRE ROPES

P-613-2035

ORIGINATED BY: Ernesto T. Roig DATE: 12 December 2016

ORIGINATOR’S COMMAND: Surface Force Logistic Center (SFLC)

DEPARTMENT / DIVISION: SFLC-IBCTPL-ENG-SES-2

INTERNAL REVIEW (IBCTPL-ENG-SES-2): Jennifer Louzon ____DATE: 01/25/18

1. SCOPE

1.1 Intent. This specification covers the fabrication, test, inspection, preservation, packing and marking requirements for marine carbon steel wire ropes installed on multiple United States Coast Guard (USCG) cutter and barge classes.

1.2 Government Furnished Property (GFP):

None.

2. REFERENCES

COST GUARD DRAWINGS

None Coast Guard Publications Surface Forces Logistics Center Technical Standard 573-2 (SFLC Tech Std 573-2), 2015, Weight Handling Equipment Surface Forces Logistics Center Technical Standard 589 (SFLC Tech Std 589), 2019, Cranes Surface Forces Logistics Center Technical Standard 613 (SFLC Tech Std 613), 2018, Wire Rope and Rigging

OTHER REFERENCES

ISO/IEC 17025, General requirements for the competence of testing and Calibration Laboratories (2017-11) 3rd Edition.

ASQ ISO Q9001, 2008, Quality Systems Requirements API Specification (API) 9A, 2020, Specification for Wire Rope ASTM International (ASTM) A29/A29M – 16, 2020, Standard Specification for Steel Bars, Carbon and Alloy, Hot-Wrought, General Requirements ASTM International (ASTM) A576-90-9B, 2017, Standard Specification for Steel Bars, Carbon, Hot-Wrought, Special Quality ASTM International (ASTM) A700, 2019, Standard Guide for Packaging, Marking, and Loading Methods for Steel Products for Shipment British Standard (BS) EN 10204 (Type-3.1), 2004, Inspection Certificate Federal Specification (FED SPEC) RR-S-550E, Type A, Finish 2, Class 1, 2018, Sockets, Wire Ropes Military Specification (MIL-SPEC) MS51844E, 2018, Sleeves, Swaging-Wire Rope Military Standard (MIL-STD) 129R, 2019, Military Markings for Shipment and Storage U.S. Department of Labor (USDL) OSHA Form-4 Wire Rope Technical Board (WRTB), U4, 2005, Wire Rope Manual, 4th Edition

3. REQUIREMENTS

3.1 General. The Contractor shall provide all labor and materials needed to fabricate, inspect, test, preserve and package the marine carbon steel wire rope listed in Appendix A of this specification.

3.1.1 Tech Rep.

Not applicable

3.2 Construction detail. The Contractor shall manufacture all wire ropes In Accordance With (IAW) SFLC Tech Std 573-2, SFLC Tech STD 589 and SFLC Tech STD 613.

3.2.1 Wire rope construction requirements. The Contractor shall fabricate the wire rope IAW Appendix A. This Appendix contains a summary of the wire rope’s construction requirements by Contract Line-Item Number (CLIN).

3.2.1.1 The Contractor shall follow the construction requirements in Appendix A without deviation.

3.2.1.2 The Contractor shall assemble the wire rope specified in Appendix A with stock wire rope manufactured to conform to API Specification 9A, 2020.

3.2.1.3 The Contractor shall provide the Mill Test Certificate for the stock wire ropes utilized in the manufacturing of the wire rope assemblies specified in Appendix A.

3.2.1.4 The Contractor shall ensure that the Mil Test Certificate specified in para. 3.2.1.3 is written in English.

3.2.1.5 The Contractor shall ensure that the Mill Test Certificate in para. 3.2.1.3 conforms to the requirements of USDL OSHA FORM-4.

3.2.2 Fitting installation. The Contractor shall install CROSBY™ manufactured fittings at the ends of the wire ropes specified in Appendix A.

3.2.2.1 The Contractor shall ensure that the CROSBY™ G-416 Poured Open or G-417 Poured Closed Spelter Socket meet the performance requirements of FED SPEC RR-S-550E, Type A, Finish 2, Class 1, 2018.

3.2.2.2 The Contractor shall ensure that the CROSBY™ S-501 Open or S-502 Closed Swage Socket meet the performance requirements of WRTB, U4, 2005.

3.2.2.3 The Contractor shall ensure that the CROSBY™ Stainless Steel Thimble fittings meet the performance requirements of WRTB, U4, 2005.

3.2.2.4 The Contractor shall ensure that the CROSBY™ fittings specified in para. 3.2.2.1, 3.2.2.2, and 3.2.2.3 have their Certificates of Conformance conforms to BS EN 10204 (Type-3.1), 2004.

3.2.2.5 The Contractor shall ensure that the CROSBY™ fittings specified in para. 3.2.2.1, 3.2.2.2, and 3.2.2.3 have their Material Test conducted IAW ASTM A29M - 12, 2012 and ASTM A576-90-9B, 2017.

3.2.2.4 The Contractor shall utilize WIRELOCK™ poured socketing compound when installing spelter socket on the wire rope.

3.2.2.5 The Contractor shall double seize any wire rope end that does not have a fitting affixed to it as specified in Appendix A and IAW WRTB, U4, 2005.

3.2.3 Fitting manufacturing specifications.

3.2.3.1 All spelter sockets utilized by the contractor shall conform to the requirements of FED SPEC RR-S-550E, Type A, Finish 2, Class 1, 2018.

3.2.3.2 All swage and stainless-steel thimble fittings utilized by the contractor shall conform to the requirements of WRTB, U4, 2005.

3.2.3.3 All sleeve fittings utilized by the contractor shall conform to the requirements of MIL SPEC MS51844E, 2018.

3.2.4 Wire rope lubrication. The contractor shall pressure lubricate the assembled wire ropes with KIRKPATRICK DYNAGARD BLUE™ lubrication product IAW SFLC-TS-613.

3.2.4.1 The Contractor shall ensure that the pressure lubrication system injects lubricant under pressure into the core of the wire rope.

3.2.5 Wire rope identification (ID) number. The contractor shall assign a unique serial number to the wire rope assembly.

3.2.5.1 The Contractor shall include this unique serial number in the wire rope assembly’s weight test documentation.

3.2.6 Wire rope identification tag (ID tag). The contractor shall fabricate non-corrosive metal ID tag for the wire rope.

3.2.6.1 The Contractor shall list the following information on the ID tag.

• Wire rope’s unique serial number

• Wire rope diameter

• Wire rope length

• Contractor’s (Manufacturer) name or Symbol

• Pull test results (load and date)

• USCG contract number

3.2.6.2 The Contractor shall ensure that the unique wire rope serial number listed in the wire rope’s ID tag is the same as the one listed in the wire rope’s Weight Test Certificate.

3.2.6.3 The Contractor shall affix the ID Tag from Para. 3.2.6 to the spelter socket side of the wire rope with a crimped short wire loop.

3.2.7 Stock wire rope material. The stock wire rope utilized by the Contractor to build the wire rope assembly shall be manufactured from carbon steel.

3.2.7.2 The Contractor shall not use stainless steel stock wire ropes to build this wire rope assembly.

3.2.7.3 The stock wire rope shall be manufactured IAW API Specification 9A, 2020.

3.3 Workmanship.

3.3.1 Wire rope. Wire ropes shall be uniform in material and quality and shall be securely laid free from kinks, loose wires, loose strands, or other defects that may be detrimental to their serviceability and appearance. Protruding wires are considered a defect and not more than one broken wire will be accepted in 1000 feet of wire rope.

3.3.2 Sockets. All sockets shall be properly shaped without sharp edges at openings, free from flaws, seams, fins, slivers, cracks and other injurious defects which may affect their serviceability and handling. The galvanized coating on wire rope sockets shall be adherent, smooth, and free from uncoated spots, injurious lumps, blisters, dross or flux.

3.4 Notifications and Inspections. The Contractor shall be responsible for notifying the Contracting Officer at least seven (7) calendar days prior to contractor being ready for any inspections or testing required herein.

3.5 Certifications.

3.5.1 Notifications. The Contractor shall provide certification stating that the materials conform to the requirements as specified in para. 4.5.2.

4. Quality assurance (QA)

4.1 Responsibility for inspections. The Contractor shall be responsible for the performance of all inspection requirements specified herein.

4.1.1 Contractor responsibility. The Contractor shall provide space, personnel and test equipment to conduct the inspection and testing requirements.

4.1.2 Inspection facilities. Inspection and testing shall be performed at the Contractor’s facility prior to acceptance and delivery.

4.1.3 Final Acceptance inspection. Final acceptance inspection shall be performed by a designated Coast Guard inspector at the point of delivery prior to acceptance.

NOTE

The Coast Guard reserves the right to perform on-site inspection of the requirements set forth herein at the Contractor’s facility where such inspections are deemed necessary to assure that supplies and services conform to prescribed requirements.

4.2 Responsibility for compliance.

4.2.1 Compliance. Wire rope shall meet the provisions of Sections 3 & 5.

4.2.2 Contractor's inspection and QA system. The inspections set forth in this specification shall become part of the Contractor's overall inspection system or quality program IAW ANSI/ASQ-Q9001, 2008.

4.2.3 Requirements compliance. The absence of any inspection requirements in the specification shall not relieve the Contractor of the responsibility of assuring that all products or supplies submitted to the government for acceptance comply with all requirements of the contract.

4.2.4 Conformance sampling. Sampling for quality conformance does not authorize submission of known defective material (either indicated or actual) nor does it commit the government to acceptance of defective material.

4.3 Inspection system. The Contractor shall maintain an inspection system IAW ASQ-ISO-Q9001, 2008.

4.3.1 Conformance to contract requirements. The Contractor’s inspection system shall ensure that each item offered to the Coast Guard for acceptance or approval conforms to the contract requirements.

4.3.2 Inspection system review. The inspection system shall be documented and available for review by the Coast Guard inspector.

4.4 Test and inspections. The Contractor shall be aware that the inspections and tests required herein are the minimum necessary and are not intended to replace any controls, examinations, or tests normally employed by the contractor to assure the quality of the product. The following inspections and tests shall be performed and witnessed by USCG Quality Assurance Inspectors (QA).

4.4.1 Dimensional inspection. The Contractor shall perform a Dimensional Check to verify that the wire rope assembly's dimensions conform to the sizes and tolerances required in Appendix A.

4.4.2 Material inspection. The Contractor shall perform a materials check utilizing Appendix A as guidance.

4.4.3 Preservation, packaging and marking inspection. The Contractor shall ensure that the Preservation, Packaging and Marking of every wire rope is per Section 5 herein.

4.4.4 Weight test consideration. The Contractor shall ensure the wire rope assembly is weight tested as a unit. That means that the wire rope shall be fully assembled when tested.

4.4.5 Weight test requirement. The Contractor shall weight test the assembled wire rope and spelter socket assembly to 40% of the stock wire rope's Rated Breaking Strength (RBS). This will test the wire rope to fitting connection.

4.5 Test and inspection reports.

4.5.1 Weight Test Certificate required information. The Contractor shall include, as a minimum, the following information in the wire rope Weight Test Certificate.

• Full wire rope description. (See Appendix A)

• Wire Rope Assembly’s Coast Guard Part Number. (See Appendix A)

• Wire Rope Assembly’s National Stock Number. (See Appendix A)

• Wire Rope Assembly’s unique Serial Number. (Contractor provided)

• Stock Wire Rope manufacturer & brand name. (Contractor provided)

• Spelter Socket manufacturer, brand name, & size (inch). (Contractor provided)

• Stock Wire Rope RBS. (Contractor provided) Pull test result (LBs)

• Date Test was performed. (Contractor provided)

• The Wire Rope Proof Test Pull (LBS). (Contractor provided)

• Testing Facility name. (Contractor provided)

• Name of the qualified technician conducting weight test. (Contractor provided)

• Pull test result (LBs)

• USCG contract number

4.5.2 Wire rope assembly provenance documents. The Contractor shall include the following documents with the Weight Test Certificate.

NOTE

See Appendix C for examples of the documents discussed in this section.

• Wire Rope Data Sheet (See Appendix B and para. 5.2.3.2)

• The Stock Wire rope MILL TEST CERTIFICATE (USDL OSHA FORM-4).

• The CROSBY™ G-416/G-417 Open/Closed Spelter Sockets CERTIFICATE OF CONFORMANCE (MEET REQ. EN 1-204-3.1) for socket size installed on Wire Rope.

• The CROSBY™ G-416/G-417 Open/Closed Spelter Sockets MATERIAL CHEMISTRY REPORT as provided by CROSBY™ for the installed socket. (This certificate shall be for the production batch of the installed socket and MEET REQ. EN 1-204-3.1).

• The WIRELOCK™ socketing compound Data Sheet and MSDS Sheet.

• The DYNAGARD BLUE™ lubricant Data Sheet and MSDS Sheet.

4.5.2.1 The Contractor shall allocate a transparent water-resistant document packing list envelope, 9 1/2 long IN X 12 IN wide, and 2-mil poly.

4.5.2.2 The Contractor shall insert the Weight Test Certificate specified in para. 4.5.1 and all the documents listed in para. 4.5.2 into the packing list envelope mentioned in para. 4.5.2.1.

4.5.2.3 The Contractor shall affix the packing list envelope mentioned in para. 4.5.2.2 to the coiled wire rope on the shipping reel underneath the last wrap of the transparent wrapping used to package the wire rope . See Table 2 for an example.

TABLE 2 PAINTED MARKINGS, CERT PACKAGE AND CERAM RAP

4.5.3 Document copies for Contracting Officer. The Contractor shall provide the Contracting Officer copies of all inspections and test reports as listed in para. 4.5.1 and 4.5.2.

4.5.4 Document copies for IBCT Product Line. The Contractor shall send copies of the test and inspection documents via email to the U.S Coast Guard SFLC Baltimore, IBCT Product Line at.

4.6 Calibration system. The Contractor shall maintain a test equipment calibration program in compliance with ANSI/NCSL Z540-3 (2006).

4.6.1 Traceability. The program shall be documented and traceable to the National Institute of Standards (NIST).

4.6.2 Calibration system record inspection. The calibration system records shall be maintained for inspection for the duration of any contract referencing this specification.

5. Preservation, packaging, and markings

5.1 Packing. Each wire rope assembly shall be individually packed in its own shipping spool or reel constructed of lumber or plywood.

5.1.1 Packaging expected performance. The Contractor shall ensure that shipping container or reel protects the wire rope assembly from damage during shipping and handling by commercial carriers IAW ASTM A700, 2017.

5.1.1.1 All containers shall conform to the requirements of Reference ASTM A700, 2017.

5.1.1.2 The Contractor shall ensure the wire rope spelter socket ID tag, and at least 2-feet of wire rope at the fitting ends of the rope, are easily accessible for visual inspection.

5.1.1.3 The wire rope spelter socket ends and ID tag shall not be placed inside the shipping reel’s hub.

5.1.1.4 The Contractor shall preserve the wire ropes by wrapping them with plastic stretch wrap film. This will protect the wire ropes from water and dust during storage.

5.2 Markings. Each packaged wire rope assembly shall be marked in the upper left-hand side of the spool or the round face of the shipping reel, whichever is utilized.

5.2.1 Painted markings. The Contractor shall paint a rectangle 6” by 12” white enamel at location specified in para. 5.2.

5.2.1.1 The Contractor shall paint, in the rectangular white background described in para. 5.2.2, the following data with 1/2” by 3/4” size text using black enamel paint: Wire Rope National Sock Number (NSN), Item Serial Number, Item Part Number and Contract Number. See Table 3 for an example:

TABLE 3 PAINTED MARKINGS

NSN: 4010-01-486-0047

SERIAL NUM: 56450987

Part NUM: PS-78D

CONTRACT NUM: HSCG40-17-Q-40278

5.2.3 Printed markings. The Contractor shall print the “Wire Rope Data Sheet” for the applicable wire rope CLIN in Appendix B.

5.2.3.1 The Contractor shall ensure the Appendix B “Wire Rope Data Sheet” information matches the wire rope CLIN and contract being accomplished.

5.2.3.2 The Contractor shall ensure the Appendix B “Wire Rope Data Sheet” information is complete.

5.2.3.3 The Contractor shall insert the applicable Appendix B “Wire Rope Data Sheet” specified in para. 5.2.3.1 into the transparent water resistant document envelope called for in para. 4.5.2.2.

5.2.3.2 The Contractor shall place the “Wire Rope Data Sheet” on top of the wire rope provenance documents listed in para 4.5.2, when inserting it in the transparent water resistant envelop.

5.3 Bar coding. A bar code label of the wire rope’s stock number shall be developed in addition to the above markings

5.3.1 Bar code label traceability. The Contractor shall develop, and affix to the wire rope packaging, one bar code label of the wire rope’s stock number in accordance with MIL STD 129R, 2014 (ISO/IEC 16388-2014, Code 39 Symbology).

5.3.1 Bar code label characteristics. The actual labels shall be Type “V”, Grade “C”, Style 2”, and Composition “a”. The Label can be applied separately or as part of the markings required in para. 5.2.

6. Notes

6.1 Wire rope documentation. See Appendix C for examples of the forms the Contractor needs to attach to the wire rope packaging.

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