A.02_Specifications_7N20Q0037.pdf

SPECIFICATIONS

1.0 GENERAL

The contractor shall furnish all labor, materials, services, equipment, and facilities to fabricate two (2) 20” suction elbow castings, two (2) “S” pipe castings, and (1) wye piece casting. Contractor services shall include casting, welding, machining, testing, and non-destructive (ND) inspection as necessary to produce a product suitable for use in a marine dredging application. Work shall be in accordance with these specifications and the following drawing.

Drawing Number Description:

353-E507-2012-02 - Elbow 353-E507-2012-03 - S pipe 353-E507-2012-04 – Wye piece

Contractor shall provide preservation, packing, marking, and delivery of finished product inclusive of all transportation for the patterns listed under section 6 below. F O B Delivery of all items required under this contract shall be within 20 weeks of contract award.

2.0 QUALITY ASSURANCE PROVISIONS

2.1 MATERIALS

Material shall be furnishes as specified herein and as shown in the referenced drawing.

Drawing No. Material

Y-1720-3 ASTM A148, Grade 130-115 S-Pipe 353-E507-2012-03, Grade 130-115 Wye Piece 353-E507-2012-04, Grade 130-115

If necessary, heat treatment shall be provided to obtain the physical properties specified. Substitutions of any kind shall be submitted in writing to the Contracting Officer for approval prior to proceeding.

The Contractor shall furnish certified analysis of the chemical and physical properties of all materials furnished under this contract. Testing costs shall be borne by the Contractor. The Government reserves the right to have additional test and analysis performed by an independent testing laboratory at the Government’s expense. If the COR elects to have such independent analysis made, the Contractor shall furnish necessary drillings and samples taken under the supervision of the Contracting Officer’s Representative.

2.2 CASTINGS

2.2.1 The structure of the metal in the castings shall be homogeneous and free from excessive non-metallic inclusions or slag (metal oxides). Excessive segregation of impurities or alloys at critical points in a casting will be cause for its rejection.

2.2.2 Unless otherwise specified on the contract drawing, the dimensions for the thickness of the cast finished surfaces shall not deviate from the drawings in an amount that would cause more than a 10% change in the strength of the casting. In addition, deviations from the overall dimensions of the cast finished surfaces shall not exceed the recommended tolerances of the Steel Founder's Society of America, Supplement 3, tolerance grade T5. Warped or distorted castings, or castings that are oversized to an extent that will interfere with proper fit with other parts of the assembly will be rejected.

2.2.3 After castings have been cleaned, and prior to any machining, the Contractor shall inspect all surfaces of the castings utilizing dye penetrant or magnetic particle tests conducted in the presence of the Government Inspector.

Testing shall be in accordance with ASTM E709 or E165 as applicable. If any discrepancies exist, the Contractor shall notify the Contracting Officer in writing within five (5) working days. Any weld repair shall be in accordance with Section 3.0 of this specification. Weld repair of castings will be allowed provided that the crack or inclusion does not exceed 10% (ten percent) of the total wall or component thickness. If a crack or surface defect exceeds 10% of thickness, the Contractor must request permission from the Government to perform weld repair. Repairs exceeding 10% thickness of any casting without prior approval of the Contracting Officer will be considered sufficient cause for rejection of the casting. Defects to be repaired shall be completely removed and the removal verified through additional non-destructive testing. Repaired areas shall be retested after welding to verify the condition of the repair.

Cracks, porosity, or inclusions in excess of 20% in any planar surface area after gouging the defect will be cause for rejection of the entire casting. The contractor shall document and provide the Government with a sketch of all weld repairs performed. If necessary, provide preheat or post heat treatment for all weld repairs. If magnetic particle test is used, castings shall be demagnetized after testing is completed. Overall the acceptable linear and non-linear surface discontinuity shall be Level III as per ASTM A903.

2.3 TOLERANCES AND SURFACE FINISH

Dimensions of castings shown on the contract drawings are final dimensions. All dimensional tolerances shall be in accordance with Tables 3, 4 and 5 of ASTM A27. All machine finished dimensions, sizes, and surface finishes shall be in strict accordance with the drawings referenced in Section 1.0. Except as otherwise specified on the drawings, tolerance for dimensions of machine finished surfaces shall be ±1/64 inch, angles shall be ±½ degrees. Machine finished surfaces shall not have a roughness height rating (RHR) greater than 250 micro-inches as defined in ANSI B46.1 except where specifically noted. All undefined fillets and break edges shall be de-burred and have no sharp edges.

2.4. FINAL DIMENSIONAL INSPECTION

After completion, but prior to preserving and packing, each item will be checked in the presence of the Government Inspector to verify dimensions, and compliance with the specifications and drawings.

2.5 TEST REPORTS

The Contractor shall furnish certified analysis of the chemical composition as well as the mechanical properties of the materials (see Section 2.2) for all castings furnished under this contract. Each test report shall be identified by Government contract number, heat number, and pieces poured from the heat. Written certification shall be furnished that states that all castings needing heat treatment, were heat treated in accordance with applicable specifications.

3.0 WELDING

Casting defects shall be weld repaired in accordance with the provisions of Section 2.2.3 of this specification. All welding performed under this contract shall be in accordance with ASTM A488 Standard Practice for Steel Castings, Welding, Qualifications of Procedures and Personnel, applicable requirements of the American Welding Society and manufacturer’s recommendations for the material used. Welding shall be performed by AWS certified welders. Welding electrodes used throughout the work shall be suitable for use with parent metals, and have physical properties equal to or better than parent metals.

4.0 MACHINING

The finished machined surface of all pipe flanges shall be per contract drawings and Section 2.3 of this specification. No drill templates will be furnished under this contract for drilling pipes flanges. The Contractor shall carefully layout and drill all holes as shown on contract drawings. Bolt washer surface areas on the back of all flanges shall be spot-faced to 250 micro-inches (for 7/8” bolt diameter, the washer O.D. will be 1.875”). The Contractor shall leave scribe marks, layout lines, etc., on each flange until completion of final dimensional inspection as provided for in Section 2.4.

5.0 SPECIFICATIONS AND STANDARDS

Where articles, materials, and equipment are required to conform to standard specifications or tests they shall conform to the latest edition in effect, including amendments thereto, unless otherwise specified on contract drawings or in this specifications.

6.0 PATTERNS

The government shall furnish the following patterns:

Drawing No. Pattern No.

353-E507-2012-02 - Elbow 353-E507-2012-03 - S pipe 353-E507-2012-04 – Wye piece

The Contractor shall provide transportation for all patterns to and from the Contractor’s facility as set forth in Section 8.0.

6.1 INSPECTION

The patterns shall be examined by the Contractor within five (5) working days after receipt. The examination shall include checking for damage as well ensuring that the finished parts will conform to the contract drawing within the allowable tolerances. Within five (5) working days of the examination, the Contractor shall submit a written inspection report to the COR, including photographs and description of any discrepancies found. If authorized by the Contracting Officer, the patterns may be repaired by the Contractor in accordance with the optional patternmaker services provisions of Section 7.0. If no discrepancy report is submitted to the Government within ten (10) working days after receipt of patterns, the patterns will be considered adequate, and any subsequent repairs must be made at the Contractor’s expense.

6.2 ALTERATIONS

Any alterations to the Government furnished pattern that the Contractor may desire to make in order to obtain a suitable casting in conformance with the Contractor’s foundry practice shall be made at the Contractor’s expense, and only after receiving the COR’s written approval for such alteration. Any pattern containing alteration by the Contractor shall be restored to the same configuration and condition as when received prior to its return to the government.

6.3 PREPERATION

The pattern shall be prepared for foundry by sanding the portions that represent the unfinished casting surfaces and applying two (2) coats of high grade aluminum pattern paint. After each coat of aluminum paint has sufficiently dried, the surface shall be rubbed smooth. Prior to pouring sand, the pattern shall be coated with rosin or parting talc.

Other methods of preparation will be acceptable, provided they are equivalent and the process approved in writing by the COR.

After foundry work has been completed, the Contractor shall re-inspect the patterns and report any damage found to the COR in a written inspection report within five (5) working days of the examination. The Contractor shall thoroughly clean the patterns, and apply two coats of “Master Kin Cote” as manufactured by Kindt- Collins of Cleveland, OH, or an approved equal, and colored in accordance with American Foundrymen’s Association standards. In addition, the condition of the pattern shall be inspected by the Government Inspector prior to crating.

6.4 STORAGE

The contractor shall take all necessary precautions to safeguard the aforementioned patterns, gauges and rig, and the crates in which they are shipped. Outside storage of any of these items or their respective shipping crates during the performance of the work listed herein is forbidden. A pattern or pattern component, which is lost or damaged due to negligence by the Contractor while in the Contractor’s possession, shall be replaced or repaired by the Contractor, without any cost to the government.

6.5 SHIPPING

The Contractor shall provide all services required for shipping of the government furnished patterns to and from the Contractor’s facility in accordance with the provisions of Section D within 30 days of final acceptance of the castings.

7.0 PATTERNMAKER

7.1 SERVICES OF PATTERNMAKER FOR GOVERNMENT FURNISHED PATTERNS (OPTIONAL)

Any additional hours required to repair Government furnished patterns, submitted in accordance with paragraph 6.1, shall be quoted under Contracting Line Item (CLIN) 0002. Work may or may not be required under this section;

nevertheless, the Offeror is required to submit a price. Failure to do so will render the quote nonresponsive, and will result in the quote being dismissed. No work shall be performed under this item unless authorized by the Contracting Officer. If work is authorized, the Contractor shall make repairs necessary to assure that the castings produced conform to contract drawings. The Contractor's price shall include labor, material, and equipment at an hourly rate.

8.0 MARKINGS

All items furnished under this contract shall have the final casting weight in pounds clearly marked with bead welded (at least 1-1/2” high) on the pipe castings.

8.1 PREPARATION FOR DELIVERY

8.1.1 COATINGS

The inner surfaces of all castings shall be thoroughly cleaned by removing all shop coatings, dirt, metal chips, rust, and other foreign matter. The outer, non-machined surfaces of all drag pipes shall be abrasive blasted and coated as follow: One layer of inorganic zinc primer. Federal color code #36076, gray, 3.0 mils dry film thickness. One layer of epoxy top coat. Federal color code #17038, black, 2.0 mils dry film thickness.

8.2 PACKING

8.2.1 Wood padding shall be provided on all pipe flanges. Padding shall be of 1-inch (nominal) plywood, exterior grade, and shall be bolted to the machined surfaces.

8.2.3 All items shall be individually packed on a sturdy platform for forklift handling, and shall be packed in a manner which will insure arrival at their destination in an undamaged condition. Packing shall comply with Uniform Freight Classification Rules and National Motor Freight Classification Rules. The pattern crates shall be reused, and returned to the Government in the condition in which they were received by the Contractor, neglecting minor wear from shipping.

9.0 FREIGHT

All freight charges are to be FOB. Transportation shall be provided by the Contractor for the pick-up and delivery of the items furnished under this contract (patterns and pipe castings) from /to the following address:

U.S. Army Corps of Engineers District Warehouse 8010 NW Saint Helens Road Portland, OR 97210 The Government will provide loading and off- loading services. Arrangements should be made a minimum of 3 working days in advance for all pick-ups or deliveries. Warehouse hours of operation are 7:30 AM to 3:00 PM, Monday – Friday, with delivery and pick-up no later than 2:30 PM.