Attachment_2a_-_Bid_Spec_BDYROFDSBTK33-430-261T__3CY_.pdf

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BDYROFDSBTK33-430-261T

STATE OF CALIFORNIA, DEPARTMENT OF TRANSPORTATION

DIVISION OF EQUIPMENT

SPECIFICATION NUMBER: BDYROFDSBTK33-430-261(T)

SPECIFICATION FOR: BODY, 3 CY, SANDER with ANTI-ICE, DIRECTIONAL, ROLL-OFF

PURCHASE ESTIMATE NUMBER: 32-12-6686__

It is the intent of this specification to describe the minimum requirements for an integrated roll-off skid directional sander body, minimum 3.0 cubic yard (CY) capacity with rear discharge directional spread spinner system with anti-ice liquid application and a pre-wet system. The finished unit shall be suitable for installation on a two-axle truck chassis. The sander body and all its components shall be constructed and assembled in accordance with the following minimum specifications. The following State of California, Department of Transportation (Caltrans), Division of Equipment reference drawings form a part of this specification:

Drawing Set Description 024040, Sheet 1 - 1 Directional Sander Body Envelope Spec 025415, Sheet 1 - 1 Caltrans Roll-Off Bodies – Features 013340, Sheets 1 - 22 Sander Body, Two-Axle Truck System Conversion 066892, Sheets 1 - 2 Sander Body Roll-Off Stand, Spinner Guard Assembly 035714, Sheet 1 - 1 Hydraulic Whip Hose Assemblies 067945, Sheets 1 - 3 Directional Sander, Ladder Location Detail P3-000030, Sheet 1 - 1 Sander Body Control Cable P3-000006, Sheet 1 - 1 Caltrans Sander Body Connector Pin Layout 030490, Sheets 1 - 3 Roll-Off Body, Controller Pigtail Cabinet P3-000019-XX, Sheets 1 - 2 Spreader Body Light Location Specification P3-000042-XX, Sheet 1 - 1 Spreader Body Lighting Plug Location CH-0043, Sheet 1 - 1 Caltrans 7-Way Connector 067792, Sheet 1 - 1 Sander Body, Delineation Detail 050912, Sheets 1 - 7 Sander Body, Chevron Tape Installation Options ISO 2867 Best Practices of Equipment Access

The unit shall be the manufacturer's standard production model and can be modified to meet these specifications. It shall be equipped with all the manufacturer's standard equipment and accessories which are part of the standard published literature. If optional equipment is identified on the invitation for bid it shall only be supplied and installed when included as a line item on the Purchase Order. The body shall be supplied as a complete, welded, working assembly free from any defects that would hinder its appearance or serviceability.

The unit shall comply with Caltrans Equipment Quality Standards for Welding, and Coatings as defined at: http://www.dot.ca.gov/programs/equipment. The Contractor will be responsible for complying with these standards.

http://www.dot.ca.gov/programs/equipment

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If a discrepancy is discovered between the specifications and the drawing(s) provided, the Contractor shall request clarification from the Department of General Services (DGS). The specifications and drawing(s) shall have precedence over the completed questionnaire and standard factory specifications or literature. The Bidder’s complete questionnaire shall take precedence over the standard factory specifications or literature.

If any referenced item listed on the drawings or in the specification is offered as an equivalent to the specified reference brand, then the Division of Equipment Specification Engineer will evaluate and determine compliance. Only technical changes authorized by DGS in writing will be accepted. Technical changes made by any other Division of Equipment, Caltrans, or State employees will not be accepted in accordance with the IFB.

NOTE: Installation of the body will be by State personnel. Any option requirement may supersede the minimum requirement specified.

TECHNICAL SPECIFICATIONS:

1. CHASSIS: The body shall be configured and integrated with the roll-off skid, while maximizing granular and liquid capacities.

a. Chassis constraints are as follows:

Chassis Constraints: Caltrans tare weight configuration:

Front Axle Max Capacity - 18,000 pounds Front axle weight – 9,280 pounds Rear Axles Max Capacity - 23,000 pounds Rear axles weight – 16,700 pounds

Reference Drawing 024040 for additional chassis layout dimensions & constraints.

b. Granular weight of 3,000 pounds per CY, to be used to calculate load.

c. Liquid weight of 10 pounds per gallon, to be used to calculate load.

2. BODY: The body shall be constructed from stainless steel and integrated with a roll‑off skid. The sander design shall consist of an auger conveyor, rear discharge, and with a directional spinner. Except where noted, all body components shall be fabricated using 12‑gauge stainless steel. Stainless steel surfaces shall have a natural or brushed finish.

a. DIMENSIONS:

i. The body interior dimensions shall be as follows:

1. Hopper Opening Length: 120 inches, minimum to allow loader bucket to dump material into the hopper without spillage.

2. Sidewall Length/Height: The sidewall length and height shall be of adequate size to provide a minimum granular capacity of not less than 3.0 CY, but no more than 3.5 CY.

ii. The body exterior dimensions shall be as follows:

1. Width: Shall not exceed 96 inches.

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b. CONSTRUCTION: The body shall be a complete electrically welded assembly and shall be absent of any holes, voids, etc., which would allow the body to leak. The unit shall be continuously welded. All sharp edges shall be deburred. Lifting eyes, loops, or similar shall be stainless steel, supplied for hoisting the body from overhead; one at each corner of the body. All hardware shall be stainless steel.

c. FLOOR/AUGER CONVEYOR: The auger trough shall be fabricated from a minimum of 12-gauge, stainless steel. The auger system shall consist of a minimum dual counter rotating 7-inch diameter variable pitch auger conveyor system or a single auger with an ice clump sifting system. The auger pulse sensor shall be required with a minimum of 100 pulses/per revolution.

d. SIDEWALLS: The sidewall sections shall be constructed from not less than 12-gauge stainless steel. The hopper shall be supported as necessary for intended use. Supports shall be skip welded to allow hopper flex and reduce opportunity for cracking. The sidewalls shall be continuously welded. The tops of the sidewalls shall be designed to shed spilled material and not allow material build-up. The exterior surfaces of the sidewalls shall be protected during fabrication and assembly such that the surface presents an acceptable appearance upon completion.

e. REAR OF BODY: The rear of the body shall have a stainless steel enclosure(s) to house all the anti-icing/pre-wetting/hydraulic components. The rear enclosure(s)/cabinet(s) shall be weatherproof and shall be reinforced as required.

All holes in cabinets shall be plugged. Rear cabinet door(s) seal shall be continuous with only one union joint.

f. LADDER: A stainless steel ladder designed to hold a minimum of 350 pounds, shall be permanently mounted on the passenger side to access hopper. Ladder shall meet ISO 2867 Seventh Edition for design. Reference drawing(s) 067945 for ladder location detail. Final locations to be determined at post award meeting.

g. TOP GRATE SCREENS: There shall be integrated heavy duty stainless-steel grate screen with anti-seize hinges and a safety lockout mechanism.

h. LEG SYSTEM: The sander body shall come with a complete integrated demounting stainless-steel leg system, as referenced, and built per drawings. Any alternative design will require prior written approval by Caltrans specification engineer.

i. LIQUID RESERVOIR: Reservoirs shall be a minimum 12-gauge stainless steel or heavy-duty low-density polyethylene mounted on the body with a tube under the spreader body to allow liquid to flow between tanks, if applicable to allow for single side fill and self-leveling. Reservoirs shall be mechanically secured to body. The mounting mechanism and tie down for the water tank shall be specifically designed to support a full tank under severe operating conditions without the tank sliding or rotating whether tank is empty or full. Tanks shall have stops at rear of tanks to

Attachment 2a - Page 4 of 10 prevent rearward sliding. All seams shall be continuously welded and tested for leaks. Appropriate hose and clamps shall be used for intended use. No nylon or ratchet straps shall be used to secure reservoir to body. A maximum fill label shall be required on tanks. Final location will be determined at post-award meeting.

Tie downs shall be stainless steel bands with rubber liner with a minimum thickness of 1/8-inch. Tie downs shall be used between tank(s) and hold down straps also between tank(s) and body.

Shut-off valves shall be corrosion resistant. The reservoir(s) capacity shall be a minimum of 200 gallons. An analog float switch shall be integrated to reservoir(s) to indicate liquid capacity and low-level alert. The analog float switch will need to operate within a voltage range of 0.0 – 5.0 Volts Direct Current (VDC).

3. SPINNER CHUTE ASSEMBLY: The spinner chute shall be 12-gauge stainless steel.

The unit shall be equipped with an adjustable (width & direction) spreader spinner system. The system shall be electronically controlled by the operator with the following functions: 1 lane left, center, 1 lane right or 2 lanes center + left/right or 3 lanes at one time. The spinner shall have a minimum of four (4) position telescopic adjustments and a tilt-up spinner bypass chute. A focus chute shall mount to the spinner disc assembly.

The direct cast spinner disc shall be driven by a motor with an integral sensor capable of providing spinner feedback to the cab controller. The hydraulic cylinder controlling the direction of the spinner cast shall be powered by downstream oil from spinner motor. Sensor shall provide a feedback response of no less than 50 pulses per revolution. A manually adjustable flow control regulator shall be part of the directional spinner circuit to provide full functional control. When a spinner with directional casting features is used, the analog input shall operate within the range of 0.0 – 5.0 VDC.

4. ANTI-ICE SYSTEM: The system shall have the capability of spraying liquid directly to the road surface and shall consist of a pumping system with inline high-volume flow metering. Flowmeter shall provide accurate liquid flow information to the hydraulic control system for precise control and monitoring. Minimum desired pulse count for an anti-ice flow meter should not be less than 150 pulses per gallon. The pump shall be sized for a 3-lane spreading application. Independent controls shall be provided for 1, 2, or 3-lane applications. Anti-Ice check valves and flowmeters shall be mechanically supported on the anti-ice boom as necessary.

5. PRE-WETTING SYSTEM: The system shall consist of a fully functional nozzle assembly, including pre-wet flow sensor. Minimum desired pulse count for pre-wet flow meter should not be less than 3,000 pulses per gallon.

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6. ROLL-OFF LIFT FRAME: A complete roll-off lift frame shall be built and supplied in accordance with Caltrans Drawings listed on page one (above) of this technical specification. Any interference issues shall be brought up to Caltrans specification engineering prior to production to finalize design or at post award meeting.

7. HYDRAULICS: Body shall be upfitted with a complete set of hydraulic hoses with appropriately sized couplings as outlined in drawing 035714. During first unit inspection, lengths will be test fit and verified for appropriate fit. The first unit will be supplied with hoses that are estimated to be correct, but not crimped. Caltrans specification engineering will verify fit and cut length if required. If changes are required, they will be documented and agreed upon for the remainder of the units.

Quick connect couplers shall be Parker FEM/FEC Series Couplers with Chromium (VI) free plating for improved corrosion resistance.

8. ELECTRICAL: Electrical equipment shall comply with all Federal Motor Vehicle Safety Standards (FMVSS) and State of California Department of Motor Vehicle (DMV) regulations. The lamp component layout for the rear combination tail, stop, and directional signal lamps along with the three (3) light cluster (Reference CFR 571.108 Identification Lamps) mounted at top rear center of body are referenced in drawing P3- 000019-XX. A wiring cable shall be included to wire directly to rear of chassis, as shown in drawing P3-000042-XX, and wired using a seven-wire Society of Automotive Engineers (SAE) standard trailer light plug with wires pinned per drawing CH-0043.

The body shall have a storage socket for the light plug while the plug is not in use. The cable covering shall meet or exceed SAE J1128 cable standard requirements. Final wire length and plug storage socket location can be determined at pilot sander body testing.

a. For all pigtail harness connections for the safety lights requirement, the loose-wire end of the pigtails shall be terminated with an Aptiv (formerly Delphi) Metri-pack 280 connector. All pigtail lengths shall be a minimum of 6 inches.

b. All valves, solenoids, flow meters and sensors to be terminated per drawing P3-

00006 and pinned to connector. This control cable shall be made in two-sections.

Main control cable from front of body control box to rear of body. The second section will be from the front of the body control box to the cab interface. Reference drawing P3-000030.

c. Pigtail Storage Box: A body control pigtail storage box shall be installed at the front passenger side of the body, either on the body or the skid frame per reference Drawing 030490. The wording for the lower label on the box will be determined at post-award meeting or pilot body testing.

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9. LIGHTS: All lights shall be L.E.D. type.

a. REVERSE LIGHTS

i. All lights shall have a black rubber grommet between lamp and mount/body.

ii. Shall be one (1) of the following item numbers:

1. Federal Signal

a. 607125-05SB

2. Maxxima

a. M63347

b. M63324

3. Grote

a. 62601 (horizontal mount)

b. 62591 (vertical mount)

b. MARKER LIGHTS

i. Additional marker lights are required for the side of the body (rear lower corner on the side of the body), and upper rear corner marker lights (for the upper left and right side of the rear of the body).

ii. All lights shall have a black rubber grommet between lamp and mount/body.

iii. Shall be one (1) of the following item numbers:

1. Truck Lite

a. 10275R

b. 30275R

c. 10375R

d. 30375R

2. Grote

a. 46132

b. 47112

c. REAR FLASHING WARNING LIGHTS

i. Rear flashing lights shall be installed on the rear of the body.

1. Shall be positioned such that two (2) total (one (1) per each upper corner) are positioned on the upper portion of the body.

ii. Flashing light shall be California Title 13 Compliant.

iii. Shall be one (1) of the following item numbers:

1. ECCO

a. 3510A

b. ED3706A

2. Federal Signal

a. MPS600U-AA

3. Maxxima

a. M20386YCL

4. Code 3

a. XT4DS-A https://www.grote.com/products/62591-supernova-clear-grommet-mount/

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d. REAR WORK LIGHT

i. Positioned over the rear spreader area, on the driver’s side of the body; to illuminate the driver-side spinner material distribution.

ii. Shall be one (1) of the following item numbers:

1. ECCO

a. EW2491

b. E92004

c. EW2110

d. E92005

2. J.W. Speaker

a. 770 XD

3. Hella

a. 006991663

e. UPPER REAR I.C.C. CLEARANCE LAMP ASSEMBLY

i. Shall be positioned on the upper rear portion of the body.

ii. Lamp assembly shall be of the following:

1. Use either quantity three (3) of the required marker lamps (as described in the specification) for upper rear I.C.C. lamp requirements.

2. Or, use one (1) of the following light bars for the I.C.C. lamp requirement:

a. Truck-Lite

i. 15050R

ii. 35740R

iii. 35741R

b. Grote

i. 49182

c. Maxxima

i. M20343R

ii. M20323R

10. MISCELLANEOUS:

a. The successful bidder shall supply a dimensional drawing to the Caltrans Specification Engineer for approval prior to beginning fabrication or at post award meeting, along with a 3D model of body to verify clearances.

b. The Contractor shall obtain the State's written consent for any modifications or alterations in the design or materials used in the construction of the unit which vary from the drawings or specifications at the post award meeting.

c. All loose parts and components shall be boxed or palletized, labeled, and supplied with each individual body. All electrical components & controller (if optioned to include) shall be in water-tight packaging.

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d. No body or components shall interfere with any moving or stationary components of the truck on which it will be installed. The directional cast body shall clear the fenders on the truck.

e. All cylinder ports (air and hydraulic) shall be supplied with threaded plugs with O-rings or “O” ring seal sealant installed in the ports.

f. All hose clamps shall be properly sized for intended use and properly tightened.

11. WEIGHT BALANCE: The spreader body shall be designed such that the weight distribution and center of gravity conform to the chassis parameters as outlined in drawing 024040. The body in no way shall overload the axles when fully loaded to its stated maximum liquid and granular capacity.

The Bidder shall supply a drawing of the proposed body with dimensions, weight distribution, and center of gravity.

12. DELINEATION STRIPING: All striping shall be installed on each body using drawings 067792 and 050912 as reference. Contractor is responsible for supplying reflective red/fluorescent lime chevron and fluorescent orange stripe on sides of body. See bill of materials for chevron reflective striping manufacturer and part number information.

Orange reflective striping shall be 3M 3924S, Nikkalite 92847, or equivalent. All stickers, labels, and striping shall be applied using dry application. All stickers, labels, and striping shall be level, straight, bubble free, and debris free. No splicing of tape or striping shall be acceptable. All edges on striping shall be trimmed 1/8-inch from the edges of doors, panels, fenders, lights, emblems etc. Any reflective type of stripe or sticker may not be pulled from the vehicle and reapplied during application since the reflective material will be compromised. Final determination of some labels or striping can be determined at post-award meeting or at pilot sander body testing.

13. WELDING: All welding shall comply with the requirements as represented in American Welding Society (AWS), D14.3-82, and American National Standard entitled "Specification for Welding Earthmoving, Construction, Agricultural, and Ground-Based Material Handling Equipment"

All welds shall be continuous except as noted. Intermittent or spot welds shall be spaced and proportioned to provide ample strength for the material being welded.

Weld sizes not indicated shall be equal to the thickness of the least of the joined plates.

All welds shall be properly fused, displaying proper penetration and a professional finish, and shall meet the qualification requirements of applicable AWS specifications.

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Examples of unacceptable weldments are:

• Cracks

• Excessive Splatter

• Undercut

• Blow Holes

• Overlap

• Slag Entrapment

Any weld failing to comply with the AWS specification or failing to pass a quality assurance inspection performed by Caltrans Quality Assurance, will be corrected by the manufacturer, at their expense, and be corrected off State property. The State shall determine if a weld is acceptable or deficient.

Any deficient weld shall be corrected by a welder who is certified in accordance with the requirements as established by the AWS. The welder shall have the proper certification documents indicating that he/she is qualified to perform the type, size, and position of the weld performed, with the welding process utilized, and on the material being welded. The Contractor will be required to supply proof of current welding certifications for personnel performing any re-welding on the unit, upon request of the State whether written or verbal.

GRINDING OF WELDS shall have prior approval of the Caltrans, Division of Equipment, Engineering Specifications. Welds which have been ground without approval shall be subject to complete re-welding upon request, at no additional cost to the State.

When drawings are supplied, the assembly dimensions and tolerances shall apply after welding. Excessive warpage of assembled parts is not acceptable. Weld symbols on supplied drawings shall be interpreted per American National Standard Welding Symbols. In the event of the lack of a weld symbol, the best commercial practice shall prevail. The covering of welds with body fillers or similar materials is unacceptable.

14. MATERIAL: Construction shall be of all new material free of rust and any defects. All components in the assembly shall be fabricated from a single piece of material.

Material which is joined by welding or other means to form a single piece of stock is not acceptable. The finished product shall be free of dents and warpage. The use of any type of body filler is unacceptable. All bolts shall be Grade 5 or better and conform to SAE and American Society for Testing and Materials (ASTM) standards. Bolt lengths shall be such that a minimum of two threads shall extend beyond the nut. Nuts shall be the locking type. Nuts and washers shall be compatible with the bolt(s) to which they are attached, as recommended by the fastener manufacturer and in accordance with SAE and ASTM standards. If requested, the Contractor shall submit proof of fastener strengths.

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15. METAL SHAPING: All breaks shall be free of cracks. Radii shall be at least twice the thickness of the material or in accordance with the requirements established by ASTM for the particular material being formed, whichever is greater. All holes shall be round, of the proper dimension, perpendicular to the material they are produced in, and finished smooth. Oblong holes or holes drilled, bored, etc. at angles are not acceptable.

Holes and slots shall be drilled, punched, saw cut, plasma cut, or milled; torch cut is unacceptable. Sharp corners on all material shall be radiused to prevent personnel injury.

16. FABRICATION: The body shall be fabricated in such a manner (ie – using tooling, fixtures, jigs, etc.) that all critical dimensions are uniform and consistent from one unit to another. The body shall be manufactured so that they are interchangeable from one chassis to another.

The State reserves the right, prior to award of the contract, to inspect a potential Contractor’s manufacturing facility to ensure the manufacturer is a “responsible contractor.” Such an inspection would include, but not be limited to; scheduling, production capability, manufacturing procedures and processes, documentation, etc.

17. PAINT: The basic unit, the primary finish surfaces of any optional equipment, and other minor or incidental component parts shall be finish painted with standard factory color(s). The finish coat shall be free from runs, drips, sags, etc., and shall be evenly applied to provide a gloss finish. The finish or topcoat shall be compatible for re-coat or touch-up with lead-free DuPont Imron 5000, polyurethane enamel; or, Sherwin Williams Genesis, equivalent color. All paint and primer shall be lead-free (300 PPM

LEAD MAX).

18. EXCEPTION: Primer or paint shall not be applied to any stainless steel, fiberglass, or poly tank surfaces.