B.01.01.01 - Harlan Cutter Head Suction Dredge SOW 2025 0714.pdf

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SECTION 01 12 00

Specifications for One Cutter Suction Head Dredge– Harlan County Reservoir

DESCRIPTION OF WORK AND GENERAL REQUIREMENTS

1. GENERAL

1.1 Existing

The U.S. Army Corps of Engineers (USACE) Harlan County Reservoir has issued this solicitation to acquire a new, non-propelled, cutter suction head dredge.

1.2 Project Description and Location

1.2.1 Description of work

The contractor is responsible for supplying, delivering, providing training, and testing a fully functioning cutter suction head dredge. When complete, the new cutter suction head dredge will operate out of Harlan County Reservoir, Republican City, Nebraska to maintain silt levels.

1.2.2 Bidding

The contract will be awarded based on a best-value assessment, which includes evaluation of price, delivery lead time, and the quality of the proposed system design. Contractors shall include cut sheets for all major components and detailed vessel drawings with their bid. Any proposed variances from the product specifications must be submitted in writing at least seven

(7) calendar days prior to the bid submission deadline for review and potential approval.

1.2.3 CLIN Structure One Cutter Suction Head Dredge

Base:

CLIN0001 Build, Deliver, and Test (1) Cutter Suction Head Dredge

Optional:

CLIN0002 Consumable Spare Parts CLIN0003 Equipment Spare Parts CLIN0004 Discharge Pipe (40 Foot Section)

CLIN0005 Transportation Beam Trailer CLIN0006 Transportation Hydraulic Trailer CLIN0007 Crane Rental for Unloading Dredge CLIN0008 Floats for Discharge Pipe

1.2.4 Project Location

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The work is located at the United States Army Corps of Engineers (USACE) project office at Harlan County Reservoir. The project office is located 1-mile south of Republican City, Nebraska.

Harlan County Project Office U.S. Army Corps of Engineers 70788 Corp Rd A Republican City, NE 68971

1.2.5 Points of Contact

Tom Zikmund Harlan County Operations Project Manager Thomas.J.Zikmund@usace.army.mil 816-389-3496

Matt Dubbs Contracting Officer Representative James.M.Dubbs@usace.army.mil 816-389-2182

1.6 Plans and Documentation

1.6.4 As-Built Drawings

Operations & Maintenance Manual – two (2) printed and professionally bound sets of manuals in English that describe the full operation of all features, systems, maintenance, common repairs, and equipment on the dredge. The manuals shall also detail the frequency and specifications for maintaining and lubricating the equipment. An electronic copy of the manual set shall also be provided to the Government that is allowed to be duplicated for internal use only.

As-Built Drawings – two (2) printed sets of as-built drawings with a complete bill of materials.

Electronic copies of the drawings shall also be provided to the Government.

At a minimum, as-built drawings shall include:

a. Dredge General Arrangement

b. Boom Detail

c. Cutter Head Detail

d. Cutter Drive Detail

e. Machinery Shop Drawings

f. Hydraulic Component Detail

g. Typical Structural Assembly

h. Lever Room Layout and System Schematics

i. Electrical One-line Diagram

j. Hydraulic Schematic

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k. Waterline Schematic

l. Cabling Layout

m. Auxiliary Component Details and Schematics

Part Lists – two (2) printed copies of the parts lists available from the contractor. An electronic copy of the list shall also be provided to the Government.

The Government will only use these drawings and deliverables to confirm the contract specifications. The Government will respect all proprietary information rights and not be the owner of the dredge design or any of the component designs.

1.6.5 Contractor Experience and Qualifications:

A statement letter of the Contractor’s experience on company letterhead.

The manufacturer shall have a minimum of five (5) years of experience with the fabrication of cutter head suction dredges and must have demonstrated competency and experience to perform the scope of work contained in this contract.

1.6.6 Production Schedule

Prior to any work being completed the Contractor shall submit a production schedule for approval. The project schedule shall contain a chronological order of major milestones such as, hull welding, paint, or any other events that would require quality assurance checks. Each activity shall have a duration with a proposed start and end date.

1.6.7 Accident Prevention Plan

Contractor shall prepare a site-specific Accident Prevention Plan (APP) for final acceptance testing of the dredge while on-site at Harlan County Lake. Prepare the APP in accordance with the format and requirements of USACE EM 385-1-1. Cover all paragraph and subparagraph elements in USACE EM 385-1-1, Appendix A, "Minimum Basic Outline for Accident Prevention Plan".

1.7 Submittals

The Contractor shall provide to the Government the submittals identified within this contract and submittals that are identified as necessary to ensure performance compliance. Once submittals are received the government has ten (10) working days for review and acceptance. All submittals except Test Plan and Closeout are required prior to fabrication commencing.

The Government will respond to the Contractor’s submittals with email, fax, or postal mail per the Contractor’s requested preference to the Government. The Government’s approval of submittals shall not be construed as a complete check of the contract requirements. Government approval will be an indication of a satisfactory submittal of the general method of compliance

01 12 00 - 4 with the requirements of the contract. Government approval will not relieve the Contractor of the responsibility for contract compliance.

Government disapproved submittals shall be resubmitted by the Contractor addressing corrections and contract compliance. At the discretion of the Government, the Contractor may be directed by the Government to proceed with work in advance the submittals; however, the Contractor shall practice due diligence and continuity with the submittal process. Each submittal shall be attached to a USACE provided form 4025 and emailed to the primary contact contained in Section 1.4. One copy of each submittal shall be provided as follows:

1.7.1 Prefabrication Submittals

1.7.1.1 Project Schedule

1.7.1.2 Accident Prevention Plan (Pre-onsite)

1.7.1.3 Insurance

1.7.1.4 Weight and Center of Gravity Estimate, and Stability Calculations

1.7.1.5 Lifting and Rigging Plans for the dredge, boom, and spuds

1.7.1.6 Winch and Hoist Arrangements (swing, spud and boom).

1.7.2 Product Submittals

1.7.2.1 General Arrangement and Control/Level House Plans

1.7.2.2 Main Engine Curve Characteristics

1.7.2.3 Dredge Pump Curve Characteristics

1.7.2.4 Dredge Paint Schedule

1.7.2.5 Wire Rope certifications

1.7.2.6 Discharge Pipe Fittings

1.7.2.7 Discharge Pipe Paint System

1.7.2.8 Fuel-Compatible Corrosion Inhibitor

1.7.2.9 Structural Material Certificates

1.7.2.10 Paint Coating System Specifications

1.7.2.11 Stern Jib Crane

1.7.2.12 Hull Anode Size and Location

1.7.2.13 Swing Winch Wire Rope Specifications

1.7.2.14 Discharge Pipe Material

1.7.2.15 Discharge Pipe Floats Design

1.7.3 Certificates

1.7.3.1 Contractor’s Qualifications

1.7.3.2 Painter’s Certification

1.7.4 Design Data

1.7.4.1 Hull Structure scantling plans with weld details (PE Stamped)

1.7.4.2 Provide ABS structural calculations if available (PE Stamped)

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1.7.5 Testing

1.7.5.1 Test Plan

1.7.5.2 Deadweight Report

1.7.5.3 As-Built Stability Reports

1.7.5.4 Test Reports

1.7.6 Closeout Submittals

1.7.6.1 Final As-Built Drawings

1.7.6.2 Warranty Information

1.7.6.3 Product Owner’s Manuals

1.7.6.4 Parts List

1.7.6.5 Machinery BOM

1.7.7 All submittals (one copy of each) shall be sent electronically or hard copy to the following:

Matt Dubbs Contracting Officer Representative James.M.Dubbs@usace.army.mil 70788 Corps Rd A Republican City Ne 68971 816-389-2182

1.8 Safety Requirements

U.S. ARMY CORPS OF ENGINEERS SAFETY AND HEALTH REQUIREMENTS

MANUAL, EM 385-1-1 (2024)

EM 385-1-1 and its changes are available at http://www.hq.usace.army.mil (at the HQ homepage, select Safety and Occupational Health). Select the appropriate manual. The Contractor shall be responsible for complying with the current edition and all changes posted on the web as of the effective date of this solicitation.

2024 Version:

https://www.publications.usace.army.mil/Portals/76/EM%20385-1- 1%20_EFFECTIVE%2015March2024.pdf

1.9 Security:

1.9.1 The Contractor shall not be on site without prior notification to the Corps of Engineers COR or otherwise designated person(s).

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1.9.2 Contractor personnel shall have valid civilian ID's and Contractor vehicles shall have a valid registration.

1.10 Applicable Publications

The publications referenced herein shall be the most recent at the time of solicitation.

1.11 Quality Control

Workmanship shall be of the highest grade in accordance with the best modern practices to conform to the specifications for the work being performed. The Contractor shall be responsible for quality control to ensure all components and workmanship meet requirements of this contract. Representatives of USACE reserves the right to inspect and witness the work, verify quality of workmanship and products used at any time, whether the work is performed in the field or at the Contractor’s shop.

1.13 Warranty

The dredge and all equipment installed, and components shall be provided with a standard commercial warranty by the contractor to be administered by the Government. The warranty shall be for a minimum period of twelve (12) months from the date of final acceptance at the destination site. All component-manufacturer warranties that extend beyond the minimum 12-month requirement shall remain in force for their full stated term.

2. PRODUCTS

2.1 Vessel Performance Characteristics

The vessel shall be able to dredge to a depth of at least 20 feet in sediment and rock less than 6-inches spherical.

At the maximum dredging depth, the vessel shall be capable of discharging the dredge material through up to 1490 feet 10-inch diameter (920 feet of floating and 570 feet of shore) discharge piping at sea level.

2.2 Vessel Characteristics

The dredge design is intended to be based on a commercially available transportable dredge. The primary characteristics are:

Overall Length: Maximum 60 feet Overall Width: Maximum 15 feet Transportation Height: Maximum 13 feet Dry Transportation Weight: Maximum 30 tons

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The hull shall be equipped with a lifting eye system to lift the dredge hull, and a second lifting eye system to lift the boom. Contractor supplied lifting slings in lieu of lifting eyes for the boom are acceptable. A lifting plan for the hull and for the boom shall be provided by the manufacturer.

The dredge shall be designed as to allow for removal from the water and transported on a flatbed trailer, with spuds removed while maintaining the Maximum 13-foot transportation height. The manufacturer shall provide any specialized supports or blocks required to safely transport the trailer on a flatbed along with placement and loading plans.

2.3 Design and Material Standards

The vessel shall be designed in accordance with the latest edition and interpretations of the rules, regulations, requirements and standards of the applicable regulatory agencies, and technical organizations listed as follows or as stipulated in each respective specification clause:

2.3.1 Hull Structural Design

Design shall comply with American Bureau of Shipping (ABS) Rules for Building and Classing Steel Vessels for Service on Rivers and Intracoastal Waterways.

Submit structural material certifications for approval prior to fabrication. All materials used in hull and boom fabrication shall be ASTM A36 steel or stronger.

The vessel design shall demonstrate compliance with intact and damage stability requirements under all of the following requirements:

2.3.2 Intact Stability

Design shall comply with 46 CFR 170.170 and 46 CFR 170.173 for vessels operating on protected routes.

2.3.3 Damage Stability

The vessel shall remain upright with any one compartment flooded, maintain a minimum metacentric height (GM) of 3 inches, and keep the deck edge above the equilibrium waterline.

2.3.4 Pontoon Design

Construct the pontoons from 3/16-inch (minimum) thick ASTM A36 or stronger with material certification submitted for approval. The pontoons shall house the double wall fuel tanks.

2.3.5 Cathodic Protection

The hull shall be equipped with magnesium alloy sacrificial anodes to provide cathodic protection in freshwater service. Anodes shall conform to DoD-A-24779(SH) or ASTM B843, as

01 12 00 - 8 appropriate for hull-mounted applications. The passive protection system shall be designed to ensure adequate cathodic protection for the vessel's intended service life. Anodes shall be of the bolt-on type with a partial plastisol coating to control exposure and direct current flow.

2.3.6 Hatches and Doors

All doors and hatches shall comply with 46 CFR 174.100(b) and 46 CFR 179.360(d)(2) for weatherproofing and hose‑tested to 0.15 bar for 3 min with no visible leakage. All doorways shall have a 3 in welded coaming in accordance with 46 CFR 179.360(d)(2)

2.4 Dredge Pump

The dredge pump shall be sized to meet the performance requirements listed in Section 2.1. The suction side shall be 12-inch diameter, and the discharge side shall be 10-inch diameter. The impeller shall come equipped with a 3-vane impeller capable of passing 6-inch (minimum) spherical abrasive material and slurry. Cleanout(s) access shall be provided for the pump and impeller.

The pump performance at a minimum shall be 3,000 GPM at 65% efficiency at 230 feet of head.

The impeller shall be attached in such a manner as to allow removal through the suction-side head. A lifting hook shall be provided for removing the impeller.

The discharge piping shall have a 10‑inch, Class 150 flange (ASME B16.5) of ASTM A105 carbon‑steel. Full‑penetration welded to the pump discharge to AWS D1.1 with 100 % MT/PT.

Provide one 10‑foot-long spool fabricated from matching 10-inch ID × 0.188‑in‑wall ASTM A106 Gr B pipe, or approved equivalent HDPE material, with an identical flange shop‑welded and faced, leaving the opposite end plain‑beveled at 37-1/2 degrees for a rubber‑sleeve/chain coupling. Hydro‑test the spool to 225 psi for 10 min in accordance with ASME B31.3. Blast all exterior surfaces to SSPC‑SP10 and coat per Section 2.21 as needed.

Supply new A193‑B7 studs, A194‑2H heavy‑hex nuts, and a 1/8‑inch reinforced graphite gasket.

Deliver the flange installed on the hull discharge with the spool shipped loose, match‑marked, and end‑capped.

2.4.1 Pump Handling Crane

The dredge shall be equipped with a handling crane for removal and servicing of the pump impeller. The crane shall be sized to safely lift the heaviest pump room assembly without exceeding 75% of its rated load capacity. The crane and hoist shall comply with ASME B30.11 and ASME B30.16, respectively. The hoist shall be a stainless-steel chain type with a B30.16-compliant hook, rated for marine or severe atmospheric conditions. The crane and hoist assembly shall be clearly marked with rated load capacity and applicable ASME compliance markings.

The hoist shall be provided with all necessary rigging equipment required to safely remove the pump impeller, in accordance with ASME B30.9.

2.5 Dredge Boom

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Boom length shall be sufficient for full production dredging at 20-foot water depth (minimum).

The dredge boom shall be removable for transportation and maintenance. A three- or four-point lifting eye system, or sling lift locations, shall be incorporated into the boom to facilitate the removal and installation. The final as-built, dry weight of the boom shall be stenciled on the boom. If a sling lift system is to be used, the contractor shall provide lifting slings/straps rated for the boom weight.

The dredge boom shall be lifted through a hydraulic cylinder system. The hoist system shall be designed to raise the boom from the deepest draft depth, with the pipe filled with dredge material.

2.6 Cutterhead

The dredge shall be equipped with a hydraulic motor-powered spiral cutterhead rated at a minimum of 40 horsepower. The cutterhead shall be removable to allow for repair, maintenance, and replacement. It shall be of spiral configuration with replaceable cutting teeth. The hydraulic drive system shall be designed to provide adequate torque and speed control, and shall include provisions for pressure relief, filtration, and maintenance access. All components shall be suitable for continuous operation in a harsh marine environment.

2.7 Spuds & Spud Hoists

Two 12-inch diameter minimum spuds shall be provided. The length of the spuds shall be adequate to allow dredging to the maximum depth. The spuds shall be raised and lowered with a hydraulic or mechanical drive. The spuds shall allow for free sliding to accommodate changing water elevations while the dredge is not in use.

The spuds shall be capable of being stowed or detached so that the dredge can be removed from the water for transportation without disassembly.

Each spud shall have a hoist point/padeye at the top of the spud for removal. The final as-built weight of each spud shall be welded on the spud prior to paint.

2.8 Swing Winches

Two fixed displacement hydraulic motor swing winches shall be provided to facilitate the dredging operations. The winches and wire rope shall be sized to swing the dredge in the cut under the maximum dredge production conditions. Each winch shall be provided with at least 200-feet of 1/2-inch (minimum) wire rope suitable for immersion service. The winch drum shall be capable of holding the entire length of wire rope.

2.9 Anchors

Swing anchors will be provided if required for normal operation of the dredge.

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2.10 Engine

One main diesel engine with US EPA Marine Tier 3 (minimum) Final emissions rated, shall be provided to power the dredge pump and hydraulics system. The engine shall have a Mechanical Electronic Unit Injector (MEUI) fuel system for worker safety. The engine shall be rated at a minimum of 400 hp continuous at 2,000 RPM or higher, under SAE J1995 conditions. The engine shall be liquid radiator cooled, with turbocharged aspiration, and battery start.

The engine shall drive the pump through a gear box with multi-plate clutch. The engine shall be equipped with a 100-amp (minimum) alternator to supply the 24 Volt D.C. battery system.

2.11 Hydraulics

The hydraulic system and reservoir shall be sized to support the full operation of the swing winches, boom hoist system, spud hoist systems and cutterhead simultaneously. Variable or fixed displacement pumps are acceptable. The system shall have 10-micron return line filtration and a magnetic 75 mesh suction strainer to protect the pumps from contaminates or better. The reservoir shall have a volume of 2–3 times the pump flow rate, measured in gallons per minute (GPM). The reservoir shall be equipped with adjustable heaters capable of maintaining 70°F at 0°F ambient environment. US EPA Environmentally Acceptable Lubricants (EALs) should be used throughout the hydraulic system if compatible without significantly degraded performance.

2.12 Fuel System

A fuel tank shall be provided, sized for a minimum of 750-gallons total. Dual particle fuel filters and a fuel water separator filter shall be installed on the supply line to the main engine.

2.13 Bilge System

Bilge alarms shall be provided for the main dredge pump room, engine room, and pontoons.

A minimum of two fixed bilge pumps shall be provided for the main engine room and pump room compartments.

For all other watertight compartments, an access through a watertight manhole in the main deck shall be provided to allow a pump 4-inch suction hose with strainer to be lowered into the space for dewatering. Please note that an emergency bilge pump and hose are not required to be provided by the contractor. The 4-inch hose size is for clearance/access into each compartment.

2.14 Service Water Pump

A variable centrifugal freshwater service pump shall be provided to supply flushing water to the dredge pump packing gland. The pump shall be sized to provide adequate cooling for continuous operation and come equipped with a removable strainer.

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2.15 Control/Lever House

A single-operator control house shall be provided, made from welded steel, watertight, and equipped with tempered glass windows offering 360-degree visibility. The control house shall be equipped with weathertight doors and windows in accordance with 46 CFR 174.100(b) and 46 CFR 179.360(d)(2). All windows shall be tinted and fitted with pull-down sunshades. An operator’s chair, with 360-degree rotation to facilitate 360-degree visibility and adjustable height, shall be installed. The floor shall be rubberized, slip-resistant, and sealed to prevent water intrusion into the subfloor.

The control console shall include all necessary levers, gauges, and controls for full operation and monitoring of the dredge. All controls and indicators shall be illuminated for low-light operation.

At a minimum, the following shall be provided:

a. Emergency shutoffs

b. Dredge pump vacuum gauge

c. Dredge pump discharge gauge

d. Cutter hydraulic pressure gauge

e. Swing hydraulic pressure gauge

f. Hydraulic filter indicator

g. Service water pressure gauge

h. Engine tachometer

i. Engine oil pressure gauge with alarm light

j. Engine water temperature gauge with alarm light

k. Engine throttle control

l. Engine diagnostic codes

m. Engine hours

n. Coolant temperature

o. Fuel level

p. System voltage

q. Instrument light switch with dimmer

r. Cutter forward/reverse speed control

s. Port swing forward/reverse speed control

t. Starboard swing forward/reverse speed control

u. Port spud raise/lower/freefall control

v. Starboard spud raise/lower/freefall control

w. Boom depth gauge (sliding board type in view of operator)

x. Dredge discharge pipe flow meter

y. Swing winch controls with dynamic braking

z. Boom raise/lower control

aa. Spud raise/lower control

bb. Dredge pump throttle control

2.15.1 HVAC System

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A roof-mounted combination air conditioning and heating unit shall be provided and installed.

The unit's compressor and the air circulation fans shall operate on the vessel’s 12-volt DC electrical system.

The unit shall be sized to maintain an interior temperature not exceeding 78°F in cooling mode and not less than 72°F in heating mode, for ambient temperatures ranging from 0°F to 100°F.

2.15.2 Communication Equipment

One marine band VHF radio with 2-way communication and all associated components shall be supplied and installed.

2.15.3 Insulation

The control/lever house shall be insulated for temperature and sound control. The target noise level inside the control room is less than 80-dB during normal operations.

2.16 Locks

All exterior doors and/or equipment enclosures shall be provided with locks. All exterior doors shall have a common lock and key. All equipment enclosures shall have a common lock and key.

2.17 Deck Fittings & Deck Equipment

A system of kevels shall be provided around the perimeter of the dredge to allow the vessel to be safely moored. A minimum of two (2) per side shall be provided. Backup structure (underdeck reinforcement with flat bar, angles, headers, etc.) in way of the deck fittings shall be provided.

A jib crane/davit shall be provided on the stern to facilitate the handling of the dredge discharge pipe for connecting/disconnecting to the dredge discharge outlet. The safe working load (SWL) of the jib crane/davit shall be welded on the equipment.

A means of handling (removing and installing) the dredge pump components shall be provided either through removable enclosure/hatch coverings to allow shore mounted equipment access, or a deck mounted pump service crane/jib.

2.18 Handrails

An industry standard, three tier, solid handrail system shall be provided around the perimeter of the vessel. The system shall either be removable or collapsible with swing gates at the exit points. The top of the handrails shall be between 39-inches and 45-inches above the deck with a midrail positioned at approximately mid-way and a 3.5-inch (minimum) toe kick.

2.19 Navigation & Safety Equipment

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All dredge equipment—including alarms, signaling devices, engine emissions systems, GFCI receptacles, electrical circuits, fuel systems, and emergency shutoffs—shall comply with EM 385-1-1, Chapter 19-8.c Floating Plant and Marine Activities. At a minimum, the vessel shall be equipped with the following:

Navigation light mast with required day shapes Four (4) 24-inch life rings, each equipped with an automatic strobe water light Two (2) 10-lb ABC-type fire extinguishers (USCG-approved) with mounting brackets Machinery guards installed over all rotating equipment, belts, and shafts Fenders Potable water according to 40 CFR 141 Emergency stops/shutoffs Explosion proof lights in locations where explosion hazards exist CO monitors in the engine room Doors must be capable of being opened from either side Indicated fuel and oil tanks with contrasting lettering

2.20 Electrical & Lighting System

The dredge shall be provided with a full 12-volt DC electrical system to provide power for lighting, equipment, controls, and monitoring. The batteries shall be charged through an alternator on the main engine. The electrical system shall be grounded in accordance with American Boat and Yacht Council (ABYC) standards.

All lights shall be LED. Exterior flood lights shall be provided to illuminate 360 degrees around the vessel . Provide normal work lighting capable of ≥ 10 foot‑candles at the deck in the lever room, pump room, and engine enclosure, with ≥ 5 foot‑candles on walkways and exits, verified by light‑meter readings in accordance with EM 385‑1‑1 and 29 CFR 1915.82. Equip each enclosure with automatically‑activated, battery‑powered emergency luminaires listed to UL 924 and meeting 46 CFR 112.39 for a minimum 3‑hour duration, arranged so that the failure of any single fixture will not reduce egress lighting below 5 foot-candles.

All enclosures within the control house shall be NEMA 4 or better. All exterior enclosures shall be NEMA 4x or better.

2.21 Paint System

All interior spaces (including voids and behind control/lever house finishings) shall be surface prepped to SSPC-SP 10 and coated with a minimum of 10 mils DFT of the manufacturer’s standard, high-solids, marine grade, epoxy coating system or approved equal.

All exterior surfaces (including spuds, boom, handrails, cranes, etc.) shall be surface prepped to SSPC-SP 10 and coated with a minimum of 10 mils DFT of the manufacturer’s standard, high-solids, marine grade, epoxy coating system or approved equal.

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Weather‑deck walking surfaces shall receive a MIL‑PRF‑24667 Type I, Composition G non‑skid coating (or equal) broadcast with 16–24 mesh aluminum‑oxide grit to achieve a minimum static coefficient of friction of 0.90 dry / 0.85 wet as demonstrated by the MIL‑PRF‑24667 drag‑sled test. Alternate systems shall show wet COF ≥ 0.60 under ASTM F1166 and not less than OSHA’s 0.50 recommendation.

Galvanized surfaces and factory‑coated components may keep their original finish if the coating is rated for immersion service.

2.21.1 Color

Paint all exterior hull surfaces in SAE AMS‑STD‑595 color 36231, flat finish. Handrails, safety gear, spuds, hoists, and other ancillary items may keep the manufacturer’s standard color. Coat the lever‑room exterior and any heat‑prone areas in white. Leave interior spaces such as the pump room, engine room, and control room in the manufacturer’s standard finish. Remove all contractor branding and logos from the vessel exterior. Factory‑coated equipment—pumps, engines, HVAC units, and similar components—may remain as supplied.

2.21.2 Fuel Tank

The interior of the fuel tank shall not be coated with paint. A fuel-compatible corrosion inhibitor (e.g., volatile corrosion inhibitor or fogging oil) shall be applied to all internal surfaces immediately after fabrication to prevent corrosion. The selected inhibitor shall be submitted for approval prior to application and shall include the manufacturer's product data sheet and application instructions. Prior to fuel loading, the tank shall be thoroughly cleaned or purged in accordance with the approved inhibitor manufacturer’s recommendations to ensure no contamination of the fuel system.

2.21.3 Certifications

Submit qualification records for each coating applicator. All applicators shall be tested and certified in accordance with ASTM D4228 prior to the start of work.

2.22 Jib Crane

The dredge shall be equipped with a 1/2-ton jib crane with a manual chain hoist in accordance with ASME B30.11. The hoist shall comply with ASME B30.16 and consist of a stainless-steel chain and a B30.16-compliant hook, suitable for marine or severe atmospheric conditions. The jib crane and hoist assembly shall be clearly marked with rated load capacity and applicable ASME compliance markings per B30.11 and B30.16 requirements. The mast shall have a minimum height of 6 feet, and the boom shall have a minimum reach of 5 feet. The jib crane shall be mounted on the stern in a location that does not interfere with normal dredging operations, discharge piping, spud removal, or the optional tail winch.

2.23 Consumable Spare Parts

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If awarded, the contractor shall provide a full set of consumable spare parts and filters to include:

Three (3) complete sets of replacement cutterhead teeth Six (6) sets of hydraulic filters One (1) dredge tool package (includes all tools required to perform standard PM’s and servicing) Three (3) flanged flexible 10-inch discharge hose

2.24 Equipment Spare Parts

If awarded, the contractor shall provide the following spare parts and equipment

a. One (1) cutter drive motor

b. One (1) swing winch motor

c. Two (2) engine turbochargers

d. One (1) battery charger

e. One (1) swing anchor

2.25 Discharge Pipe

If awarded, the Contractor shall provide 40-foot section(s) of discharge pipe. All pipes shall be compatible with the existing pipe fittings and field verified by the Contractor prior to ordering. If awarded, the contractor shall provide up to a maximum of 1000 feet of High-Density Polyethylene Pipe (HDPE), or approved equal, dredge pipe in 40-foot sections. The pipe shall be of sufficient strength to support its own weight, both in operation and when dry, without compromising its structural integrity. Final total amount of supplied pipe shall be determined based on pricing after award. The maximum length per section shall be no more than 50 feet.

Couplings or flanges shall be provided for each section along with the required hardware for connection. Removable pipe floats shall be provided to maintain the buoyancy of the pipe while fully loaded with dredge material. Floats shall be arranged to ensure that both ends of the floating pipe are maintained at equal elevation with respect to the waterline under all normal operating conditions. The floats shall be adequately sized so that no more than four (4) floats are required per section. The floating sections will be connected by rubber sleeves. The sleeves will be at least 7-ply and 4-feet in length or approved equal. The clamps to secure the sleeves to the pipeline may be chain, wire, rope, or half-oval band types.

2.26 Transportation Trailer

If awarded, the Contractor shall provide a trailer that can move the completed dredge in full compliance with U.S. DOT requirements. The trailer’s rated payload must be at least 125 percent of the dredge’s final as‑built weight. Fit the trailer with a standard 2‑inch kingpin compatible with a conventional fifth‑wheel tractor. The trailer shall be furnished with all lighting, brakes, and conspicuity markings required by FMCSA 49 CFR 393 and SAE J560 compatible. Price two versions: a conventional flatbed and a self‑loading hydraulic‑deck model.

2.26.1 Standard Trailer

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The trailer shall meet all DOT highway standards. It must include fixed cribbing, supports, and certified tie‑down points aligned with the dredge’s lifting eyes so that a mobile crane can launch or retrieve the vessel safely.

2.26.2 Hydraulic Deck Trailer

The self‑loading option shall use a powered deck that lowers to the water, allowing launch and recovery without a crane. If deck geometry makes winching necessary, include a winch sized for the dredge. Brake and lighting systems must be sealed or specifically rated for brief immersion in accordance with SAE J2681.

2.28 Crane Rental for Unloading

If awarded, the contractor shall furnish a rental crane—sized for the required load and reach— along with a qualified operator to handle dredge unloading at delivery.

3. EXECUTION

3.1 Fabrication, Assembly & Quality Assurance at the Contractor’s Facility

The contractor shall be responsible for the full fabrication and assembly of the dredge at their facility. The Government will inspect the dredge throughout the fabrication process against the contractor’s approved submittals to verify compliance with these specifications.

During the design phase, the contractor shall provide a milestone production schedule to the Government. The schedule shall include at a minimum the hull fabrication and weld-out, major machinery and outfit, and painting milestone events.

It is not the intention of the Government to disrupt the manufacturer’s production process. The Government will perform quality assurance on the vessel while it is going through production.

The Government will coordinate with the contractor on the structural completion, tank tightness testing, paint completion, vessel completion and testing events.

For the structural fabrication and welding of the hull, the contractor shall notify the Government at least 14 calendar days before the scheduled completion date. Following the structural fabrication and welding of the hull completion, a period of no more than 2 business days shall be made available for the Government to perform quality assurance of the work. When requested by the Government, material certifications for the structural plate, internal members and the boom shall be provided. Painting shall not occur until after this period.

At the direction of the Contracting Officer’s Representative, Non-Destructive Testing (NDT) of welded connections, may be ordered to confirm fabrication quality. The NDT will only be requested if the Government has weld quality concerns. The Government will work closely with the contractor to determine the type and quantity of tests to perform. The contractor shall bear the costs of any welding NDT directed.

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The contractor shall perform hull and tank tightness testing in accordance with ABS rules. The contractor shall notify the Government at least 14 days before any scheduled tightness testing. At the discretion of the Government, a quality assurance representative may be onsite to witness the testing. Painting shall not occur on the hull or tanks until their tightness have been tested and verified.

At the completion of the vessel fabrication, outfitting, machinery installation, painting and assembly, the Government will perform quality assurance of the work. The Government shall be notified at least 14 calendar days before the scheduled completion date. A period of no more than 2 business days shall be made available for the Government to perform quality assurance. The areas of quality assurance by the Government will include:

Dimensions: Confirm the as-built hull dimensions, spud length and weight, boom length and weight, transportation dimensions (including height) and air draft dimensions (with and with/out spuds).

Hull & House Tightness: All manholes, hatches, house structure, windows and doors shall be tested with hose water spray for weathertight integrity.

Paint System: verify the interior and exterior of the hull, and all other components are coated in accordance with the contract requirements.

Equipment Installation: Verify all equipment is professionally installed

3.2 Testing

The following tests shall take place at the contractor’s facility:

a. Main Engine: In the presence of an authorized manufacturer’s representative, demonstrate the following:

a. Cold starting (minimum 4 times)

b. Starting and stopping

c. Operation of all emergency stops. Resetting at the local engine panel.

d. All engine controls and instrumentation.

e. Operation of all engine alarms from all control panels. Ensure the proper operation of all alarm test circuits for each main engine.

b. Hydraulic System: In the presence of an authorized manufacturer’s representative, demonstrate the full operation of the hydraulic system, including the function of the equipment attached to the system (swing winches, spud winches/hoist cylinders, cutterhead, etc.) and all monitoring and alarm components. Confirm the system is filled with US EPA EAL fluid. Check the system for leaks.

c. Dredge Pump: Confirm the proper installation and alignment of the dredge pump.

d. Cutterhead: Confirm the operation and rotational speed of the cutterhead. Confirm the teeth are removable.

e. Spuds: Confirm the as-built weight is welded on the spud. Confirm the as-built spud length. Confirm the spuds can travel their full range.

f. Spuds Winches/Hoist Cylinders: Demonstrate the raising and lowering of each spud.

Demonstrate all controls and monitoring gauges for the spud winches/hoists.

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g. Swing Winches & Anchors: Confirm 500 feet of wire rope is provided on each winch.

Demonstrate the ability of the swing winches to haul in and payout wire rope. Confirm the anchors are provided.

h. Fuel System: The contractor shall provide all of the fuel necessary to conduct the tests at the contractor’s facility. Demonstrate the ability of the fuel system to supply and return fuel from the main diesel engine. Demonstrate the duplex filter cleaning operations.

i. Bilge System: Demonstrate the bilge alarm function. Demonstrate the ability of the bilge pump to evacuate water from the engine room.

j. Demonstrate passing 4-inch hose with intake strainer through the manholes in all other compartments.

k. Demonstrate the service water system to provide adequate water to all service points.

l. Doors: Demonstrate all doors open and close freely. Demonstrate the locks on all doors.

m. Jib Crane/Davit: Confirm the jib crane/davit is properly installed, marked and fully functional.

n. Handrails: Confirm the handrail system is installed properly. Demonstrate the removable/collapsible feature of the handrail system.

o. Safety Equipment: confirm all safety equipment is properly installed and marked.

p. Control/Level House: Demonstrate the operation of all controls and gauges. Confirm the heater, air conditioner, and lights.

q. Demonstrate operation of the marine VHF radio.

r. Electrical: Verify the operation of the main engine starting batteries and battery chargers before and after starting the main engines. Demonstrate the operation of all circuit breakers in the DC distribution panels. Confirm the system is properly grounded.

All fuel and fluids required for testing shall be provided by the contractor.

3.3 Transportation & Reassembly

Following testing at the contractor’s facility, the dredge shall be prepped by the contractor for transportation. The contractor shall arrange for over-the-road transportation from the contractor’s facility to the Harlan County Reservoir. The contractor is responsible for all stages of transportation and launching of the dredge.

All ancillary equipment and spare parts as optional items awarded shall be packaged and shipped to the Harlan County maintenance facility located near the Project Office.

The final destination and assembly site is:

Gremlin Park Cove Harlan County Reservoir Republican City, NE 68971 Latitude 40.085267 N, Longitude -99.216662 E

At the final assembly location, crane services will not be provided to support final reassembly and launching of the dredge. The location site is secure, will have adequate storage and staging space, and with access to the waterfront.

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The contractor shall provide all personnel and tools required to reassemble the dredge, launch and final testing. The Government will coordinate with the contractor on the exact date(s) for the reassembly.

During the off-loading of the dredge and components at the final destination site, the Government and contractor will monitor the process and perform a joint full inspection to document the condition found after unloading.

3.4 Final Testing

Following reassembly of the dredge, the Government will confirm the equipment has not been damaged, is successfully reassembled, and the following tests shall be demonstrated again:

a. Main Engine: demonstrate the following:

a. Cold starting (minimum 4 times)

b. Operation of all emergency stops. Resetting at the local engine panel.

c. All engine controls and instrumentation.

d. Operation of all engine alarms from all control panels. Ensure the proper operation of all alarm test circuits for each main engine.

b. Hydraulic System: Demonstrate the full operation of the hydraulic system, including the function of the equipment attached to the system (swing winches, spud winches/hoist cylinders, cutterhead, etc.) and all monitoring and alarm components. Confirm the system is filled with US EPA EAL fluid or approved equal. Check the system for leaks.

c. Dredge Pump: Confirm the proper installation and alignment of the dredge pump.

d. Cutterhead: Confirm the operation and rotational speed of the cutterhead.

e. Spuds Winches/Hoist Cylinders: Demonstrate the raising and lowering of each spud.

Demonstrate all controls and monitoring gauges for the spud winches/hoists.

f. Swing Winches & Anchors: Demonstrate the ability of the swing winches to haul in and payout wire rope.

g. Fuel System: Demonstrate the ability of the fuel system to supply and return fuel from the main diesel engine. Demonstrate the duplex filter cleaning operations.

h. Bilge System: Demonstrate function of the bilge alarm. Demonstrate the ability of the bilge pump to evacuate water from the engine room.

i. Demonstrate the service water system to provide adequate water to all service points.

j. Doors: demonstrate all doors open and close freely. Demonstrate the locks on all doors.

k. Jib Crane/Davit: Confirm the jib crane/davit is properly installed, marked and fully functional.

l. Handrails: Confirm the handrail system is installed properly. Demonstrate the removable/collapsible feature of the handrail system.

m. Safety Equipment: confirm all safety equipment is properly installed and marked.

n. Control/Level House: demonstrate the operation of all controls and gauges. Confirm the heater, air conditioner, and lights.

o. Demonstrate operation of the GPS indicating system, and of the VHF radio.

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p. Electrical: Verify the operation of the main engine starting batteries and battery chargers before and after starting the main engines. Demonstrate the operation of all circuit breakers in the DC distribution panels. Confirm the system is properly grounded.

Following successful reassembly tests, the contractor shall launch the vessel and perform sea trails. The sea trials shall include:

a. Following the launch, with the dredge in a lightship condition, a deadweight survey shall be conducted by the contractor to obtain the vessel’s lightship characteristics. The survey shall be conducted in accordance with the applicable sections of ASTM F1321-14. The results of the deadweight survey shall be used to confirm the vessel stability.

b. Demonstrate the free fall ability of each spud.

c. Confirm the ability of the dredge pump to take suction (water only) and discharge. Check the system for leaks. Demonstrate all controls and monitoring gauges for the dredge pump. Demonstrate the function of the flow meter.

d. Verify the dredge pump performance, pumping water, with a discharge orifice installed at the dredge discharge flange.

e. Set the spuds and demonstrate the ability the ability of the dredge to “swing in the cut”.

f. With the dredge fully operational, the contractor shall demonstrate the dredging capability of the dredge, making cuts as close to the maximum dredging depth as possible, using the swing winches, and discharging the material into the waterway.

All fuel and fluids required for testing shall be provided by the contractor.

A Government furnished assist vessel/tender will be available during the launch and testing to support operations.

3.5 Training

If awarded, following successful testing of the dredge, the contractor shall provide onsite training for up to five students for operation and maintenance of the provided equipment. The training shall be for a minimum period of two (2) working days.

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