Bldg_9320_Overhead_Crane_SOW_v2 Dean.docx

STATEMENT OF WORK (SOW) Comment by DEAN, SEAN CIV USSF SSC SLD 30/SEAL: This is an excellent SOW and perhaps the best I have seen. Well done.

Hoist / Crane Replacement – Building 9320 Vandenberg Space Force Base, CA

1. SCOPE

1.1 Scope

This Statement of Work (SOW) defines the tasks required for the removal of the existing indoor overhead crane system and the furnishing, installation, and commissioning of a new under-running single-girder bridge crane system with two cross-mounted monorail hoists in Building 9320 at Vandenberg Space Force Base (VSFB), California.

The work includes engineering, fabrication, delivery, removal of existing equipment, installation, field adjustments, testing, documentation, and turnover to the Government. This SOW applies to non-critical loads only. Operator training, daily inspections, and routine operations are outside the scope and will be performed by Government personnel.

1.2 Existing Conditions

The existing system consists of an indoor overhead crane and associated hoists, runway, electrification, and controls. Existing building drawings and any available crane/runway documentation will be provided by the Government, where available, for reference.

The contractor shall verify all critical dimensions and field conditions before fabrication and installation.

2. APPLICABLE DOCUMENTS

2.1 Government / DoD Documents

The contractor shall comply with the latest applicable revisions of, at a minimum:

a. AFMAN 91-203, Air Force Occupational Safety, Fire and Health Standard, sections applicable to cranes, hoists, and material handling equipment.

b. AFSPCMAN 91-710, Range Safety User Requirements, and associated implementation guidance, as tailored for non-critical lifting operations and ground support systems in the facility.

c. Applicable Vandenberg SFB and Space Force instructions, including but not limited to safety, security, lockout/tagout (LOTO), fall protection, hot work, and confined space requirements.

d. SSCMAN 91-710, Volume 3, Chapter 6, “Cranes and Hoists,” including the Bldg 9320 Crane Compliance Matrix (Non-Critical V3 Crane).

e. SSCMAN 91-710, Volume 5, Attachment 2, crane and hoist data requirements, as applicable to the Bldg 9320 crane.

2.2 Drawings and Existing Data

a. Existing crane and runway drawings for Building 9320 (provided by Government if available).

b. Facility structural drawings and electrical one-lines, if available.

c. Existing safety documentation and facility safety data packages, as applicable.

2.3 Industry Standards

All work shall conform to the latest applicable revisions of the following standards, as applicable:

a. CMAA Specification No. 74 or CMAA Specification No. 70, as appropriate to the final crane configuration and design.

b. ASME B30 series for cranes, hoists, and related equipment, including but not limited to ASME B30.2, B30.11, B30.16, and B30.10.

c. ASME HST-4 / HST-4M, Performance Standard for Overhead Electric Wire Rope Hoists.

d. NFPA 70, National Electrical Code (NEC).

e. OSHA 29 CFR 1910, General Industry Standards (including Subpart N, O, and S, as applicable).

f. Applicable International Building Code (IBC), California Building Code (CBC), Unified Facilities Criteria (UFC), and local seismic requirements for structures and equipment supports.

g. NEMA 250 and NEMA ICS where applicable to electrical enclosure types and control equipment.

h. Hoist Manufacturers Institute (HMI) standards for overhead hoists.

i. American Welding Society (AWS) structural welding and inspection standards, as applicable.

j. American Institute of Steel Construction (AISC) standards and codes for structural steel design and fabrication.

k. Software safety hazard analysis for any software-based crane control functions, performed in accordance with SSCMAN 91-710 Volume 3, Chapter 6, paragraph 6.3.1.1.11, when applicable.

2.4 Order of Precedence

In case of conflict between this SOW and the referenced documents, this SOW takes precedence, except where it would result in noncompliance with applicable law, regulation, code, or higher-level directive.

3. REQUIREMENTS

3.1 New Crane System

3.1.1 General Description

The contractor shall furnish and install a complete indoor under-running, single-girder bridge crane system serving the existing runway in Building 9320, configured with:

a. One under-running single-girder bridge rated for 4 tons total capacity (minimum), CMAA Class C or better, suitable for indoor, non-critical, industrial service.

b. Two cross-mounted 2-ton electric wire rope hoists on monorail trolleys, providing independent lifting of non-critical loads.

c. System design and controls such that the combined use of the hoists does not exceed the rated capacity of the bridge or runway under any operating condition.

3.1.2 Hoist and Trolley Performance

Each hoist and trolley shall, at a minimum:

a. Rated Capacity: 2 tons (minimum) per hoist.

b. Lift: Minimum of 36 feet, or sufficient lift for the building and application as verified by field measurement.

c. Hoist Speed: Nominal 15 FPM with variable frequency drive (VFD) control, including a low-speed or microspeed function (approximately 25 percent of full speed or better) for precise positioning.

d. Trolley Speed: Nominal 50 FPM with VFD control and microspeed function for precise positioning.

e. Duty Class: Hoists shall meet or exceed H4 duty classification as defined by the hoist manufacturer and ASME HST-4 / HST-4M, suitable for high-volume handling of heavy loads in industrial service.

f. Wire Rope: Wire rope shall be of extra improved plow steel or equivalent, with independent wire rope core and compatible with sheaves and drums provided by the manufacturer.

g. Hooks and Suspension: Hooks shall comply with ASME B30.10 and include safety latches. Lower hook blocks shall be swiveling or otherwise configured to minimize rope twist and load rotation.

h. Reeving: Hoists shall be dual-reeved with equalizer sheaves and reeving arrangements consistent with SSCMAN 91-710 Volume 3, paragraphs 6.3.1.11 and 6.3.5.1.8, unless otherwise tailored by the Government in the Bldg 9320 Crane Compliance Matrix. Comment by DEAN, SEAN CIV USSF SSC SLD 30/SEAL: FYI 6.3.5.1.8 is for cranes used to lift critical loads and may increase crane cost.

3.1.3 Bridge and End Trucks

a. Bridge span, wheelbase, and end truck configuration shall match existing runway geometry and clearances, as verified by the contractor with field measurements.

b. The bridge shall be rated for a minimum of 4 tons total capacity, under-running configuration, Class C or better, and suitable for the existing runway and building environment.

c. End trucks shall be VFD-driven with nominal bridge travel speed of approximately 115 FPM (or as appropriate for the runway length and service), with dual drives and AC brakes with manual release. Comment by DEAN, SEAN CIV USSF SSC SLD 30/SEAL: Recommend 30 to 50 FPM on the high end.

d. Bridge shall be designed and fabricated in accordance with CMAA 74/70, ASME B30.2 / B30.11, and applicable seismic and structural requirements.

3.1.4 Electrical and Controls

The contractor shall provide a complete crane control system, including:

a. Power supply for crane and hoists: 460 V, 3-phase, 60 Hz (or as specified by the Government), and 115 V control power as needed.

b. Control enclosures: NEMA Type 12 or better steel control enclosures for indoor industrial service in a non-hazardous location. Alternative enclosure types (e.g., NEMA 3R) may be accepted if suitable for the actual environment and approved by the Government.

c. Drives: VFD drives shall be provided for all motions (hoist, trolley, bridge), including appropriate line reactors, braking resistors, and protective devices as required by manufacturer recommendations and code.

d. Motors: All hoist, trolley, and bridge motors shall be inverter-duty, with Class H insulation and Class B temperature rise, and shall include integral AC brakes with manual release.

e. Pendant and/or Radio Controls: The system shall include, at a minimum, a pendant control station with the following functions: mainline emergency stop, hoist 1 up/down, hoist 2 up/down, trolley travel, bridge travel, horn, and any required auxiliary safety functions. Radio remote control may be included if requested or accepted by the Government; the pendant shall remain available as a backup or alternate control method.

f. Control Circuit Design: Control circuits shall be designed to prevent unsafe simultaneous commands, provide fail-safe stop functions, and comply with ASME B30 and NEC requirements. Over-travel, limit switch, and emergency stop functions shall be hardwired and shall not depend solely on programmable logic.

g. Safety and lockout features: Control panels shall incorporate a lockout feature (such as a keyed switch) to prevent unauthorized operation, hard-wired emergency stop circuits, and a design that prevents automatic restart after power loss or RF communication loss. Where radio controls are used, loss of RF signal shall cause the controls to revert to a safe state with all motion inhibited until control is deliberately re-established.

3.1.5 Overload Protection

Each hoist shall incorporate integral overload protection in accordance with ASME B30.16 and ASME HST-4 / HST-4M.

a. The overload protection system shall prevent hoisting when the load exceeds the specified overload threshold (typically not less than 125 percent of rated capacity, or per the hoist manufacturer’s standard), while still allowing controlled lowering.

b. Overload protection shall not be field-adjustable by operating personnel and shall be configurable only by qualified maintenance personnel following manufacturer procedures.

c. Where required by the SSCMAN 91-710 V3 Crane Compliance Matrix for Bldg 9320, the hoist control system shall support torque-proving and adjustable overload test functions, including any keyed overrides and load indication required for proof testing.

3.1.6 Safety Features

The crane system shall include, at a minimum:

a. Two independent “up” hoist limit functions on each hoist: (1) a primary control-circuit upper limit that stops upward motion and is reset by reversing the hoist control, and (2) a final upper limit that mechanically interrupts power to the hoist drive and requires keyed reset before motion can resume.

b. Bridge travel limit switches or other devices to prevent the bridge from impacting mechanical end stops.

c. Audible warning horn, operable from the pendant/remote, for use during crane movement and lifting operations.

d. Visual warning device (e.g., red strobe) that activates during crane or bridge travel.

e. Main disconnect(s) with lockable handle, accessible from the floor or from a permanent platform.

f. Capacity and warning signage on the bridge, hoists, and operator controls in accordance with ASME B30 and AFMAN 91-203.

g. If specified in the SSCMAN 91-710 V3 Crane Compliance Matrix for Bldg 9320, the hoist shall incorporate dual fault-tolerant braking and uncommanded motion detection with appropriate visual and aural warnings, in accordance with SSCMAN 91-710 Volume 3, paragraph 6.3.5.1.4. Comment by DEAN, SEAN CIV USSF SSC SLD 30/SEAL: FYI 6.3.5.1.4 is for cranes used to lift critical loads and may increase new crane cost.

3.1.7 Environmental and Finish

a. The crane system shall be suitable for indoor, non-hazardous environment service in Building 9320.

b. Hoists shall be painted safety yellow; bridge and end trucks shall receive an industrial primer and topcoat or equivalent corrosion-resistant finish.

c. No paint shall be applied to wire rope, hooks, wheels, or sheaves.

3.2 Removal of Existing Equipment

The contractor shall develop and submit a removal plan that addresses rigging, lockout/tagout, fall protection, and sequence of work; coordinate outage windows, access, and staging with the Government to minimize mission impact and interference with ongoing operations; disconnect, disassemble, and remove the existing bridge, end trucks, hoists, trolleys, controls, and associated festoon/electrification that are not being reused; and palletize and stage removed components at a Government-designated location for disposition or remove them from the installation for disposal, as directed by the Contracting Officer’s Representative (COR). The work area shall be kept clean, free of debris, and safe for Government operations at the end of each workday.

3.3 Installation of New Equipment

3.3.1 Structural Verification and Engineering

The contractor shall verify that existing runway beams, supports, and connections are adequate for the new crane loads and service class, including vertical loads, lateral loads, impact, and seismic effects.

The contractor shall perform (or subcontract) structural analysis and design for the crane, runway, supports, end stops, and building attachment points, including applicable seismic requirements for Vandenberg SFB in accordance with AFSPCMAN 91-710 (Volumes 3 and 5), applicable UFC, IBC, CBC, and local codes, and CMAA/ASME B30 standards.

Structural calculations and drawings for any new or modified supports, hangers, bracing, and anchorage shall be prepared and sealed by a Professional Engineer (PE) licensed in the State of California.

Structural calculations and drawings shall be submitted to the Government for review and acceptance (e.g., Civil Engineering, structural engineering, and Range Safety, as applicable) prior to fabrication or installation of any structural modifications or permanent attachments.

If the Government provides structural capacity limits or analyses, the contractor shall design the crane system to remain within those limits and shall still provide detailed drawings reflecting the final configuration for Government review and record.

The crane, runway, and supporting structure shall be detailed to prevent the crane from leaving its rails (derailing or “walking”) anywhere along the track during seismic events, consistent with seismic hazard provisions for the Western Range in SSCMAN 91-710 Volume 3, paragraph 6.3.4.2.2.

3.3.2 Mechanical Installation

The contractor shall install new end trucks, bridge girder, hoists, and trolleys in accordance with manufacturer instructions and approved drawings; use Grade 5 or better load-bearing bolts and appropriate fasteners assembled with thread-locking compound or locking devices; and set crane clearances, stops, bumpers, and alignment to meet CMAA and ASME requirements and to avoid interference with building structures and existing equipment.

3.3.3 Electrification and Controls Installation

The contractor shall provide a complete electrification and controls installation, including power feed from the existing facility power source (with division of work between line-side and load-side connections as specified by the contract); conductor bars or festoon systems on the runway and bridge with hangers, tow arms, and drops; control wiring between pendant/remote, control panels, motors, brakes, limit switches, horn, strobe, and auxiliary devices; and grounding, bonding, and surge protection in accordance with NEC and manufacturer requirements, including GFCI/CFCI protection, line reactors, and other protective devices where required.

3.3.4 Alignment and Functional Checks

The contractor shall verify that the crane is level, square, and properly aligned with the runway; adjust hoist limits, bridge and trolley limits, and braking devices to manufacturer tolerances; and perform no-load and incremental loaded functional checks prior to formal proof load testing.

3.4 Testing and Acceptance

3.4.1 Documentation Deliverables

The contractor shall provide the following documentation for Government review and use:

a. OEM Operation and Maintenance (O&M) Manuals for the bridge crane (bridge, end trucks, cabling/electrification), each hoist and trolley, and the control system including VFDs, pendant/remote controls, limit switches, and associated equipment.

b. Electrical Documentation: one-line diagrams showing power distribution to and within the crane system; detailed control schematics including terminal numbering, wire numbering, fuse sizes, motor HP ratings, and protective devices; and panel layouts, terminal schedules, and I/O lists for any programmable devices, if applicable.

c. Mechanical and Structural Drawings: general arrangement drawing showing crane, runway, clearances, and major components; details of runway beams, hangers, supports, end stops, and anchorage to the building, including any modifications; and drawings corresponding to the PE-stamped structural calculations for record.

d. Spare Parts Documentation: recommended spare parts list with OEM part numbers, descriptions, and suggested stocking quantities for critical components.

e. Format of Deliverables: all documentation shall be provided in electronic format. Drawings and calculations shall be provided as PDF and in native editable format (e.g., DWG/DXF for CAD drawings, original calculation files or searchable PDFs). Manuals, schematics, and reports shall be provided as PDF and, where available, in a reasonably editable electronic format (e.g., DOCX, native manufacturer electronic manuals, or equivalent). Scanned images of hardcopy materials are not acceptable as the only format unless the original is only available in that form.

In addition to the documentation listed above, the contractor shall provide all crane and hoist data required by SSCMAN 91-710 Volume 3, paragraph 6.3.3, and Volume 5, Attachment 2, in the format specified by the Government for incorporation into facility safety and configuration records.

3.4.2 Field Load Test and Commissioning

The contractor shall provide manufacturer test reports and certificates for hoists, trolleys, and bridge components where available; develop a field test plan for initial testing and commissioning of the crane system, consistent with ASME B30, AFMAN 91-203, and manufacturer requirements; perform operational checks of all motions and safety devices prior to applying test loads; and perform static and dynamic proof load tests in accordance with ASME B30 and AFMAN 91-203 (typically at 125 percent of rated capacity unless otherwise directed by the Government or the manufacturer). The test plan and proof load levels shall be reviewed and accepted by the Government prior to execution. Written test reports and crane certification signed by a qualified person as defined by ASME/OSHA shall be provided.

Following completion of proof load testing, the contractor shall perform nondestructive examinations (NDE) of safety-critical welds and load-bearing components, including hooks and rope attachment components, to the extent required by SSCMAN 91-710 Volume 3, Chapter 6 and the project-specific NDE plan approved by the Government. The contractor shall submit an NDE plan identifying methods, coverage, and acceptance criteria for Government review and acceptance prior to performing NDE.

3.4.3 Preventive Maintenance and Inspection Plan

The contractor shall provide a preventive maintenance (PM) and inspection plan for the crane and hoists, consistent with OEM recommendations, AFMAN 91-203, and ASME B30 requirements. The plan shall, at a minimum, include a list of inspection and maintenance tasks for all major components; recommended inspection and maintenance intervals (e.g., pre-use, weekly, monthly, quarterly, annual, or duty-cycle-based intervals) aligned with AFMAN 91-203’s prior-to-use, frequent, and periodic inspection categories; required tools, test equipment, and special procedures needed to perform tasks safely and correctly; clear acceptance criteria or pass/fail limits (e.g., allowable wear, deformation, wire rope discard criteria, brake performance); and any OEM-specific tasks required to maintain warranty coverage.

3.5 Program Management

The contractor shall designate a single Project Manager who will serve as the primary point of contact for all technical and contractual matters, responsible for coordinating schedules, submittals, field work, and communication with the Government. A kickoff meeting shall be held within 30 calendar days of contract award (virtual or in-person) to review scope, schedule, submittals, and access/safety requirements. Coordination meetings shall be held as needed during installation and testing to resolve issues and confirm progress. Submittals shall include the removal and installation plan, structural calculations and drawings, electrical drawings, field test plan and proof load procedure, and a schedule identifying major milestones.

3.6 Tools, Equipment, and Temporary Works

The contractor shall furnish all tools, lifting devices, temporary supports, scaffolding, manlifts, and other equipment required for safe performance of the work. Temporary works shall be designed and used in accordance with OSHA, AFMAN 91-203, manufacturer instructions, and good engineering practice.

3.7 Facility Modifications and Services

No permanent modifications to the facility structure shall be made without prior written Government approval. The Government will identify available power sources, laydown areas, and access routes. Any temporary utility needs beyond those provided shall be the contractor’s responsibility. The contractor shall protect existing finishes, equipment, and utilities from damage and shall repair any damage caused by their work to the satisfaction of the Government.

3.8 Access, Security, and Safety

Contractor personnel shall comply with all Vandenberg SFB and Space Force access, badging, escort, and security requirements. The contractor shall implement and follow a site-specific safety plan in compliance with AFMAN 91-203, AFSPCMAN 91-710, OSHA, and base requirements, including but not limited to crane safety, electrical safety, lockout/tagout, and fall protection for work at height. The contractor is responsible for providing fall protection and associated equipment for its employees and for coordinating any use of existing facility anchor points with the Government.

3.9 Warranty

The contractor shall provide a minimum one-year warranty on all furnished equipment and installation labor, starting at Government final acceptance. The warranty shall cover defects in materials, workmanship, and performance. The contractor shall correct such defects at no additional cost to the Government, including labor, parts, and any necessary re-testing.

4. DATA DELIVERABLES (SUMMARY)

At a minimum, the contractor shall provide the following:

a. As-built mechanical, structural, and electrical drawings – PDF plus native editable format.

b. O&M manuals for crane, hoists, controls, and electrification – electronic PDF and editable format where available.

c. PE-stamped structural calculations and drawings – PDF and native electronic format.

d. Load test and commissioning reports, including proof load results and functional test checklists – electronic PDF.

e. Preventive maintenance and inspection plan – electronic PDF and editable format.

f. Warranty certificates and OEM documentation needed to support future warranty claims.

g. Crane and hoist data package meeting SSCMAN 91-710 Volume 3, paragraph 6.3.3, and Volume 5, Attachment 2 requirements, in electronic PDF and native editable formats as applicable.