P-1112 B72 Resiliency Improvement Delivery Order N40085-23-F-4245

SECTION 41 22 13.14

BRIDGE CRANES, OVERHEAD ELECTRIC, TOP RUNNING

11/19, CHG 1: 02/21

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

AMERICAN GEAR MANUFACTURERS ASSOCIATION (AGMA)

AGMA 908 (1989B; R 1999) Information Sheet:

Geometry Factors for Determining the Pitting Resistance and Bending Strength of Spur, Helical and Herringbone Gear Teeth

ANSI/AGMA 2001 (2004D; R 2010) Fundamental Rating Factors and Calculation Methods for Involute Spur and Helical Gear Teeth

ANSI/AGMA 2015-1 (2001A; R 2014) Accuracy Classification System - Tangential Measurements for Cylindrical Gears

ANSI/AGMA 6013 (2006A; R 2016) Standard for Industrial Enclosed Gear Drives

ANSI/AGMA 6113 (2016B) Standard for Industrial Enclosed Gear Drives (Metric Edition)

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

AISC 360 (2016) Specification for Structural Steel Buildings

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI B4.1 Preferred Limits and Fit for Cylindrical Parts

AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING (ASNT)

ASNT SNT-TC-1A (2024; Addendum 2025) Recommended Practice for Personnel Qualification and Certification in Nondestructive Testing

AMERICAN SOCIETY OF CIVIL ENGINEERS (ASCE)

ASCE 7-16 (2017; Errata 2018; Supp 1 2018) Minimum Design Loads and Associated Criteria for Buildings and Other Structures

SECTION 41 22 13.14 Page 1

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME B17.1 (1967; R 2017) Keys and Keyseats

ASME B30.2 (2022) Overhead and Gantry Cranes (Top Running Bridge, Single or Multiple Girder, Top Running Trolley Hoist)

ASME B30.10 (2024) Hooks

ASME B30.17 (2020) Overhead and Gantry Cranes (Top Running Bridge, Single Girder, Underhung Hoists)

ASME HST-4 (2021) Performance Standard for Overhead Electric Wire Rope Hoists

ASME NOG-1 (2020) Rules for Construction of Overhead and Gantry Cranes (Top Running Bridge, Multiple Girder)

ASME B30.17 (2020) Overhead and Gantry Cranes (Top Running Bridge, Single Girder, Underhung Hoists)

AMERICAN SOCIETY OF SAFETY PROFESSIONALS (ASSP)

ASSP Z359 (2013) Fall Protection Code

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2020; Errata 1 2021) Structural Welding Code - Steel

AWS D14.1/D14.1M (2019) Specification for Welding of Industrial and Mill Cranes and Other Material Handling Equipment

ASTM INTERNATIONAL (ASTM)

ASTM A275/A275M (2023) Standard Practice for Magnetic Particle Examination of Steel Forgings

ASTM A668/A668M (2023) Standard Specification for Steel Forgings, Carbon and Alloy, for General Industrial Use

ASTM A931 (2008; R 2013) Standard Test Method for Tension Testing of Wire Ropes and Strand

ASTM A1023/A1023M (2021) Standard Specification for Stranded Carbon Steel Wire Ropes for General Purposes

ASTM E543 (2021) Standard Specification for Agencies Performing Non-Destructive Testing

ASTM E1417/E1417M (2016) Standard Practice for Liquid Penetrant Testing

SECTION 41 22 13.14 Page 2

ASTM F3125/F3125M (2019) Standard Specification for High Strength Structural Bolts and Assemblies, Steel and Alloy Steel, Heat Treated, Inch Dimensions 120 ksi and 150 ksi Minimum Tensile Strength, and Metric Dimensions 830 MPa and 1040 MPa Minimum Tensile Strength

CRANE MANUFACTURERS ASSOCIATION OF AMERICA (CMAA)

CMAA 70 (2020) Specification for Top Running Bridge and Gantry Type Multiple Girder Electric Overhead Traveling Cranes

CMAA 74 (2020) Specifications for Single Girder Cranes

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA 250 (2020) Enclosures for Electrical Equipment (1000 Volts Maximum)

NEMA ICS 2 (2000; R 2020) Industrial Control and Systems Controllers, Contactors, and Overload Relays Rated 600 V

NEMA ICS 5 (2017) Industrial Control and Systems:

Control Circuit and Pilot Devices

NEMA ICS 6 (1993; R 2016) Industrial Control and Systems: Enclosures

NEMA ICS 8 (2011) Crane and Hoist Controllers

NEMA MG 1 (2021) Motors and Generators

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2023; ERTA 1 2024; TIA 24-1) National Electrical Code

OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)

29 CFR 1910.219 Mechanical Power-Transmission Apparatus

RESEARCH COUNCIL ON STRUCTURAL CONNECTIONS (RCSC)

RCSC A348 (2020) RCSC Specification for Structural Joints Using High-strength Bolts

SOCIETY FOR PROTECTIVE COATINGS (SSPC)

SSPC SP 6/NACE No.3 (2007) Commercial Blast Cleaning

U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)

29 CFR 1910 Occupational Safety and Health Standards

SECTION 41 22 13.14 Page 3

29 CFR 1910.147 The Control of Hazardous Energy (Lock Out/Tag Out)

29 CFR 1910.179 Overhead and Gantry Cranes

29 CFR 1910.306 Specific Purpose Equipment and Installations

UL SOLUTIONS (UL)

UL 50 (2024) UL Standard for Safety Enclosures for Electrical Equipment, Non-Environmental Considerations

UL 489 (2025) UL Standard for Safety Molded-Case Circuit Breakers, Molded-Case Switches and Circuit-Breaker Enclosures

UL 943 (2016; Reprint Sep 2023) UL Standard for Safety Ground-Fault Circuit-Interrupters

UL 1004-1 (2012; Reprint Nov 2020) UL Standard for Safety Rotating Electrical Machines - General Requirements

UL 1449 (2021; Reprint Dec 2022) UL Standard for Safety Surge Protective Devices

1.2 DEFINITIONS

a. Bridge Crane: That part of an overhead crane system consisting of girder(s), end trucks, end ties, walkway, and drive mechanism which carries the trolley(s) and travels along the runway rails parallel to the runway.

b. Crane Runway: The track system along which the crane operates horizontally, including track hangar rods, track connection devices, and runway structural supports.

c. Dead Loads: The loads on a structure which remain in a fixed position relative to the structure.

d. Girder: The principal horizontal beam of the crane bridge. It is supported by the crane end trucks.

e. Lifted Load: The load consisting of the rated load and the weight of lifting devices attached to the crane such as the load block, bucket, or other supplemental devices.

f. Pendant: A control for a hoist and a crane. The pendant hangs from the hoist or the crane by a cable at a height that is easy for the operator to reach.

g. Rated Load: The maximum working load suspended under the load hook.

h. Standard Commercial Cataloged Product: A product which is currently being sold, or previously has been sold, in substantial quantities to the general public, industry or Government in the course of normal business operations. Models, samples, prototypes or experimental

SECTION 41 22 13.14 Page 4 units do not meet this definition. The term "cataloged" as specified in this section is defined as "appearing" on the manufacturer's published product data sheets. These data sheets must have been published or copyrighted prior to the issue date of this solicitation and have a document identification number or bulletin number.

i. Top Running Crane: An electric overhead traveling crane that runs on rails on top of support girders.

j. Trolley Load: Weight of the trolley and its associated equipment carried by the trolley wheels.

k. Operating Environments:

(1) General Purpose Service: This applies to most cranes and are, in large measure, the manufacturers' standard designs. Cranes should be classified as General Purpose Service if they are operating in routine environments.

1.3 SYSTEM DESCRIPTION

The overhead crane system shall be a top-running, single-girder bridge crane, with underhung trolley designed and constructed in accordance with CMAA Class C minimum service requirements, and the hoist shall conform to ASME HST-4 Duty Class H4 minimum. The system shall include a 7.5-ton wire rope hoist with a motor-driven trolley, dual bridge drives, and variable frequency drive (VFD) controls to provide smooth acceleration and deceleration of bridge and trolley motions. The hoist shall provide true vertical lift through a double-reeved configuration and include both electro-mechanical and mechanical load brakes for safe load handling. The hoist headroom shall not exceed 24 inches, measured from the hook saddle to the underside of the bridge girder. All motors shall have a 60-minute duty rating, and the bridge control panel shall include a keyed bypass for the hoist brake circuit. The crane shall be suitable for indoor service in an industrial environment typical of Navy maintenance facilities.

Requirements for the crane runway system and supporting structures are specified in 05 12 00 STRUCTURAL STEEL and shall conform to AISC 360 .

1.3.1 Crane Design Criteria

Cranes will operate in the given spaces and match the runway dimensions and rails indicated. Hook coverage, hook vertical travel, clear hook height, lifting capacity, and load test weight must not be less than that indicated.

1.3.1.1 Classification

Provide top running overhead electric traveling (OET) single girder cranes conforming to CMAA 74 service class C for operation in an indoor environment, general purpose service.

The crane must be pendant controlled and operate in the spaces and within the loading conditions indicated. The pendant controller must be mounted on a separate festooned cable system from the trolley power supply. The crane must operate on 480-volts AC, 60 Hz, three phase power source.

Maximum crane wheel loads (without impact) due to dead, trolley, and lifted loads, with the trolley in any position, must not cause a more severe loading condition in the runway support structure than that produced by the design wheel loads and spacing indicated.

SECTION 41 22 13.14 Page 5

a. The 7.5-ton top running crane shall consist of a single girder and a structural runway with a festoon system. The crane shall have a maximized lifting height as shown on the Drawings. Top Running girder and structural runway dimensions shall be based on the limits identified on the Contract Documents.

b. The crane manufacturer shall be responsible for furnishing and installing the gantry beam, hoist, and runway rail system on top of horizontal structural beams provided by the General Contractor, as shown on the structural drawings, to deliver a complete and operable system. The crane manufacturer shall coordinate with the General Contractor and the structural engineer to confirm final runway elevation, anchorage details, and interface tolerances prior to fabrication and installation. The gantry crane shall be sized to span as indicated on the structural plans, and shall provide a minimum lifting height of 15 feet. The crane manufacturer shall ensure the crane rails are installed in accordance with applicable Crane Manufacturers Association of America (CMAA) tolerances. The Contractor shall furnish a complete, coordinated, and fully operable crane system in accordance with the crane manufacturer's requirements for rated load and duty cycle. The Contractor shall also submit a design certification letter, stamped by a licensed structural engineer, verifying that the crane girders, rails, and all related components have been designed, detailed, and installed in accordance with CMAA requirements, applicable building codes and standards, and are capable of safely supporting the crane's rated capacity under all operating conditions.

c. Hoist to include 7.5-ton capacity R&M wire rope hoist, two speed (19/3.2 FPM) motor.

d. All crane supporting members, connections, and attachment details shall be fabricated of structural steel, plate or forgings only. No castings will be permitted. System shall be suspended using components supplied by the crane manufacturer or approved equal.

e. The rated load of the crane shall be the maximum load for which the crane is designed and built by the manufacturer. In determining the rated load, all handling devices such as buckets, magnets, grabs, etc., shall be included as part of the load to be handled.

1.3.1.2 Rated Capacity and Speeds

Provide crane with rated capacity of 7.5 tons . Lower load block or assembly of hook, swivel bearing sheaves, pins, and frame suspended by the hoisting ropes are not considered part of the rated capacity.

Rated (maximum) speeds plus or minus 10 percent (feet/min) for the main hoist, bridge, and trolley at the rated load are specified in the table below. The minimum speed must not exceed the values listed. Values in the table are for a fully loaded crane.

Rated Speeds feet/min

Description Minimum Maximum Main Hoist 10 20

SECTION 41 22 13.14 Page 6

Rated Speeds feet/min

Auxiliary Hoist NA NA Trolley 15 65 Bridge 20 100

1.4 VERIFICATION OF DIMENSIONS

The Contractor is responsible for the coordination and proper relation of their work to the building structure and to the work of all trades.

Verify all dimensions of the building that relate to fabrication of the crane and notify the Contracting Officer of any discrepancy before finalizing the crane order.

1.5 SUBMITTALS

Government approval is required for submittals with a "G" classification.

Submittals not having a "G" classification are for Contractor Quality Control approval. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES. Submittals shall include complete data demonstrating conformance with this specification and all referenced standards. Drawings and data shall clearly indicate equipment arrangement, performance ratings, electrical characteristics, and all interfaces with structural and electrical systems. Shop drawings shall show the runway beams, rail alignment, gantry assembly, and all connections to the supporting structure furnished by others. Submittals shall provide sufficient detail to verify compliance with CMAA and NAVFAC requirements.

SD-01 Preconstruction Submittals

Engineering Geometrics Surveyor ; G

List Of The Survey Equipment ; G

Certification Of Survey Equipment Capability ; G

Survey Work Plan ; G

SD-02 Shop Drawings

Overhead Electric Traveling Crane ; G

Complete Schematic Wiring Diagram ; G

Control System and Network Drawings ; G

Runway Rails (rails, beam connections, and end truck interface details only; supporting columns by others); G

Bridge Conductor System

SD-03 Product Data

Gear Reducers ; G

Hoist Brakes ; G

Travel Brakes ; G

SECTION 41 22 13.14 Page 7

Couplings ; G

Load Blocks and Hooks ; G

Wheels ; G

Hoists ; G

Sheaves ; G

Drives ; G

End Trucks ; G

Runway Rails ; G

End Stops ; G

Bumpers ; G

Variable Frequency Drives ; G

Motors ; G

Runway Conductor System ; G

Bridge Conductor System ; G

Limit Switches ; G

Pendant Pushbutton Station ; G

Pendant Conductor System ; G

Controls ; G

Control Parameter Settings ; G

Capacity Overload Protective Device ; G

Painting System ; G

Control System and Network ; G

SD-05 Design Data

Load and Sizing Calculations ; G

SD-06 Test Reports

Hook Proof Test ; G

Hook Non-destructive Test (NDT) ; G

Post-erection Inspection ; G

Operational Tests ; G

Hook Tram Measurement ; G

SECTION 41 22 13.14 Page 8

Load Tests ; G

Crane Rail Survey ; G

Hardness Testing for Results of Sheaves and Wheels ; G

SD-07 Certificates

Wire Rope including Breaking Strength Test Report ; G

Crane Runway System ; G

Hazardous Material ; G

Loss of Power Test ; G

Coupling Alignment Verification Record ; G

Overload Test ; G

Brake Adjustment Record ; G

Compliance with Listed Standards ; G

Public Domain Software ; G

Software and Services ; G

Welding Certificates ; G

SD-10 Operation and Maintenance Data

Operation and Maintenance Manuals ; G

SD-11 Closeout Submittals

Disabled Ports, Connectors, and Interfaces ; G

Network-Capable Control Devices ; G

Control System Access Control ; G

Control System Account Management ; G

Patch Management and Updates ; G

Malware Detection and Protection ; G

Wireless Technology Provisions ; G

Control System Inventory ; G

Evaluation Status of Hardware and Software ; G

Precise Alignment Survey ; G

Raw Survey Data ; G

SECTION 41 22 13.14 Page 9

Post-Installation Letter ; G

1.6 QUALITY ASSURANCE

1.6.1 Manufacturer Qualification

Overhead Electric Traveling Crane must be designed and manufactured by a company with a minimum of 10 years of specialized experience in designing and manufacturing the type of overhead crane required to meet requirements of the Contract Documents. Crane design must be accomplished by, or directly supervised by, a registered professional engineer (PE). PE licensing must be by a board or agency authorized to license and register professional engineers. The PE may be a Contractor's regular employee or a consultant. The PE's review and attestation of specification compliance and professional responsibility must be signified by his or her PE original seal and dated signature on the final drawings. The professional engineers must only undertake and perform work under this contract in the branch(s) of engineering in which they are licensed.

1.6.2 Pre-Delivery Inspections

Contractor is responsible for performance of quality control inspections, testing, and documentation. Submit all crane test data recorded on appropriate test record forms suitable for retention for the life of the crane.

1.6.2.1 Inspection of Steel Castings

Visually inspect load-carrying steel castings All load bearing components, couplings, shafts, and gears, in the hoist drive train must be rolled or forged steel, except brake drums which may be ductile iron.

Methods of repairing the discontinuities is subject to review by the Contracting Officer.

1.6.2.2 Inspection of Hook Assembly

Inspect hook by a magnetic-particle type inspection prior to delivery.

Furnish documentation of hook inspection to Contracting Officer prior to field operational testing. As part of the acceptance standard, linear indications are not allowed. Welding repairs of hook are not permitted.

A hook showing linear indications, damage or deformation is not acceptable and must be replaced immediately.

1.6.2.2.1 Hook Non-Destructive Test (NDT)

Perform a magnetic-particle inspection of the entire hook in accordance with ASTM A275/A275M . Acceptance standard is no defects. A defect is defined as a linear indication that is greater than 1/16 inch long. For hooks of non-magnetic material, NDT will be liquid penetrant (PT) method in accordance with ASTM E1417/E1417M . For PT testing of hooks containing stainless steels, titanium, or nickel based alloys, total halogens and Sulphur used in the NDT process must be controlled as specified in

T9074-AS-GIB-010/271.

Inspect each hook and shank over the entire surface area by magnetic particle inspection.

a. Procedure: Conduct magnetic particle inspection in accordance with ASTM A275/A275M with the following restrictions: Do not use DC yokes

SECTION 41 22 13.14 Page 10

(including switchable AC/DC yokes used in the DC mode) or permanent magnet yokes. Do not use automatic powder blowers or any other form of forced air other than from a hand-held bulb for the application or removal of dry magnetic particles. Remove arc strikes. Equipment ammeters must have an accuracy of plus or minus 5 percent of full scale (equipment ammeter accuracy other than that stated is acceptable provided the MT procedure states that a magnetic field indicator is used to establish and verify adequate field strength for all aspects of the inspection.)

b. Acceptance Criteria: Defects found on the hook will result in rejection of defective items for use on furnished hoist. For this inspection, a defect is defined as a linear indication for which the largest dimension is greater than 1/16 inch.

c. Test Report: Submit a test report of the magnetic particle inspection of each hook provided the Contracting Officer for approval prior to final acceptance of hoist installation. Certify test reports by the testing organization. The performing organization must provide a written statement of certification to ASTM E543, current within one year of the date the NDT was performed. The NDT procedures including technique sheets specific to the types, shapes, and size of the parts being examined must adequately describe the orientation of the hooks within the magnetizing equipment. The performing organization must have the NDT procedures and its technique sheet used for testing of the hook reviewed and approved by an independent Level III examiner per ASNT SNT-TC-1A . Submit the (Level III examiner) approved procedures, technique sheet, and certification to the Contracting Officer with the test report.

1.6.3 Certificates

All certifications must be dated and bear the original signature (above the printed name) of the authorized representative of the Contractor or the manufacturer of the items or equipment being certified. Each certification will clearly identify the crane, the drives, components, and location (as applicable) to which it applies:

a. Submit a Wire Rope Certification with the wire rope manufacturer's certification that the rope meets the published breaking strength or the actual breaking strength of a sample taken from the reel and tested. Certification is to be traceable to the hoist, crane, and reel.

b. Submit a Crane Runway System Certificate stating that the new crane will operate properly on the runway; if the crane(s) cannot operate without restriction, the Contractor must indicate crane limitations.

c. Submit a Hazardous Material Certificate that the crane does not contain hazardous material including asbestos, lead, cadmium, chromium, PCBs, or elemental mercury. Products required for the designing and manufacturing of cranes must not contain the prohibited materials.

d. Submit a Loss of Power Test Certificate stating that a test may be performed in which power is removed from the crane while the hoist, bridge, and trolley are in operation. This certificate must indicate that no damage will be caused by performing this test.

SECTION 41 22 13.14 Page 11

e. Submit a Certificate of the Coupling Alignment Verification Record .

f. Submit an Overload Test Certificate stating that the crane can be periodically load tested to 125 percent (plus 0 minus 5 percent) of rated load.

g. Submit a Certificate of the Brake Adjustment Record . Provide a brake adjustment record and installation/maintenance manuals for each brake on the crane. Each brake measurement must have a tolerance traceable to the associated brake manual or documentation provided by the brake manufacturer, location of measurements, and the actual brake setting.

Changes made to settings of the brake, at any time, will void the record.

h. Submit a Certificate of Compliance with Listed Standards

i. The Contractor must provide a Public Domain Software Certificate declaring that public domain software (e.g., freeware, shareware) is not used in the system.

j. The Contractor must provide a certificate stating that all Software and Services that are not required for operation and/or maintenance of the product have been removed. The software/services to be removed are identified in paragraph SOFTWARE AND SERVICES.

k. The Contractor must provide Welding Certificates stating that all welders, welding operators, weld inspector(s) and welding procedure (qualification) meet the requirements of AWS D14.1/D14.1M for all work performed in manufacturing the crane. The contractor shall provide a certificate stating that all welders, welding operators, weld inspector(s), and welding procedure (qualification) meet the requirements of AWS D1.1/D1.1M for all work performed in installing/welding parts supporting the crane at/to building interfaces.

1.6.4 Drawings: Overhead Electric Traveling Crane

a. Submit drawings showing the general arrangement of all components in plan, elevation, and end views. Show all major features of the crane including: hook approaches on all four sides, clearances and principal dimensions, assemblies of hoist, trolley and bridge drives, motor nameplate data, overcurrent protective device ratings, and electrical schematic drawings. Include weights and centers of gravity of major components. Provide maximum wheel loads (without impact) and spacing imparted to the crane runway system track beams. Indicate the crane speeds along the runway, the trolley speeds along the bridge girder, and the hoist lifting speeds; all speeds indicated are speeds with hoist loaded with rated crane capacity load.

b. Submit shop drawings of all fabricated components. Shop drawing quality must be equivalent to the contract drawings accompanying this solicitation. Drawings must be reviewed, signed, and sealed by a registered professional engineer.

c. Provide integral schedule of crane components on each drawing.

Drawings should also include fastener torques (installation/mounting fasteners) and specific lubrication (Greases/oils) as applicable. The schedule must provide a cross reference between manufacturer data and shop drawings. Components listed on the schedule of crane components

SECTION 41 22 13.14 Page 12 must include total quantity, description, original manufacturer, and part number. Distributing agents will not be acceptable in lieu of the original manufacturer.

d. Provide control system and network drawings . Network diagram must show equipment locations, names, models, and IP addresses on network communications schematic for all Programmable Logic Controllers (PLCs), Remote Terminal Unit (RTU), Supervisory Controller, and Other Network-Capable Devices. In addition, the drawings must consist of all software block, flow, and ladder diagrams.

e. Submit drawings for information as follows:

(1) SD-02.E Electrical Drawings These drawings shall show the layout of electrical equipment on the crane(s), including control panel enclosures, radio/pendant control panel enclosures, motors, brakes, limit switches, conduits, disconnects, and conductor systems.

(2) The drawings shall at a minimum include: SD-02.El Complete schematic diagram with narrative of any special description of operation.

(3) All components shown on schematics shall have labels that correspond to the nameplates that will be on the crane.

(4) Wiring type, size, stranding class, and temperature ratings shall be included on schematic diagrams.

(5) All optional equipment not installed on the crane shall be removed from the schematic diagrams.

(6) Locations of contacts and coils shall be cross referenced to each other within the schematic diagrams.

(7) For components with adjustable settings, final settings shall be shown on the schematics.

(8) SD-02.E2 Motor nameplate data (including all information called for in NFPA 70 , Section 430.7 (A) items 1 through 7).

(9) SD-02.E3 Rating and types of over-current protective devices.

SD-02.E4 A comprehensive component material list showing all electrical components used on the crane.

(10) SD-02.E5 Layout diagrams showing component placement in control panel enclosures.

(11) Each layout drawing shall have a Bill of Materials listing component descriptions for all items found in the electrical drawings.

(12) SD-02.E6 Festoon layout drawings showing festoon cables used, carrier system, and cable loop depth.

1.6.5 Design Data: Load and Sizing Calculations

Submit complete list of equipment and materials, including manufacturer's descriptive data and technical literature, performance charts and curves, SECTION 41 22 13.14 Page 13 catalog cuts, and installation instructions. Submit calculations reviewed, signed, and sealed by a registered professional engineer verifying the load cases, sizing of the bridge girders, end trucks, travel drives, brake selections, and overcurrent protection for motors, controllers, and branch circuits. Provide a list of all codes and standards, design assumptions, equations, specified efficiencies, limits, factors of safety, component ratings, and sources of values used. Include free body diagrams or sketches of each load case.

1.6.6 Welding Qualifications and Procedures

Welding must be in accordance with qualified procedures using AWS D14.1/D14.1M as modified. Written welding procedures must specify the Contractor's standard dimensional tolerances for deviation from camber and sweep and not exceed those specified in AWS D14.1/D14.1M and CMAA 70.

Welders and welding operators must be qualified in accordance with AWS D1.1/D1.1M or AWS D14.1/D14.1M .

1.7 CRANE SAFETY

Comply with the mandatory and advisory safety requirements of ASME B30.10 , ASME B30.2 , CMAA 70, 29 CFR 1910.147 , 29 CFR 1910.179 , 29 CFR 1910.306 , and all applicable provisions of 29 CFR 1910 and NFPA 70 . Where personal fall arrest anchorages are provided, design anchorages in accordance with

ASSP Z359 .

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 General

Provide materials and equipment which are standard products of manufacturers regularly engaged in the fabrication of complete and totally functional cranes including necessary ancillary equipment. Material will be free from defects and imperfections that might affect the serviceability and appearance of the finished product. All material must be new and unused. Refer to ASME NOG-1 and ASME B30.17 .

2.1.2 Nameplates

Secure nameplates to each major component of equipment with the manufacturer's name, address, type or style, model or catalog number, and serial number. Provide two bridge identification plates, one for each side of the bridge. Provide noncorrosive metal identification plates with letters "072-B-6987" such that they are easily read from the floor.

2.1.3 Capacity Marking

Mark the rated capacity in pounds on each side of the crane on the bridge girders and both sides of the hook block. Capacity marks must be large enough to be clearly visible from the floor. The markings must be positioned to be visible at the operator's position after the crane has been installed.

2.1.4 Safety Warnings

Affix labels in a readable position to each lift block or control station in accordance with ASME B30.2 . Submit safety warnings, diagrams and other

SECTION 41 22 13.14 Page 14 instructions suitably framed and protected for display as indicated by the Contracting Officer as follows:

Design and locate the word "WARNING" or other legend to bring the label to the attention of the operator. Provide durable type warning labels and display the following information concerning safe-operating procedures:

Cautionary language against lifting more than the rated load; operating the hoist when the hook is not centered under the hoist; operating hoist with twisted, kinked or damaged rope; operating damaged or malfunctioning hoist; operating a rope hoist with a rope that is not properly seated in its hoist drum groove; lifting people; lifting loads over people; and removing or obscuring the warning label.

2.2 STRUCTURAL REQUIREMENTS

Structural requirements must be in accordance with CMAA 74, Section 3.

Structural steel materials must conform to the standards permitted in CMAA 74, ASCE 7-16 and AISC 360 .

2.2.1 Structural Connections

High-strength bolted structural connections must be designed and installed in accordance with RCSC A348. Bolts must be of ASTM F3125/F3125M Grade A325/A325M or Grade A490/A490M material. Galvanized bolts are not acceptable.

Welded connections must be performed in accordance with AWS D14.1/D14.1M .

Allowable stress values must comply with CMAA 74.

2.2.2 Bridge Girder or Girders

Provide wide flange beam, standard I-Beam, or section fabricated from rolled plates and shapes bridge girders. If the ends of bridge girders are notched to fit over the end trucks, the notches must be reinforced with vertical diaphragms and horizontal stiffeners.

2.2.3 Runway Rails Top Running Runway and Support Structure

a. Runway design shall follow the CMAA 74. Any rail splices shall be directly supported by the structure. A rail alignment is required for newly installed track. Make all rail joints flush and true without misalignment of running tread and design to minimize vibration. Fasten rail to support structure with rail clips positioned in pairs, and at not more than 36 inches apart on center. The use of "J" bolts for rail fastening shall not be permitted.

b. The support structure shall be supported by the floor of the building and shall be designed in accordance with CMAA 74, ASME B30.17 and AISC standards where applicable. Loads transmitted to the building through the support structure shall have the review and approval of the building engineer of record (EOR) prior to installation, per ASCE 7.

2.2.4 End Ties and Bridge Girder End Connections

If equalizing end trucks are used, provide rigid end ties between girders

SECTION 41 22 13.14 Page 15 to form a frame that is rigid about the vertical and horizontal axes. If compensating end trucks are used, provide end ties which are rigid about the vertical axis but relatively flexible about the horizontal axis to permit partial rocking motion for wheel load compensation. Provide full depth diaphragms at girder connections and jacking points. Provide horizontal gusset plates at the elevation of top and bottom end tie flanges for connection to girder ends. Make end connections with high-strength bolts in accordance with the Structural Connections section of this specification. Use tapered alignment pins to maintain original shop alignment between bridge girders and end ties/trucks.

2.2.5 End Trucks

Provide fixed axle type end trucks fabricated from structural steel plate to provide a rigid box section structure. Center wheels between the webs of the box section. Configure bridge and trolley trucks with a feature that limits load movement to 1 inch and does not interfere with crane rails in the event of wheel or shaft failure. Provide jacking pads for removal of wheel assemblies. Wheel axle bearing seats must be designed such that wheel and axle bearing assembly can be removed with not more than 3 inches of jacking. Provide tapered alignment pins between bridge girders and end truck flanges to ensure accurate field alignment of components, in accordance with NAVFAC 11450.2A paragraph 2-1.3.1.4(c).

2.2.6 Trolley Frame

Provide trolley frame as a one-piece structural steel weldment. Provide pads for the use of jacks or wedges when changing truck wheels. Make all trolley yokes and load bars of drop forged, cast or rolled steel. Provide safety lugs (drop stops) or functionally equivalent feature on trolley frame to prevent derailment and limit drop to no more than 1 inch.

2.2.7 End Stops and Bumpers

The contractor shall fabricate and install runway end stops. Runway end stops shall not be mounted to the runway rails. Fit bridge girders with structural steel end stops. Locate stops to permit maximum trolley travel. Fit bridge end trucks and trolley frames with shock-absorbing bumpers capable of decelerating and stopping the bridge and trolley within the limits stated by 29 CFR 1910 and CMAA 74. Bumpers must be properly aligned and fully engage end stops. Trolley and bridge design shall ensure travel wheels do not contact the end stops. Mount bumpers so that there is no direct shear on mounting bolts (if any) upon impact. Bumpers must provide adequate clearance between the crane and surrounding structure when compressed to preclude damaging equipment. Ensure bridge and trolley bumper retention in accordance with ASME B30.17 . Bumpers shall not be drilled through as a means of retention. Provide safety protection that prohibits allowance for wheels to contact end stop.

2.3 MECHANICAL REQUIREMENTS

a. Provide steel shafts, gears, keys, and couplings. Cast iron and aluminum used to support components of the hoist power transmission train must be ductile.

b. All bearings, except those subject only to small rocker motion, must be anti-friction type. All connections subject only to small rocking motion are to be fitted with bushings or thrust washers in the pivot pin bore, as applicable. Bronze bushings must have provisions for

SECTION 41 22 13.14 Page 16 grease lubrication.

c. All mechanical components must be accurately aligned and positively secured to maintain the alignment. Parts must not be forced into position to obtain apparent alignment.

d. All components that transmit drive or brake torque shall be interference fitted onto their respective shaft or axle. Interference fits shall conform to the force fit requirements prescribed in ANSI B4.1 and shall be medium drive fits unless length of engagement, material, or loading indicates otherwise. The individual component manufacturers shall endorse these interference fits. Drive wheels installed on rotating axles without keys shall be machined to have the wheel/axle inference fit in the FN2 to FN3 fit range. Bridge function speed reducers may use keyless connections. Keys in reversing torque applications shall have a metal to metal fit to the keyseat and keyway. Single keys shall be fitted in their keyseats and keyways to ASME B17.1 Class 2 requirements. Double keys may be fitted to ASME B17.1 Class 1 requirements. Fits of components within standard commercial assemblies, such as gear reducers and electric motors, shall comply with the applicable industry standards or with the manufacturer's standard practice if industry standard criteria are not available.

2.3.1 Hoists

Provide hoist conforming to ASME B30.2 and CMAA 70 service class C or better, double reeved, except as modified and supplemented in this section. Hoist shall conform to ASME HST-4 Duty Class H4 minimum.

2.3.2 Drives

2.3.2.1 Bridge Drives

Provide A-4 bridge drive arrangement as specified in CMAA 70 consisting of a single electric motor mechanically connected through gear reduction and drive shafts to the drive wheels or separate drive motors at each end of bridge.

Acceleration and deceleration must meet the requirements identified in CMAA 74. Gears must conform to applicable AGMA standards. Provide oil tight fully enclosed gear reducers with pressure or splash type lubrication.

2.3.2.2 Trolley Drives

Provide complete trolley drive arrangement with a minimum of two wheels driven by an integral electric motor. Drive mechanism must run in totally enclosed oil bath. Acceleration and deceleration controls must meet requirements identified in CMAA 74.

2.3.3 Load Blocks and Hooks

The load block shall be designed to prevent steel-to-steel contact of moving parts. The block must be fully enclosed, concealing the sheaves and wire ropes, except for wire rope slots and drain holes. The block must be clearly marked with the capacity in pounds on both sides. Standard commercial blocks may be used at their published ratings when their published design factors are 5.0 or greater.

SECTION 41 22 13.14 Page 17

Provide an unpainted single barbed forged carbon steel hook complying with ASTM A668/A668M and exhibit a minimum elongation of 16 percent in 2.00 inches.. Fit hook with a safety latch designed to preclude inadvertent displacement of slings from the hook saddle. The hook and hook nut must be removable without unreeving of the hoist. Provide hook nut with a removable type set screw or other similar fastener, installed in a plane parallel to the longitudinal axis of the hook shank. Do not weld hook nut and the hook shall not be welded except by the original hook manufacturer.

Uniquely mark the hook and nut in a permanent fashion that is traceable to the NDT certification. Hook must be class 2 fit of shank and nut.

Hook must be free to rotate through 360 degrees when supporting the test load up to 125 percent of the rated capacity. Provide only hooks which are designed and commercially rated in accordance with CMAA and conforming to ASME B30.10 , CMAA 74 and CMAA 70.

2.3.4 Wire Ropes

a. Wire ropes must conform to ASTM A1023/A1023M and be tested as required by ASTM A931. The wire rope must be in a double reeved configuration and equalized with a sheave. Provide wire rope with a minimum design factor of 5 to 1 based on the load experienced at rated capacity and minimum breaking strength of the wire rope.

b. Provide hoisting ropes with improved plow steel, extra improved plow steel, or extra-extra improved plow steel, regular lay, bright, and uncoated with an independent wire rope, wire strand, or otherwise, steel core. Hot-dipped galvanized wire rope is not permitted.

c. Maximum hoisting rope fleet angles must be 4 degrees for drums and

4.75 degrees for sheaves.

(1) For hoists utilizing a true vertical lift configuration with equalizer sheaves, rope dead ends are located at the drum only, and this requirement is not applicable.

(2) Provide proof of wire rope Breaking Strength Test Report . Wedge sockets or aluminum swages are not permitted on wire rope end connections.

d. Wire rope dead ends will be anchored on the drum barrel by clamping or by inserting end fittings into reinforced pockets. If a package hoist is utilized, drum end anchoring by means of wedge sockets is permitted.

e. Provide proof of wire rope Breaking Strength Test Report.

2.3.5 Sheaves

Provide steel sheaves. Minimum pitch diameters must be not less than 18 times the rope diameter for running sheaves, and not less than 12 times the rope diameter for equalizer sheaves. Sheave surfaces that contact wire rope must not be painted. Sheaves must be heat-treated to a minimum hardness of 320 Brinell Hardness Number (BHN) in the wire rope contact area, have a groove depth not less than 1.5 times the hoisting rope diameter, and a throat angle of 30 to 40 degrees. Sheave nest designed shall prevent metal-to-metal contact of moving parts. All sheaves shall be provided with close-fitting guards, or other means, to prevent the wire rope from leaving the groove or to guide the momentarily unloaded wire

SECTION 41 22 13.14 Page 18 rope back into the groove when the load is reapplied.

2.3.6 Hoist Drum

Provide drum made of steel. Design the drum such that all hoisting rope is wound in a single layer and so that not less than two dead wraps of hoisting rope remain on each anchorage when the hook is in its extreme low position. Drum grooving must be machined right and left hand beginning at the ends and grooving toward the center of the drum. Minimum drum groove depth must be 0.375 times the rope diameter. Minimum drum groove pitch must be either 1.14 times the rope diameter or the rope diameter plus 1/8 inch, whichever is smaller. Do not paint, coat, or galvanize the surface of the drum which comes in contact with wire rope. One empty groove when hoist is in its final upper limit is required. Drum end flanges shall extend a minimum of one wire rope diameter above top layer of wire rope.

For wire rope drums installed directly onto the output shaft of the hoist speed reducer without an intermediate flexible coupling, the drum to shaft connection must be a barrel coupling.

2.3.7 Gearing

Provide gearing of the enclosed gear reducers type. Provide steel spur, helical, or herringbone type gears and pinions only. Gearing must conform to ANSI/AGMA 2001 and AGMA 908. Internal and external gear dimensional tolerances must conform to the applicable AGMA standard for tooth geometry and tolerances. Gearing within hoist, trolley, and bridge reducers shall meet these requirements. Open-type gearing is not acceptable, except for final drives.

2.3.7.1 Gear Reducers

Gear reducers must be integral components of the hoist, trolley, and bridge drive assemblies furnished with the crane package and shall be the standard products of manufacturers regularly engaged in the design and manufacture of gear reducers for CMAA Class C cranes. Gear reducers must be designed, manufactured, and rated in accordance with ANSI/AGMA 6113 ( ANSI/AGMA 6013 for hoist and bridge drives), fully enclosed and oil-tight except for final reduction, and operate in an oil bath with smooth, quiet performance. Reducers shall have a minimum service factor of 1.25 for bridge and trolley drives and 1.5 for hoist drives, with bearings providing a minimum L10 life of 10,000 hours at rated load and duty.

Enclosed gearing shall be selected for Industrial Duty and designed in accordance with CMAA 70 and NAVFAC 11450.2A requirements. Enclosed reducers shall have a convenient means of lubricant level indication and draining.

2.3.7.2 Open Gearing

Provide all gears and pinions with adequate strength and durability for the crane service class and manufactured to ANSI/AGMA 2015-1 Accuracy Grade A8 or better. Open gears must be enclosed with safety guards provided with openings with covers for inspection and access for grease lubrication.

a. Open gear teeth shall be spur, double helical or herringbone to preclude axial loads on their supports.

b. The open gear horsepower rating shall be greater than the

SECTION 41 22 13.14 Page 19 horsepower rating of the driving motor. NAVCRANECENINST 11450.2A December 2018 96

c. Stress cycle factors, ZN and YN, and reliability factor, KR (from AGMA 2001), shall be taken as 1.0.

d. Gear tolerances shall be A8 or better (A10 or better for slewing ring bearing gears) in accordance with AGMA 2015. This roughly corresponds to old AGMA 2000 quality numbers of Q8 and Q6 respectively.

e. Open bevel gears shall not be utilized.

f. Open pinion teeth of last stage gear sets shall be crowned.

g. The bending strength of idler gears driving more than one wheel on travel drives shall be reduced to 70 percent of their normal rating.

h. Open gearing shall be protected whenever feasible by a metal cover with a closable lid for inspection of the gear teeth, tooth contact at the mesh, and lubrication.

2.3.8 Wheels

Provide double flanged, straight tread trolley and bridge travel wheels of rolled-to-shape or roll-forged steel. The rim, flanges, and wheel tread must be hardened to not less than 320 Brinell Hardness Number (BHN).

Submit Hardness Testing for Results of Sheaves and Wheels . Wheel sizing and flange-to-rail head clearances must be in accordance with CMAA 70 recommendations.

2.3.9 Bridge and Trolley Travel Brakes

Provide bridge and trolley drives with electro-mechanical brakes or non-freecoasting mechanical drive capable of stopping the motion of the bridge or trolley within a distance in feet equal to 10 percent of the full load speed in feet per minute when traveling at full speed with a full load. Brakes must have an externally accessible means to manually release the brake.

2.3.10 Hoist Brakes

a. Equip hoist with a minimum of two electro-mechanical holding brakes, each with a minimum torque rating of 150 percent of the rated load hoisting torque. Designate one brake as the primary brake (mounted closest to the motor) and one as the secondary brake.

b. The primary brake shall be non-time-delayed and shall set immediately upon removal of power to the hoist motor.

The secondary brake shall have an adjustable setting time delay of 1 to 3 seconds after the primary brake sets in all stopping conditions.

Do not use an uninterruptible power supply (UPS) or other stored-energy device to create the time delay.

c. Each brake shall be adjustable to 50 percent of its rated capacity, have externally accessible manual release means, and be designed for inspection and adjustment without disassembly.

Brakes shall have manual or automatic return-to-ON feature upon release. Torque adjustments shall not be required where brakes are used solely as holding brakes.

SECTION 41 22 13.14 Page 20

d. Brake components shall comply with NAVFAC 11450.2A paragraphs 2-4.2.1 and 2-4.2.2.

2.3.11 Couplings

Provide flexible, grid, or gear-type couplings between motor and gearbox shafts, and between gearbox and drum shafts, where applicable. Couplings shall be designed for continuous duty and capable of transmitting 150 percent of rated motor torque.Chain and continuous sleeve type couplings are not permitted. Spline couplings are acceptable when provided as part of C-face or D-face motor assemblies. Conventional couplings must not be loaded in the radial direction. Brake wheel or brake disc couplings (if used) must be compatible with the required coupling type. Flexible couplings must not be relied upon to compensate for poor alignment.

Ends of coupled shafts must be aligned within the manufacturer’s recommended tolerances. Provide coupling guards in accordance with OSHA

29 CFR 1910.219 .

2.3.12 Shims

Provide shims in accordance with NAVCRANECENINST 11450.2A § 2-2.15.3.

Shims shall be corrosion-resistant for all indoor and outdoor applications. Shim stacks shall not exceed four shims, and commercially available shim kits shall be used to ensure consistent, pre-cut shims sized for standard fasteners. All new base-mounted equipment shall be installed with shims under each foot, with a minimum shim thickness of

0.100 inch. Soft foot shall be limited to 0.001 inch and shall not exceed

0.003 inch after installation.

2.4 ELECTRICAL REQUIREMENTS

2.4.1 Motors

Motors must meet all applicable requirements of NEMA MG 1 and UL 1004-1 .All motors must have a minimum of a 60-minute duty rating and be Totally Enclosed Non-Ventilated (TENV), Totally Enclosed Fan Cooled (TEFC), or Totally Enclosed Blower Cooled (TEBC).Provide inverter-duty motors for open-loop variable frequency drives (VFDs). Provide vector-duty motors for closed-loop VFDs.Provide single-speed AC squirrel-cage induction type motors for the bridge and trolley drives. Provide vector-duty AC squirrel-cage induction type motor with encoder for the hoist.Provide motors with a minimum of Class F insulation and Class B temperature rise at rated load. Provide motor overload protection utilizing thermal sensors embedded in the windings and include space/anti-condensation heaters where applicable. For hoist functions, a motor thermal overload should only prevent raising of the load. The load should still be able to be lowered.

For bridge and trolley function, a motor overload should prohibit operation in either direction.Coordinate motor ratings with the drive manufacturer to ensure compatibility with the specified VFD system.

2.4.2 Controls

a. Provide static reversing, variable frequency drives (VFD) for the bridge and trolley electric controls. Provide static reversing, VFD, speed regulated, closed loop, flux vector electric controls for the hoist. For feedback, provide hoist motors with encoders. Encoder wiring must be continuous and minimum PPR should be 1024 unless application dictates higher or lower PPR. The hoist controller must

SECTION 41 22 13.14 Page 21 enable the drive motor to develop full torque continuously at zero speed. The hoist secondary brake must be controlled separate from the primary and connected to different output (within the drive) from the primary brake.