N6247013R4001-Spec.pdf

Four (4) 7.5-TON AND ONE (1) 5-TON UNDERRUNNING UNDERHUNG HOIST

ELECTRIC TRAVELING CRANES

at

ROTARY AIRCRAFT DEPOT MAINTENANCE FACILITY, NAVBASE CORONADO,

SAN DIEGO, CALIFORNIA

PREPARED BY:

Navy Crane Center Bldg. 491, Norfolk Naval Shipyard Portsmouth, Virginia 23709-5000

SPECIFICATION PREPARED BY:

Lead Design Engineer: David Brown, P.E.

Project Manager: Phil Dill, P.E.

Contract Specialist:

Quality Assurance Specialist:

barbara.t.spruill Typewritten Text Barbara Spruill

N62470-12-R-3000 Page 2 of 37

TABLE OF CONTENTS

Four (4) 7.5-TON AND ONE (1) 5-TON UNDERRUNNING CRANES

PART 1 GENERAL

1.1 REFERENCES

1.2 UNIT PRICES

1.3 SYSTEM DESCRIPTION

1.4 SUBMITTALS

1.5 QUALITY ASSURANCE

1.6 DELIVERY, STORAGE, AND HANDLING

1.7 PROJECT/SITE CONDITIONS

1.8 SEQUENCING AND SCHEDULING

1.9 CONTRACTOR REQUESTED ENGINEERING CHANGES

1.10 WARRANTY

1.11 MAINTENANCE

PART 2 PRODUCTS

2.1 MATERIALS

2.2 MANUFACTURED UNITS

2.3 EQUIPMENT

2.3.1 Structural Design

2.3.2 Mechanical Design

2.3.3 Electrical Design

2.4 COMPONENTS

2.5 ACCESSORIES

2.6 MIXES

2.7 FABRICATION

2.8 TESTS, INSPECTIONS, AND VERIFICATIONS

PART 3 EXECUTION

3.1 EXAMINATION

3.2 PREPARATION

3.3 ERECTION

3.4 INSTALLATION

N62470-12-R-3000 Page 3 of 37

3.5 APPLICATION

3.6 FIELD QUALITY CONTROL

3.7 ADJUSTING AND CLEANING

3.8 DEMONSTRATION

3.9 PROTECTION

3.10 SCHEDULES

Four (4) 7.5-TON AND ONE (1) 5-TON UNDERRUNNING CRANES

PART 1 GENERAL

1.1 REFERENCES

The following documents, of the issue in effect on date of invitation for bids or request for proposal, form a part of this specification to the extent specified herein. In case of difference between the following documents and this specification, this specification shall govern to the extent of such difference. If standards other than those listed below are used, proof of equivalence shall be provided. NEMA, OSHA, ASME, AWS, AISC, and NFPA rules shall govern.

AMERICAN GEAR MANUFACTURERS' ASSOCIATION (ANSI/AGMA)

2001 - Fundamental Rating Factors and Calculation Methods for Involute Spur and Helical Gear Teeth

6013 - Standard for Industrial Enclosed Gear Drives 6034 - Practice for Enclosed Cylindrical Wormgear Speed Reducers and Gear Motors 6035 - Design, Rating and Application of Industrial Globoidal Wormgearing B4.1 -Positional Fits and Tolerance for Cylindrical Parts

ASSOCIATION FOR IRON & STEEL TECHNOLOGY (AIST)

TR-06 - Specification for Electric Overhead Traveling Cranes for Steel Mill Service TR-13 - Guide for the Design and Construction of Mill Buildings

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

360 - Specification for Structural Steel Buildings

AMERICAN SOCIETY OF MECHANICAL ENGINEERS INTERNATIONAL (ASME)

B1.1 -Unified Inch Screw Threads B17.1 -Keys and Keyseats B30.10 - Hooks B30.11 - Monorails and Underhung Cranes B30.16 - Overhead Hoists (Underhung) B30.17 -Overhead and Gantry Cranes (Top Running Bridge, Single Girder, Underhung

Hoist) HST-4 - Performance Standards for Overhead Electric Wire Rope Hoists

AMERICAN SOCIETY OF CIVIL ENGINEERS (ASCE/SEI)

7 - Minimum Design Load for Buildings and Other Structures

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

A27 - Mild to Medium Strength Carbon Steel Castings for General Application A36 - Structural Steel A148 - High Strength Steel Castings for Structural Purposes A275 - Magnetic Particle Exam of Steel Forgings A325 - Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi

Minimum Tensile Strength A434 - Standard Specification for Steel Bars, Alloy, Hot-Wrought or Cold-Finished, Quenched and Tempered A490 - Standard Specification for Heat-Treated Steel Structural Bolts, 150 ksi

Minimum Tensile Strength

A504 - Wrought Carbon Steel Wheels A521 - Standard Specification for Steel, Closed Impression Die Forgings for General

Industrial Use A536 - Standard Specification for Ductile Iron Castings A563 - Standard Specification for Carbon and Alloy Steel Nuts A572 - Standard Specification for High-Strength Low-Alloy Columbium-Vanadium

Structural Steel A588 -Standard Specification for High-Strength Low Alloy Structural Steel, up to 50 ksi Minimum Yield Point, with Atmospheric Corrosion Resistance A668 - Steel Forgings, Carbon and Alloy, General Industrial Use A992 - Standard Specification for Steel for Structural Shapes for Use in Building

Framing A1023/A - Standard Specification for Stranded Carbon Steel Wire Ropes for General

Purposes B26 - Aluminum Alloy Sand Castings B108 - Specification for Aluminum Alloy Permanent Mold Castings E543 - Standard Specification for agencies performing Nondestructive Testing F436 - Standard Specification for Hardened Steel Washers F593 -Stainless Steel Bolts, Hex Cap Screws, and Studs F594 -Stainless Steel Nuts

AMERICAN WELDING SOCIETY (AWS)

D1.1 - Structural Welding Code Steel D14.1 - Welding of Industrial and Mill Cranes and other Material Handling Equipment

CRANE MANUFACTURERS' ASSOCIATION OF AMERICA, INC (CMAA)

70 - Specification for Top Running Bridge & Gantry Type Multiple Girder Electric Overhead Traveling Cranes

74 - Specification for Top Running & Under Running Single Girder Electric Overhead Traveling Cranes Utilizing Under Running Trolley Hoist

DEFENSE FEDERAL ACQUISITION REGULATIONS (DFAR)

252.211-7003 - Item Identification and Valuation

INTERNATIONAL STANDARDS ORGANIZATION (ISO)

4309 -Cranes – Wire Ropes – Care and Maintenance Inspection and Discard

MONORAIL MANUFACTURERS ASSOCIATION, INC. (MMA)

MH27.1 - Specifications for Patented Track Underhung Cranes and Monorail Systems

NATIONAL ELECTRICAL MANUFACTURERS' ASSOCIATION (NEMA)

ICS 8 - Industrial Control and Systems Crane and Hoist Controllers MG 1 - Motors and Generators 250 - Enclosures for Electrical Equipment (1000 Volts Maximum)

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

70 - National Electric Code

NAVAL FACILITIES ENGINEERING COMMAND (NAVFAC)

P-307 - Management of Weight Handling Equipment

NAVSEA TECHNICAL PUBLICATION

T9074-AS-GIB-010/271 - Requirements for Nondestructive Testing Methods

OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)

29 CFR, Part 1910.66, Appendix C -Personal Fall Arrest System 29 CFR, Part 1910.179 -Overhead and Gantry Cranes 29 CFR, Part 1910.306 -Specific Purpose Equipment and Installations 29 CFR, Part 1910.23 -Guarding Floor and Wall Openings and Holes 29 CFR, Part 1910.27 -Fixed Ladders

RESEARCH COUNCIL ON STRUCTURAL CONNECTIONS (RCSC)

Specification for Structural Joints Using High-Strength Bolts

SOCIETY OF AUTOMOTIVE ENGINEERS (SAE)

J429 - Mechanical and Material Requirements for Externally Threaded Fasteners J995 - Mechanical and Material Requirements for Steel Nuts

1.2 UNIT PRICES

Not applicable for this specification.

1.3 SYSTEM DESCRIPTION

The intent of this specification is to procure five underrunning bridge, underhung hoist, pendant controlled, overhead electric traveling (OET) cranes. The capacity of four cranes shall be 7.5-ton and the remaining crane shall be a 5-ton capacity. A 7.5-ton crane will be located in the Structural Bay (Rm 101), Assembly/Disassembly Bay (Rm 102), MOD/ISR Bay (Rm 103), and MOD/ISR Bay (Rm 104). The 5-ton crane will be located in the Tail Pylon MGB (Rm 134).

Each 7.5-ton crane shall have three runway rails and the 5-ton crane shall have two runway rails.

All cranes will be installed in the Rotary Aircraft Depot Maintenance Facility, NAVBASE Coronado, San Diego, California.

The cranes shall be designed, fabricated, assembled, shop tested, delivered, installed, inspected, field tested, and made ready for use in accordance with this specification. The cranes shall be built to the design drawings of a registered professional engineer. The crane’s capacities, spans, runways, hook lifts, and appendices shall be as follows:

Location Capacity Span Runway Hook Lift Appendix (lbs.) (ft-in) (ft-in) (ft-in)

Room 101 15,000 66’ 0” 195’ 8” 34’ 0” A-1

Room 102 15,000 66’ 0” 169’ 8” 34’ 0” A-2

Room 103 15,000 66’ 0” 169’ 8” 34’ 0” A-2

Room 104 15,000 66’ 0” 195’ 8” 34’ 0” A-1

Room 134 10,000 36’ 0” 66’ 6” 16’ 0” A-3

NOTE: Spans and runway length are estimates and shall be verified by the contractor.

1.3.1 Design Requirements

The design of the cranes shall conform to 29 CFR 1910.179, 29 CFR 1910.306, paragraph (b), ASME B30.16, ASME B30.11, ASME HST-4, MMA MH27.1, CMAA 74, and other requirements specified herein. The cranes shall be equipped with a single underrunning motor-operated trolley including wire rope hoist. Each crane shall be pendant controlled and designed to operate on a 480 VAC, 3-phase, 60-Hertz system. The cranes shall comply with all applicable requirements (“shall” statements) and recommendations (“should” statements) of CMAA 74 and MMA MH27.1 for class C service (minimum), as well as ASME B30.16 and ASME B30.11 (all “should” statements shall be considered “shall” statements).

Packaged hoist design shall be in accordance with applicable requirements (“shall” statements) and recommendations (“should” statements) of ASME HST-4 for duty class H3 service. A packaged hoist is defined as a hoist where the components are mounted via c, d, or p-face flanges as opposed to base mounted. All packaged hoists shall be produced by established manufacturers of the crane industry.

Each crane shall be designed to operate in the space, and match the runway dimensions and rails shown on the sketches in Appendices A-1 through A-3. All crane dimensions in the Appendices are approximate and shall be verified by the contractor. The hook work envelope shall be the maximum practical consistent with good design, but shall not be less than that indicated in Appendices A-1 through A-3. The runway rail shall be vertically supported by gimbel attachment points. See Appendices A-1 through A-3 for attachment point locations and maximum allowable loads. The contractor shall also verify all clearance and other building/crane interface, including those features shown in Appendices A-1 through A-3. Building designs/drawings shall be provided to the contractor for planning the design, shipping, and erecting of the components.

The contractor shall install new patented track crane runway systems for the cranes. The alignment tolerance of the new runways shall be in accordance with the requirement of MMA MH27.1. The contractor shall design the crane support system in accordance with the building drawing(s) and Appendices.

1.3.2 Performance Requirements

The rated speeds (plus or minus 10%), in feet per minute for the crane shall be as follows:

Crane Capacity (Tons)

Function Capacity (lbs) Rated Speed

(fpm) Minimum Speed

(fpm)*

7.5

Bridge 15,000 115 6

Trolley 15,000 80 4

Main Hoist 15,000 20 2

Bridge 10,000 75 5

Trolley 10,000 50 3

Main Hoist 10,000 20 2

* The minimum speeds shall not exceed the values listed above.

1.3.3 Capacity Plate

Provide two capacity plates per crane with permanent lettering, one for each side of the bridge.

Each plate shall indicate the rated hoisting capacity of the crane in pound units, and shall be securely attached to the bridge. Rated capacity of the hooks shall also be included if the hooks are a different capacity from the bridge. Beneath the rated capacity the following information shall be included:

Naval Facilities Engineering Command Contract Number N62470-10-D-xxxx; DO xxx Manufacturer’s name, address, and crane serial number Voltage, Phase, and Frequency of AC power supply

Provide cardinal direction indication letters centered on the bottom of the crane. The direction shall denote N-S-E-W and shall reflect the travel directions given on the controller. All lettering shall be of sufficient size to be easily read from the floor.

1.3.4 Crane Installation

The contractor shall verify all crane envelope clearances and other building/crane interface features, including those identified in Appendix A-1, Appendix A-2, and Appendix A-3.

1.3.5 Crane Removal

Not applicable for this specification.

1.3.6 Unique Identifier Tag

In accordance with DFARS 252.211-7003, the contractor shall assign a unique identifier to the crane, the Unique Identification Tag shall be attached to the outside of each crane disconnect panel.

1.4 SUBMITTALS

The contractor shall submit to the contracting officer all items of technical documentation listed hereinafter. The contractor shall ensure that all submittals are entirely legible and suitable for reproduction. The content, number of copies, time of submission, and distribution shall be in accordance with Exhibit A of this specification and as specified below. Compliance with the requirements of this specification will be determined by a review of the design and construction submittals by the contracting officer and by field inspection.

For submittals that reference a Navy Crane Center form, the form can be found on NCC website at https://portal.navfac.navy.mil/portal/page/portal/NAVFAC/NAVFAC_WW_PP/NAVFAC_NCC_PP under the “Downloads” page.

SD-01 Preconstruction Submittals

Contractor shall submit monthly status reports. The first page of the report shall contain the following identifying information: Title/Project Description, Reporting Period, Contract Number, Name and Title of Report Preparer, Security Classification - when required, and Distribution Statement. The content of the report shall address: the overall project status and the status of each milestone/task, for designs in process indicate the percent complete and estimated submission dates, for designs under review indicate level of government review and projected approval date, list and describe current CCRFs, describe outstanding problems and proposed resolutions indicating who has the next action, describe significant results from conferences and trips, list directives given from the Contracting Officer's representatives, list all contract modifications issued, provide a summary of work planned in the next month, provide any necessary supporting documentation as an attached appendix. Provide an updated milestone schedule with every monthly status report. The Contractor shall submit a schedule which identifies key milestone events in the design, fabrication, and installation of the crane acquisition. At a minimum, the schedule shall include the following:

a. Post Award Conference

b. Initial General Arrangement and Design Submittals

c. Government Review of Initial Design

d. Final General Arrangement and Design Submittals

e. Government Review of Final Design

f. Fabrication Initiation

g. Fabrication Completion

h. Pre-Installation Conference

i. Shop Test

j. Crane Delivery

k. New Crane Installation

l. Field Inspection & Acceptance Test

m. Crane Acceptance

n. Completion of Warranty

SD-02 Drawings

The contractor shall submit for approval the drawings and catalog cuts listed below via ProjNet (www.projnet.org). After Navy Crane Center design approval and prior to shop test, the contractor shall submit a complete set of Final design drawings. Initial design drawings shall include certification of review by a professional engineer. Any subsequent drawing submittals satisfying a design review comment or Contract initiated changes shall bear a new revision number for each sheet that has been modified. Final and “As-built” drawings shall bear a complete title block with a permanent drawing number, a registered professional engineer’s original seal and dated signature. Drawings within each category (such as structural, mechanical, etc.) shall be numbered consecutively. Each assembly and subassembly drawing shall include an integral Bill of Materials or shall be followed by a consecutively numbered drawing with the applicable Bill of Materials. There shall be no proprietary notes on any drawing. All drawings shall be created for viewing in AutoCAD 2010 with a drawing file format of .dwg or .dxf, and a separate copy viewable in Adobe Acrobat (.pdf). An index for all drawings shall be included.

SD-02.G General Arrangement Drawings

Each crane assembly and each major component shall be shown in plan, elevation, and end views to demonstrate proper interface with the facility building. All major features of each crane shall be shown including: clearances, lifts, spans, wheel spacing, speeds, hook approaches on both sides, maximum wheel loads, electrical power supply, and general locations of components such as: brakes, motors, speed reducers, and control panels (including size). The type of structural bolted connection shall be specified on the drawing. In addition, estimated weights shall be shown for the completely assembled crane. Approximate locations of center of gravity and location of lifting points for completely assembled crane and for each major component (girders, trolleys, and end trucks) shall be provided on the design drawings.

SD-02.S Structural Drawings

The structural design drawings shall be based upon consideration of the design loads and forces to be resisted by the structural steel in the completed project, and completed in accordance with AISC 303, Section 3, “Design Drawings and Specifications.”

The structural design drawings shall show the fabrication details, weldments, fastener joint details, Bill of Materials and location and size of all structural members. The fabrication details shall clearly show the size, section, material grade and location (dimensions) of all members; all geometry necessary for layout; elevations; centers and offsets; camber requirements; and joining requirements between elements of built-up elements. Other critical information that shall be provided on the structural design drawings includes the welded-joint configuration in accordance with AWS D1.1 and D14.1, and structural bolted-joint configuration in accordance with the RCSC “Specification for Structural Joints Using High-Strength Bolts.” All members required for fabrication shall be shown on drawings and shall be labeled to correspond with the Bill of Materials.

Dimensioned locations of lift points (for components to be lifted by suspended rigging) and approximate locations of center of gravity for each major component listed below shall be provided on the structural design drawings.

Structural drawings shall be provided for the following as a minimum:

a. Girder Fabrication

b. Lift Point(s) Fabrication

SD-02.E Electrical Drawings

The drawings shall at a minimum include:

a. Complete schematic diagram with narrative of any special description of operation. All components shown on schematics shall have labels that correspond to the nameplates that will be on the crane. Wiring type, size, and temperature ratings shall be included on schematic diagrams. All optional equipment not installed on the crane shall be removed from the schematic diagrams. For components with adjustable settings, final settings shall be shown on the schematics.

b. Motor nameplate data (including all information called for in NFPA 70, Section 430.7

(A) items 1 through 7).

c. Rating and types of over-current protective devices.

d. A comprehensive component material list showing all electrical components used on the crane. Layout diagrams showing component placement in control panel enclosures.

e. Layout diagrams showing component placement in control panel enclosures.

f. Festoon layout drawings showing festoon cables used, carrier system, and cable loop depth.

g. Complete assembly (wiring) diagrams showing all conductor routings and terminations.

SD-02.M Mechanical Drawings

The drawings shall at a minimum include:

a. Drive arrangements (including assembled components).

b. Base mounted component bolt torque values shall be provided for installed fasteners with consideration for any lubrication and/or washer types used; generic bolt torque tables shall not suffice.

c. Wheels and Sheaves (if not standard commercially available items).

SD-03 Product Data

Manufacturer’s catalog data shall be provided for all major components of the crane. The catalog cuts shall be marked-up or supplemented with additional sheets to clearly identify the model or size, selected options, features, and/or modifications to demonstrate compliance with specification requirements. Catalog cuts which show modifications beyond the standard options and all supplemental pages shall bear original signatures and dates of the equipment manufacturer’s authorized representative. Each catalog cut and each supplemental sheet shall clearly identify the item to which it applies. All catalog cuts shall be submitted in one file viewable in Adobe Acrobat and bookmarked as to the location of each catalog cut. In accordance with Exhibit A, the contractor shall submit for approval the catalog cuts listed below:

SD-03.M Mechanical Product Data

SD-03.M1 Complete Hoist/Trolley Units

SD-03.M2 Speed Reducers including gear ratio

SD-03.M3 Brakes (including electrical information)

SD-03.M4 Bearings and Bearing Housings

SD-03.M5 Couplings

SD-03.M6 Load Blocks

SD-03.M7 Bumpers

SD-03.M8 Wheels and Sheaves

SD-03.E Electrical Product Data

SD-03.E1 Variable Frequency Drives (including Dynamic Braking Resistor and Reactor selection)

SD-03.E2 Motors and Encoders (if applicable)

SD-03.E3 Electrical Enclosures

SD-03.E4 Runway Electrification (including Collectors if applicable)

SD-03.E5 Limit Switches

SD-03.E6 Bridge-to-Trolley Electrification

SD-03.E7 Warning and Pilot Devices

SD-03.E8 Disconnect Switches

SD-03.E9 Contactors and Relays

SD-03.E10 Operator Controllers

SD-03.E11 Lighting / Heating / Air Conditioning (if applicable)

SD-03.E12 Circuit Breakers

SD-03.S Structural Product Data

SD-03.S1 End Trucks (including Drive Units)

SD-03.S2 Patented Track Girder

SD-03.S3 Trolley Frame

SD-03.S4 Painting System

SD-03.S5 End Stops

SD-03.S6 Patented Track Runway Beam and Support System

SD-03.S7 Lift Point(s)

SD-04 Samples

Not applicable for this specification.

SD-05 Design Data

These calculations shall demonstrate compliance with all design requirements of this specification. Design data and calculations will not be approved if their evaluation/review is dependent on data or information not previously approved. All variables shall be listed and defined at the beginning of each calculation section; variables shall be in accordance with required references.

SD-05.S Structural Calculations

SD-05.S1 Calculations verifying compliance with MMA MH27.1 and Section 2.3.1.1 of this specification for any non-commercial items

SD-05.S2 Calculations verifying design of bridge rail stops in accordance with AIST TR-13 and all bumpers in accordance with the dynamic requirements of AIST TR-06.

SD-05-S3 Calculations verifying compliance with the maximum allowable load at runway track beam support point specified in Appendix A.

SD-05.M Mechanical Calculations

SD-05.M1 Calculations verifying compliance with Section 4 of CMAA 74 for any non-commercial items

SD-05.M2 Calculations verifying brake selections (not applicable to packaged hoists)

SD-05.M3 Calculations verifying coupling selections (not applicable to packaged hoists)

SD-05.M4 Calculations verifying bumper selection

SD-05.E Electrical Calculations

SD-05.E1 Minimum required horsepower for each drive motor. For the bridge drive the minimum acceleration time to rated speed shall be 4 seconds. For the trolley drive the minimum acceleration time to rated speed shall be 3 seconds.

Calculations are not required for packaged hoists, but packaged hoists shall still meet acceleration and deceleration requirements for trolley and bridge drives and CMAA sizing calculations for hoist drives. All motor horsepower calculations may be performed with the allowable 10% speed reduction, however no additional latitude in selecting the nearest rated horsepower under the calculated value is allowed.

SD-05.E2 Overcurrent protection

SD-05.E3 Conduit fill calculations (using tables from NFPA 70, Chapter 9 or manufacturer’s data sheets). Grounding conductors shall be included in the calculations.

SD-05.E4 Protective device coordination study showing proper coordination for any overcurrent devices that have the same rating as another overcurrent device upstream. This study shall include all devices from the line side of the primary facility overcurrent device.

SD-06 Test Reports

The following reports, outlines, and plans shall be submitted in accordance with Exhibit A.

SD-06.1 Hook Non-Destructive Test (NDT) Report

SD-06.1.1 The contractor shall provide a certification that the NDT vendor meets the requirements of ASTM E543. The certification shall be current, within one year of the date the NDT was performed.

SD-06.1.2 The contractor shall submit for review the NDT vendor’s procedures, including technique sheets specific to the types, shapes, and size of the parts being examined (e.g., shank hook, eye hook, duplex hook, eye pin, swivel eye bar). For the magnetic particle method, the procedures shall adequately describe the orientation of the hooks, swivel eye bar, or eye pins with the magnetizing equipment.

Procedures must be reviewed and bear the approval signature of a SNT-TC-1A qualified Level III examiner stating they are independent of the vendor.

SD-06.1.3 Prior to performing any operational testing of the crane, the hook and eye pin or swivel eye bar (as applicable) shall be inspected by the magnetic particle method over their entire surface area in accordance with NAVSEA Technical Publication T9074-AS-GIB-010/271. ASTM A275 may be used with the following restrictions:

DC yokes (including switchable AC/DC yokes used in the DC mode) and permanent magnet yokes shall not be used; automatic powder blowers or any other form of forced air other than from a handheld bulb shall not be used for the application or removal of dry magnetic particles; arc strikes shall be removed; and equipment ammeters shall have an accuracy of 5 percent of full scale (equipment ammeter accuracy other than that stated is acceptable provided the magnetic particle method procedure states that a magnetic field indicator is used to establish and verify adequate field strength for all aspects of the inspection). If NDT cannot be performed on surfaces inside holes, those surfaces shall be visually inspected to the maximum extent practical. Acceptance criterion shall be no linear indications greater than 1/16 inch. The NDT report shall be provided to the Government and shall be traceable to the unique ID number of the hook and eye pin or swivel eye bar (as applicable).

SD-07 Certificates

All certifications shall be dated and shall 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 shall clearly identify the hoist, the drives, components, and location (as applicable) to which it applies:

SD-07.1 Wire Rope

The contractor shall provide the wire rope manufacturer’s certification that the rope meets the published breaking strength of samples taken from reels and tested. Certification shall be traceable to the hoist, crane and reel.

SD-07.2 Periodic Overload Testing

The contractor shall certify the cranes and support systems are capable of being load tested semi-annually up to 131.25% of the rated capacity without any detrimental effects.

SD-07.3 Crane Runway Rail

The crane contractor shall install the runway rails for the cranes and provide a rail survey performed in accordance with the criteria of MMA MH27.1. The contractor shall certify that the runway rails are straight, parallel, and level in accordance with the requirements of MMA

MH27.1.

All rail certifications shall be supplied to the Contracting Officer prior to field testing.

SD-07.4 Hazardous Material

The contractor shall certify that the cranes contain no asbestos, lead paint, Polychlorinated Biphenyl’s (PCB’s), or elemental mercury, and that Chromates have been avoided where feasible.

SD-07.5 Loss of Power Test

The contractor shall certify that the loss of power tests as identified in Appendix C-1 and Appendix C-2 can be performed without any detrimental affects to the electronic control systems.

SD-07.6 Coupling Alignments

Contractor shall submit coupling alignment data records with certification that the alignment of all shafting connected by means of flexible couplings are within manufacturer's installation tolerances. The coupling alignments shall be made using laser alignment equipment. The data records shall be taken after the coupling's final installation and after installation of shear bars or dowel pins in all base-mounted components. Coupling alignments shall be verified by the contractor after crane installation. The coupling alignment data record shall be submitted on the official form, which can be found on the NCC website.

SD-07.7 Hook and Nut Proof Test

Contractor shall submit certification that the hooks and nuts have been proof tested and satisfies the acceptance criteria of ASME B30.10.

SD-07.8 Welding Certifications

The contractor shall provide a certificate stating that all welders, welding operators, weld inspector(s) and welding procedure (qualification) meet the requirements of AWS D 14.1 for all work performed in manufacturing the cranes.

The contractor shall provide a certificate stating that all welders, welding operators, weld inspector(s), and welding procedure (qualification) meet the requirements of AWS D 1.1 for all work performed in installing/welding parts supporting the crane at/to building interfaces.

SD-07.9 Design Review by Professional Engineer

The contractor shall provide a certificate stating that the initial design has been reviewed by a professional engineer. The certificate shall indicate the name, state of licensure and license number of the professional engineer.

SD-07.10 Contractor’s Self Test

The contractor shall provide a certificate stating that the contractor’s self test has been completed in accordance with section 2.8.1 of this specification.

SD-08 Manufacturer’s Instructions

SD-08.1 Shop Test Procedure

The contractor shall develop and submit a shop test procedure that will demonstrate operation, performance, and safety of the crane. The test procedure shall be submitted and approved prior to conducting the shop test. As a minimum, the test procedure shall conform to those requirements specified in Appendix B of this specification.

SD-08.2 Crane Installation Plan

The contractor shall submit a plan detailing the logistics involved in crane mobilization to the site and installation of the new crane. The plan shall include, as a minimum, lifting configurations, lay-down areas, installation, and transport through the activity. A detailed lifting and handling plan meeting the minimum requirements shown in Appendix D and NAVFAC P-307 shall be submitted by the contractor, for review and acceptance by the Government. The construction crane and rigging gear shall comply with OSHA requirements and any local requirements. Lifts of all major components for crane removal and installation are considered to be critical lifts and include any lifts performed by equipment such as forklifts and jacks. Actual locations of center of gravity and location of lifting points for completely assembled crane and for each major component (girders, hoist/trolleys, and end trucks) shall be provided with the crane installation plan.

NOTE: On-site changes of the plan are not allowed without Government review and acceptance.

SD-08.3 Accident Prevention Plan (APP)

The APP shall be prepared in accordance with Appendix E (Safety), and Exhibit A and B and shall be submitted for review and comment by the Contracting Officer. Installation of the cranes cannot proceed prior to the review and acceptance of the APP by the Contracting Officer.

SD-08.4 Training Course Outline

The contractor shall prepare and submit to the Contracting Officer for approval, a training course outline. The outline shall contain enough detail for the Government to determine that all topics are adequately covered as prescribed in section 3.8 of this specification.

SD-09 Manufacturer’s Field Reports

SD-09.1 Brake Adjustment Records.

The contractor shall provide a brake adjustment record for each brake on the cranes. The brake adjustment records shall be submitted on the official form, which can be found on the NCC website. Each brake measurement shall have a tolerance traceable to the associated brake manual or documentations provided by brake manufacturer and an “actual” setting. Changes made to settings of the brake at any time will void this record.

SD-09.2 Shop Test Deficient Items List

Upon completion of the government witnessed shop test and inspection of the cranes, a list of deficient items will be compiled and attached to NCC Form 08-002 and signed by the contractor, Navy Crane Center Representative, and activity representative (if applicable) and forwarded to the Contracting Officer.

SD-09.3 Shop Test Record

Upon successful completion of the shop test for the cranes, the contractor shall submit records of all test data.

SD-09.4 Field Test Record

The contractor shall follow the test procedure found in Appendix C-1 and Appendix C-2 that will demonstrate operation, capacity, and safety of the crane. Any deviations to the field test required by the crane contractor must be approved by the Government. Upon successful completion of all testing, the contractor shall submit records of all test data.

SD-10 Operation and Maintenance Data

The contractor shall submit the crane’s operation and maintenance manual to the Government for review. The operation and maintenance manuals shall include the following: table of contents, operation instructions, maintenance information, parts information, drawing list, all drawings, catalog cuts, and calculations.

Operation instructions shall include contractor’s detailed written procedures as well as crane operating and safety instructions including special precautions for starting/stopping.

Maintenance information shall include recommended maintenance procedures, preventative maintenance, manufacturer’s installation and maintenance manuals (for purchased components), lubrication instructions, and maintenance and programming instructions for the drives.

Programming instructions shall include a complete listing of all control system parameters with an explanation of their functions. Maintenance instructions shall also include alignment, adjustment, and calibration instructions for commercial components and parts lists. Lubrication instructions shall include the location of lubrication points, type of lubricant to be used, and the frequency of lubrication, which shall agree with the lubrication drawing provided.

Parts information shall include a recommended spare parts list, all information on all contractor-designed parts, all purchased sub-assemblies and components including the manufacturer’s part number. The information shall be broken-out to the smallest replacement part.

SD-11 Closeout Submittals

SD-11.1 Drawings on CD-ROM

The contractor shall provide the crane’s as-built drawings on CDs viewable in AutoCAD 2010. The file shall be in .dwg or .dxf format and a separate copy in Portable Document Format (.pdf). The as-built drawings shall be submitted to the Government following final Government acceptance of the crane. The CDs shall include an index of the drawings.

SD-11.2 Operation and Maintenance Manuals

The contactor shall provide the operation and maintenance manuals on CDs and hard copies following final Government acceptance of the manuals. The manuals shall be in Portable Document Format (.pdf). The manuals shall be indexed using bookmarks in Adobe Acrobat.

SD-11.3 Control System Parameter Record

After the crane has passed the final field test, the Contractor shall complete a control system parameter record for the crane. The record shall include the contract number, Contractor’s name and address, date, all control system parameters and their final settings. Each control system parameter shall be designated as either used or unused.

SD-11.4 Product Data

Electronic submission of catalog cuts shall be submitted as one unit with a cover sheet containing a title block and index sheet identifying individual catalog cuts. Ensure each page is numbered and identified to allow proper filing if separated or if provided in .PDF format. Linked bookmarking is acceptable vice page numbering. The minimum sections for indexing shall be the sections noted in paragraph SD-03.

SD-11.5 Frequency Allocation Application

Not applicable for this specification.

SD-11.6 List of Parameters and Crane OEM's Approved Crane Range

After the cranes have passed the final field test, the contractor shall submit Appendix F for each electronic drive to document the crane designed parameter ranges in which each parameter can be safely tuned by the end user for each parameter specified in Appendix F used on the crane. The crane contractor-determined design range shall be the applicable portion of the drive’s default range for each parameter. The crane contractor must provide justification for each range of each parameter on the list. When necessary, the justification shall include appropriate calculations.

SD-11.7 Property Transfer Verification

After the cranes have passed the final field tests, the contractor shall transfer possession of all small items associated with the operation and maintenance of the cranes, including but not limited to: keys, control software, computer cabling, remote controls, etc. The property shall be given to the point of contact of the supported command. The contractor shall provide an itemized invoice showing the quantity and description of items transferred; obtain the signature of the recipient and date on the invoice. Submit a copy of the signed invoice.

1.5 QUALITY ASSURANCE

1.5.1 Qualifications

Crane design shall be accomplished by, or directly supervised by, a registered professional engineer (PE). PE licensing shall be by a board or agency authorized to license and register professional engineers in the U.S. or Canada. The PE may be a contractor's regular employee or a consultant. The PE's review and attestation of specification compliance and professional responsibility shall be signified by his or her PE original seal, and dated signature on the final drawing.

1.5.2 Regulatory Requirements

All crane functions and components shall comply with all Occupational Safety and Health Administration (OSHA) and other listed references in this specification.

1.5.3 Post-Award Conference

The contractor shall attend a post-award conference that will typically be held at the fabrication site or via teleconference. This conference will cover design submissions, shop testing, shipping, site mobilization, erection dates, Exhibit A submissions, Accident Prevention Plan, crane installation plan, roles and responsibilities of the entities involved and the schedule. Meeting minutes shall be prepared by the Contractor and reviewed by the Government.

1.5.4 Pre-Installation Conference

The contractor shall attend a Government conducted pre-installation conference that will be typically held at the installation site. This conference will allow the crane contractor and any sub-contractors, the Navy Crane Center, and the supported command the ability to review any necessary precautions to insure a safe and accurate installation. A draft of the Crane Installation Plan should be available at the pre-installation conference. Meeting minutes will be prepared by the contractor and submitted for review and approval to the Government in accordance with Exhibit A.

1.6 DELIVERY, STORAGE, AND HANDLING

The cranes will be installed in a new facility that is under construction.

The contractor shall be responsible for transporting new cranes to the job sites. In the event that the Government is unable to receive the crane from the crane contractor as scheduled by the contract, storage will be arranged, and storage expenses shall be the responsibility of the Government. The contractor shall be responsible for transporting the cranes from storage to jobsite. Moisture control (desiccant) shall be included in all electrical panels that are the responsibility of the contractor. Quantities shall be sufficient to keep these environments free of moisture, minimally, for the period of time from final shipment from the contractor's facility until permanent power is applied to the crane at the activity.

The completed facility spaces will have the floor coatings applied as the last major work item.

Should the crane installation be delayed at the Crane Contractor’s option from the Government’s window, the Crane Contractor will be responsible for protecting the coated floors during the crane installation.

1.7 PROJECT/SITE CONDITIONS

1.7.1 Environmental Requirements

The cranes shall be designed to operate in an indoor environment with an ambient temperature of 40° to 110° F.

Operation of the cranes shall not appreciably increase ambient noise level and shall in no case exceed 70 dB from the operator’s location when loaded at rated capacity and unloaded.

1.7.2 Existing Conditions

Prior to mobilization the site shall be inspected by the crane contractor, a facility representative, and a NCC representative to document the condition of all existing construction and record any existing damage. A Pre/Post Installation Building Inspection Checklist form shall be initiated at that time, NCC Form 11-001. Upon completion of the work, the crane contractor, a facility representative, and a NCC representative shall again inspect the facility to determine the extent of any damage that may have occurred as a result of work performed under this contract. During this final inspection the NCC Form 11-001 shall be completed. Any damage to either the facility and/or its contents as a result of the crane installation and/or testing shall be the responsibility of the crane contractor under this contract.

1.7.3 Government Furnished Equipment

The Government shall provide certified test weights and associated rigging gear at the facility for acceptance testing of the crane. Two weeks’ notice to the government is required in order to coordinate availability of test weights and rigging gear.

1.8 SEQUENCING AND SCHEDULING

The cranes are to be installed in a new facility. The construction schedule is reflecting a two week window for each crane installation. The crane installation window for each of the spaces is sequential and not concurrent except the Structural Bay (Rm 101) and the Tail Pylon MGB (Rm

134) cranes are planned for concurrent installations. The specific order of crane installations will be provided as the facility construction nears completion. The contractor shall provide an onsite work schedule with durations and desired start/stop dates. The Contracting Officer will coordinate with the building manager and determine a final mobilization date and the sequencing of crane installations. The Contractor will provide a minimum of thirty days notice prior to a desired mobilizing date at Naval Base Coronado, CA.

The crane contractor should plan to mobilize at Naval Base Coronado no sooner than early December 2014. The receiving facility is currently under construction and the facility construction schedule may be impacted prior to crane delivery. Therefore the Government reserves the right to delay on-site mobilization start date by up to sixty days.

1.9 CONTRACTOR REQUESTED ENGINEERING CHANGES

All contractor requested engineering changes must be submitted to the Navy Crane Center on the “Contractor Change Request Form” (NCC Form 07-001). The “Cost Worksheet” (NCC Form 07-001A) shall be attached to any engineering changes. The worksheet shall compare the cost of equipment as specified in the contract with the cost of the proposed change. CCRFs shall be disapproved if submitted without Cost Worksheet. The forms are available at https://portal.navfac.navy.mil/ncc under the “downloads” page.

1.10 WARRANTY

See Section I of the contract for warranty information.

1.11 MAINTENANCE

Not applicable for this specification.

PART 2 PRODUCTS

2.1 MATERIALS

Material shall be free from defects and imperfections that might affect the serviceability and appearance of the finished product. All material shall be new and unused.

2.1.1 Ductile Materials

All non-redundant components directly supporting the load shall be of ductile materials (except for C-face mounted components in packaged hoist). These components include, but are not limited to all motor frames and end bells, flanged adapters, and brake wheels and discs. For the purposes of this specification, ductile is defined as having a minimum elongation of 5% in 2 inches. Furthermore, all shafts, keys, gears, torque carrying coupling components, wheels, load block components, brake components and wire rope drum shall be steel.

2.1.2 Structural Steel

Structural steel shall conform to ASTM A36, A572 OR A992.

2.1.3 Cast Steel

Cast steel shall conform to ASTM A27 or ASTM A148.

2.1.4 Ductile Cast Iron

Ductile Cast Iron shall conform to ASTM A536.

2.1.5 Forged Steel

Forged steel shall conform to ASTM A668 or ASTM A521, grade as applicable.

2.1.6 Steel Shafts

Steel shafts shall conform to ASTM A434

2.1.7 Aluminum Castings

Aluminum castings shall conform to ASTM B26 or ASTM B108.

2.1.8 Welding Materials for Crane

Welding materials shall conform to AWS D14.1

2.1.9 Welding Materials for Facilities

Welding materials shall conform to AWS D1.1

2.2 MANUFACTURED UNITS

Not applicable to this specification

2.3 EQUIPMENT

2.3.1 Structural Design

The structural design of each crane shall conform to MMA MH27.1, OSHA 1910.179, ASME B30.11, OSHA 29 CRF, Part 1910.23, ASCE 360, and other requirements specified herein.

2.3.1.1 Additional Load Combinations

In addition to load cases specified in MMA MH27.1, the following additional loads shall also be considered in Case 3, Extraordinary Loads:

Test Loads

The crane will be periodically tested up to 131.25% of rated capacity; therefore, a test load of 131.25% of rated capacity shall be included in Case 3.

Seismic forces

Provide seismic analysis in accordance with ASCE 7, or a statement that seismic analysis is not a controlling load case.

2.3.1.2 Welding

All welding procedures and qualifications shall be in accordance with the requirements of AWS D14.1 and D1.1 as required by SD-07.8. The contractor shall have available for review records of all welder and welding operator qualifications, all procedure qualifications, other tests that are made, and other information that may be required for weld acceptance.

2.3.1.3 Structural Bolted Connections

Structural bolts shall be ASTM A325 or A490 bolts. Structural bolted connections shall be designed and installed in accordance with RCSC Specification for Structural Joints Using High- Strength Bolts

2.3.1.4 Bridge Girder

Bridge girders shall be patented track beam type conforming to MMA MH27.1. Splices shall not be permitted in the unsupported length of the patented track. Splices shall be done in accordance with the patented track manufacturer’s recommendations and requirements. Splice assemblies shall be from the same manufacture as the patented track.

2.3.1.5 End Trucks

The bridge and trolley wheels shall be equipped with rail sweeps. Provision shall be made to prevent bridge end truck and trolley from dropping more than one inch in case of wheel or axle failure. Three end trucks shall be provided for each of the 7.5 ton cranes and two end trucks shall be provided for the 5 ton crane.

2.3.1.6 Bridge Rails

Not applicable to this specification (see Bridge Girders 2.3.1.4).

2.3.1.7 Walkways

Not applicable for this specification.

2.3.1.8 End Stops

The contractor shall design, fabricate, and install all new runway end stops in accordance with AIST TR-13 to resist crane bumper dynamic response specified in AIST TR-6.

Trolley end stops shall be designed in accordance with AIST TR-13 to resist crane bumper dynamic response specified in AIST TR-6.

2.3.1.9 Major Components Attachments for Lifting and Handling

Major components (e.g. bridge girder(s), end truck(s), runways and trolley(s)) shall be designed with structural or mechanical attachment points (lifting lugs, safety hoist rings, hoist rings or approved equivalent) when they are to be lifted or handled by suspended rigging.

2.3.1.10 Runway Rails

Runways shall be patented track beam type conforming to MMA MH27.1. Three runways shall be provided for each 7.5 ton crane and two runways shall be provided for the 5 ton crane.

2.3.2 Mechanical Design

The mechanical design of the cranes shall conform to MMA MH27.1, ASME HST-4, ASME B30.11, ASME B30.16 and other requirements specified herein. All drives which are not direct-connected with shafts in line shall be driven through gears. Retaining rings shall not be relied upon for axial retention of sheave pins or bearings on pins and axles; they shall be permitted only on standard commercial assemblies. Press fits shall not be relied upon for transmission of torque, except where permitted in travel drives. Cotter pins shall be permitted only for locking nuts to prevent against loosening and for retention of secondary components (i.e.

retaining pins) which are not in the primary load path. Cotter pins shall be corrosion resistant.

2.3.2.1 Design Factors

As a minimum, the cranes shall be designed for duty service classification H-3 as defined by

ASME HST-4.

2.3.2.2 Alignment

All components shall be aligned in accordance with the manufacturer’s instructions. Coupling alignments shall be measured and recorded. Couplings shall be measured by the contractor and witnessed by the Government after field installation.

2.3.2.3 Threaded Fasteners

Fasteners connecting load bearing/load controlling mechanical components shall consist of bolts and nuts conforming to SAE J429 and SAE J995, Grade 2 or better, or their international equivalents. Mounting fasteners from flange-mounted components, including keeper bars, may be installed into tapped holes provided there is adequate thread engagement to develop the full tensile strength of the fastener. All nuts shall have a minimum of one thread pitch of the bolt protruding above the nut top surface. Fastener connections shall be sized neglecting any benefit to be derived from shear bars or dowel pins.

2.3.2.4 Load Blocks

Load blocks shall be entirely of steel construction. The designs shall preclude the wire rope from being cut, pinched, crushed, or chafed in case of two-blocking, unloading of the wire rope, or under normal operating condition.